VDRG01 01GB

Reachstackers 42-45 tonnes
Publ. no VDRG01.01GB
Workshop Manual in original WORKSHOP MANUAL
DRG 420–450
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Workshop Manual
2 Transmission
DRG 420–450
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
G Terminology and index

A:1
A Foreword
Contents A Foreword
Foreword ............................................................................................................A:3
About the Workshop Manual........................................................................... A:3
General ...................................................................................................... A:3
Conditions .................................................................................................. A:3
Storage....................................................................................................... A:3
About machine version............................................................................... A:3
Copyright .................................................................................................... A:3
Reading instructions ....................................................................................... A:4
Warning information ................................................................................... A:4
Important information ................................................................................. A:4
Read operator's manual ............................................................................. A:4
Read the Maintenance manual .................................................................. A:4
The workshop manual's contents............................................................... A:5
Function group structure ............................................................................ A:6
References between different information types ........................................ A:7
Product alternatives and optional equipment ............................................. A:8
Machine card.............................................................................................. A:9
Function descriptions ............................................................................... A:10
About the documentation .............................................................................. A:12
The documentation's parts ....................................................................... A:12
Ordering documentation........................................................................... A:12
Feedback ................................................................................................. A:12
Workshop Manual DRG 420–450 VDRG01.01GB

A:2
VDRG01.01GB Workshop Manual DRG 420–450

A Foreword – Foreword A:3
A Foreword
About the Workshop Manual
General
Thank you for choosing Cargotec as your machine supplier. We hope
that we will meet your expectations.
Conditions
The instructions are based on the use of generally available standard
tools. All lifting devices, such as slings, straps and ratchet blocks, must
meet the national standards and regulations in force for lifting devices.
Cargotec will not accept any responsibility in the event of a modification

performed without permission from Cargotec. Further, Cargotec will not
accept any responsibility if other lifting devices, tools or work methods
are used other than those described in this manual.
Storage
NOTE
The workshop manual should be accessible to service personnel.
About machine version

The information in this publication corresponds with the machine's
design and appearance on delivery from Cargotec. Deviations may
arise due to customer adaptations.
Cargotec reserves the right to make changes to specifications and

equipment without prior notice. All information and data in this manual
are valid at the time of publication.
DANGER
External equipment may only be used if it is approved
by Cargotec.
Extreme hazard to personal health and risk of property
damage!
Only use equipment that is approved by Cargotec.
Copyright
Cargotec Sweden AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Cargotec Sweden AB.
All duplication by any means, such as copying, printing, etc., is

prohibited.

A:4 A Foreword – Reading instructions
Reading instructions
Warning information
Warnings provide information about potential dangers that, if the
warnings are not followed, could result in injury or product damage.
DANGER
Situation that could lead to severe personal injury or
death if regulation is not followed.
WARNING
Situation that could lead to personal injury if regulation
is not followed.
CAUTION
Situation that could lead to product damage if
regulation is not followed.
Important information
Important information is denoted with NOTE and is intended to
facilitate the work process, handling or to increase understanding of
the information.
NOTE
Important information not related to safety.
Read operator's manual

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

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

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

The workshop manual contains information to facilitate maintenance
(part replacement) and is a supplement to the maintenance manual.
Accompanying the workshop manual is supplier documentation for
engine, transmission and drive axle. Where possible, the workshop
manual provides reference to supplier documentation instead of printing
the same information twice. Methods for preventive maintenance and
certain checks are found in the maintenance manual, no references
are given for these. Use the function groups to locate the information in
the maintenance manual.
The workshop manual is divided into the following sections.
A Foreword General information about the workshop manual's purpose, contents and reading
instructions as well as survey for feedback of views and any inaccuracies.
B Safety Keep in mind for your safety.
C Preventive maintenance Reference to maintenance manual: Preventive maintenance.
0 Complete machine
1 Engine
2 Transmission
3 Driveline/Axle
Technical description, comprehensive function descriptions and a description of the
4 Brakes function of components included in the machine, divided into function groups.
5 Steering The components used for each respective function are described under each
subfunction. Consequently, common components are described in several
6 Suspension locations, but in general under the first function to use the component.
7 Load handling Together with the general description is a detailed description of what is unique
about the specific subfunction. The next subfunction to use the same component
8 Control system only has a description what is unique for the new function.
9 Frame, body, cab and Work instructions for corrective maintenance (replacement of components).
accessories
11 Common electrics
12 Common pneumatics
D Error codes Error code information and instructions for reading error code information.
E Schematics Wiring diagrams, hydraulic diagrams and list of electrical components.
F Technical data Technical data, conversion tables, information for conversion of units.
G Terminology and index General terminology and abbreviations, explanation of terms and abbreviations that
can appear in the sections, index for headings in the manual.

Function group structure

The information in the manual is divided in a structure of functions at
different levels, based on the machine's design and use, called function
groups.
The upper level (called main group) determines area, e.g. group 7
Load handling. The second level (called two-digit) determines function,
e.g. 7.2 Lifting/lowering. The third and fourth levels are used to break
down functions into smaller parts (components).
The function groups' structure for main group and two-digit group level
are common for all machines from Cargotec, e.g. 4.3 Power-assisted
brake system. Machine-unique adaptations of function groups are
made at the third and fourth group level, e.g. 4.3.9 Wheel brake and
4.3.9.1 Disc pack. This means that certain function groups (headings)
will be left out in the documentation for certain machines since the
machine is missing that specific function or component. In turn, this
means that there may be jumps in the function groups' numbering, e.g.
the three-digit heading level 4.8.7 Oil cooler may be included for some
machines, but is missing for others.
The function groups are intended to be used as search terms in

order to find different types of information between different sections
and manuals. The information in a function group is divided in
smaller sections according to the type of content, e.g. description or
replacement.
The maintenance manual and the workshop manual contain different

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

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

section and group number, e.g., "see section 4 Brakes, group 4.3.9
Wheel brake". References within a section are indicated with a page
number, e.g. "see Sensor fuel level, description page 24".
References between Maintenance manual and Workshop manual

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

References between different information types

The maintenance manual and workshop manual are mainly divided
into function groups, see The workshop manual's contents, page A:5.
Certain parts are broken out as separate parts to increase usability,
e.g. "Technical data".
The basic rule of searching for information is to use the function

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

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

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

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

Product alternatives and optional equipment

The information in the manual is divided into modules. If a product
alternative or optional equipment is fitted, handling may differ from
that indicated in the modules depending on what is being described.
See below.
Special equipment is not described in the manual. If uncertain as

to what equipment is fitted to the machine, use the machine card to
determine which information is relevant. See Machine card, page A:9.
Product alternative
Product alternative describes options that are fitted instead of a specific
piece of standard equipment (e.g. engine alternative).
Equivalent information for different product alternatives is described

consecutively in separate segments within the same function group.
To indicate that there are different alternatives, "Product alternative"
is added to the heading together with a simple description of the
alternative, e.g. "(Product alternative Climate control system ECC)". In
addition, the alternative that is an option is marked with the symbol for
optional equipment.
Optional equipment
Optional equipment
000264
Optional equipment refers to options that can be added to standard

Symbol for optional equipment equipment for more or increased functions.
Information on auxiliary equipment is described in separate segments

together with the standard equipment as the basis. The optional
equipment description covers how the equipment option affects the
standard function and what additional components are involved.

Machine card
NOTE
If the machine has been modified after delivery, information on the
machine card may be incomplete or incorrect.
IMPORTANT
Modifications made to the machine must be reported to
Cargotec so that the machine card can be updated. A
new updated machine card is sent when the customer
requests this.
The machine card indicates which drawings the machine is

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

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

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

valves, sensors, etc.
7:14 7 La s tha nte ring – Lyft och s ä nk
Lyft och sän k, fu n ktio n s b e s krivn in g

Fö ru ts ä ttn in g Börv ärde Hän vis n in g
Manö ve rbryta re Frikoppla d Ma növe rbryta rs pä nning (15E), funktions be s kriv-
ning, sid a 11:19
Twistlocks Lå s t e lle r olå s t, inte mella nlä ge Twistlocks , be s krivning, sid a 7:103
Överbe last ning s s ys te m Bom upp: pa s s ivt Öve rbe la s tnings ys te m, funktions be s krivning,
Bom ne d: pa s s ivt e lle r förbikoppling aktive ra d sid a 8:7
Förbikoppling, be s krivning, sid a 8:8
Anliggning Bom ne d: inge n a nliggning Twistlocks , funktions be s krivning, sid a 7:98 1
Höjdbe grä ns ning Förbikoppla d e lle r bomhöjd lä gre ä n Höjdbe grä ns ning, be s krivning, sid a 8:10
höjdbe grä ns ninge n.
1
D1
2
2, 4
D7902 D7950
D7971 D7911
3, 5, 16, 21 27
D26
4
12 UDS D7940
D20 >°
D25 3
D7930 6 D5 6 17 22 25 26
D16
15 PSS PSL
D21
Pa
PP
A1 VA
C-M 19, 24
12 7
P C-
T
11 LS P D
B1
C+
C+M Pa
4
14 20
18, 23
LSP1 A H
LSP2
8, 813
LSPR EF CF 11
LSP3 LSHY C13 P
LSP3X P T T P LSO
LSM
12
10 C9 5
C9 C10
016338
9 9 10
9 Pos Fö rkla rin g S ig n a lb e s krivn in g Hän vis n in g

6
1 Manö ve rs pa k (S8 150 -Y) sänd e r S ä nk: U = 0,5–2,0 V Ma növe rs pa k, be s krivning, sid a 7:7
spän ningsign a l pro portione ll mot Nolläge : U = 2,0–3,0 V D1: Diagnos me ny, s e 7.1 Controls
spakröre lsen till Reg lere nhe t KPU a nd Ins tr 5/XX DIAGNOS E, sid a 8:42
(D79 02). Lyft: U = 3,0–4,5 V
0,5 V ä r högs ta s ä nkha s tighe t
och 4,5 V ä r hög s ta
lyfthasti ghe t. Läg re s pä nning
8 ä n 0,5 V och högre s pä nning 7
ä n 4,5 V a nvä nds för a tt
upptä cka fe l i ka bla ge och
reg lag e .
2 Reg lere nhe t KPU (D79 02) sänd e r Kontrolle ra s a v s tyr- och 11.5.3.2 Re gle re nhe t KP U (D7902),
be gä ra n om Bom upp e lle r Bom ne d med övervakni ngs s ys te me t, fe l sid a 11:28
ha s tighe ts informa tion på CAN-bus s e n. visa s med fe lkod.
017426
VDRG01 .01SE Verkstad s ma nua l DRG 420–450
Example of function description

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

Symbol explanation function descriptions
Symbol explanation function descriptions

The following symbols are used in function descriptions. The symbols
1 2
are based on standard symbols for wiring and hydraulic diagrams.
3 4 1. Electric control signal
2. Electric force
5 6 3. Hydraulic control signal
4. Hydraulic force
5. Hydraulic oil pump with fixed displacement
7 8 M
6. Hydraulic oil pump with variable displacement
7. Hydraulic motor
9 10 8. Electric motor
9. Accumulator
11 12 10. Valve block

11. Filter
12. Radiator
13 14
13. Non-return valve
15 16 14. Shuttle valve
15. Restriction
17 18 16. Adjustable restriction
17. Spring brake cylinder
19 20 °C
18. Hydraulic cylinder
19. Disc brake
21 22 20. Thermal bypass valve
21. Inductive position sensor
23 °C 24 °C
22. Electrically controlled solenoid valve
25 Pa 26 Pa 23. Temperature sensor

24. Temperature-controlled switch
27 28 25. Pressure-controlled switch
D7901 26. Pressure sensor

29 30 27. Bulb
D7971 28. Horn or buzzer
29. Control and monitoring system, two control units with CAN bus
014726
31 30. Relay
31. Double-acting hydraulic cylinder

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

The documentation's parts
The documentation for the machine consists of the following parts:
Operator's manual
The operator's manual is delivered with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
supplied for the machine as a separate documentation kit.
Supplementary documentation
There is supplementary documentation that can be ordered for the
machine.
• Workshop manual.
• Supplier documentation for engine, transmission, and drive axle.
Ordering documentation
Documentation is ordered from your Cargotec dealer.
Always indicate publication number when ordering.
For publication number, see machine card.
Feedback
Cargotec's ambition is that you who work with maintenance of Kalmar
machines shall have access to correct information.
Your feedback is important to be able to improve the information.
If you have any comments, please send them or fax them to the
address below. Thanks for your help!
Cargotec Sweden AB
Technical Documentation
Torggatan 3
SE-340 10 Lidhult
SWEDEN
Fax: +46 372 263 93

B:1
B Safety
Contents B Safety
Safety..................................................................................................................B:3
General safety information.............................................................................. B:3
Safety concerns everyone!......................................................................... B:3
A near accident is a warning! ..................................................................... B:3
Safety instructions........................................................................................... B:4
General ...................................................................................................... B:4
Service position .......................................................................................... B:5
Hydraulic and brake systems, depressurising............................................ B:6
Oils ............................................................................................................. B:9
Fuel system .............................................................................................. B:10
AdBlue...................................................................................................... B:11
Clothing, etc. ............................................................................................ B:12
Several mechanics on the same machine................................................ B:13
Working under the machine ..................................................................... B:13
Lifting heavy components ........................................................................ B:14
Vibration ................................................................................................... B:14
Noise ........................................................................................................ B:15
Dissolvent................................................................................................. B:15
Fire and explosion risk ............................................................................. B:16
Fluid or gas under pressure ..................................................................... B:19
Coolant ..................................................................................................... B:20
Refrigerant ............................................................................................... B:20
Air pollution .............................................................................................. B:21
Tensioned springs .................................................................................... B:22
Electrical system and electric motors ....................................................... B:22
Rotating components and tools................................................................ B:22
Tyres and rims.......................................................................................... B:23
Lifting equipment ...................................................................................... B:23
Welding .................................................................................................... B:24
Spare parts............................................................................................... B:25
Non-ionised radiation ............................................................................... B:26
Environment.................................................................................................. B:27
General .................................................................................................... B:27

B:2

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

and risks that may occur in connection with the use of, as well as
service or repair of, the machine during normal circumstances.
For this reason it is important that all who work with the machine, or
repair or service the machine, read and follow the information in the
Operator's manual, Maintenance manual and Workshop manual.
A near accident is a warning!

A near accident is an unanticipated event where no person is injured,
nor is there any damage to the machine or property. However, near
accidents show that there is an injury/damage risk and that actions
must be taken to avoid the risk of injury/damage.

B:4 B Safety – Safety instructions
Safety instructions
General
Read and observe the following safety instructions below before
starting to work with the machine:
• Service position, page B:5
• Hydraulic and brake systems, depressurising, page B:6
• Oils, page B:9
• Fuel system, page B:10
• AdBlue, page B:11
• Clothing, etc., page B:12
• Several mechanics on the same machine, page B:13
• Working under the machine, page B:13
• Lifting heavy components, page B:14
• Vibration, page B:14
• Noise, page B:15
• Dissolvent, page B:15
• Fire and explosion risk, page B:16
• Fluid or gas under pressure, page B:19
• Coolant, page B:20
• Refrigerant, page B:20
• Air pollution, page B:21
• Tensioned springs, page B:22
• Electrical system and electric motors, page B:22
• Rotating components and tools, page B:22
• Tyres and rims, page B:23
• Lifting equipment, page B:23
• Welding, page B:24
• Spare parts, page B:25
• Non-ionised radiation, page B:26

B Safety – Safety instructions B:5
Service position
General
General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
Service position is the starting point in most instructions. Certain work

requires that service position is not used.
Service position entails:

• The machine is parked, i.e. parking brake applied.
• Boom fully retracted and lowered to horizontal position.
• Engine switched off, start key in position 0.
• Where required, the cab is moved forward or the engine covers
are removed.
016252
On machines with mechanical cab sliding:
Machine with fully retracted and lowered boom
DANGER
The cab is very heavy and the machine must
not be moved without first securing the cab.
Extreme danger! Risk of crushing!
Always make sure that the cab locks on both
sides are locked in their rear position before
operating, and that the locks are secured with
the lock pins.
• If the engine is being started, connect exhaust-venting equipment

to the exhaust pipe when working indoors.

Hydraulic and brake systems, depressurising

Depressurising depressurises both the brake system and the hydraulic
system. This is a safety precaution in order to reduce the risk of
damage if components are mixed up.
Before the hydraulic system is opened

1 Machine in service position, see Service position, page B:5.
2 Depressurise the hydraulic system.
Turn the start key to position I and activate extension out, a loud
hissing noise is heard if there is pressure in the hydraulic system.
Activate lift, extension and side shift several times.
3 Turn the start key to position 0.
016256
4 Depressurise the attachment.

Open relief valve top lift.
016255
Relief valve for top lift, the figure above shows an

open valve.

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

accumulator charging valve.
NOTE
Keep the drain valve open as long as work is in progress.
016821
After work is finished

6 Close the drain valve on the accumulator charging valve
NOTE
Check that the accumulator drain valve is fully closed and tighten
the lock ring.
016822

7 Close the relief valve for top lift.
016255
Relief valve for top lift, the figure above shows an

open valve.

Oils
The following safety instructions must be followed for work when
handling oils.
WARNING
Hot and pressurised oil.
Always depressurise hydraulic and brake systems
before starting to work on the systems. The hydraulic
and brake systems are pressurised and the oil may
cause personal injuries.
Avoid skin contact with the oil, use protective gloves.
Hot oil can cause burn injuries, rashes and irritation!
The oil can act corrosive to eyes and skin, and mucous
membranes in the throat.
CAUTION
Always clean the area around components and
connections before they are loosened, and plug the
connections. Dirt in oil systems causes increased
wear, resulting in subsequent material damage.
Always take action to avoid spills. In locations where
drainage containers cannot be used, use a pump or
hose for safe handling.
Always check that plugs are sealed tightly before
receptacles are moved.
Handle all oil as environmentally hazardous waste.
Oils freely discharged cause environmental damage
and can also be a fire hazard. Waste oils/fluids must
always be handled by an authorised company.

Fuel system
handling fuel.
DANGER
Pay attention to the risk of fire when working on the
fuel system.
Work on the fuel system must be avoided when the
engine is warm since fuel can spill on hot surfaces
and may ignite.
Make sure that open flames, sparks, or red-hot/glowing
objects have been extinguished before starting work
on or near the fuel system.
Do not smoke near the machine during work on the
fuel system.
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
injure the skin, resulting in severe injuries.
Risk of personal injury.
Use protective gloves and protective safety glasses,
avoid skin contact with fuel. If a component is being
loosened then hold a rag over the connection as
protection and collect the fuel. Fuel acts corrosive to
eyes and skin, and mucous membranes in the throat.
CAUTION
Always clean the area around components and
connections before they are loosened, and plug the
connections. Dirt in the fuel causes malfunctions
and engine stops in undesirable situations as well
as increased wear, resulting in subsequent material
damage.
Always take action to avoid spills. In locations where
drainage containers cannot be used, use a pump or
hose for safe handling.
Always check that plugs are sealed tightly before
receptacles are moved.
Handle the fuel as environmentally hazardous waste.
Fuel freely discharged cause environmental damage
and can also be a fire hazard. Fuel must always be
handled by a company authorised for this activity.

AdBlue
handling AdBlue.
WARNING
AdBlue spilled on hot components evaporates quickly.
AdBlue can cause irritation in the event of contact with
the skin and eyes and inhalation.
Health hazard!
Turn your head away. Vaporised AdBlue can act
corrosive to eyes and mucous membranes in the
throat. If inhaled, breathe fresh air and seek medical
advice if necessary.
Handle with care and avoid skin contact, wear
protective gloves. In the event of skin contact and
spillage on clothing, rinse the skin with large amounts
of water and change contaminated clothing and
gloves. In the event of contact with the eyes, rinse
thoroughly with water for several minutes and seek
medical advice if necessary.
CAUTION
Switch off the engine and wait at least 2 minutes before
working on the AdBlue system.
Risk of unnecessary large spillage.
When the engine is turned off the AdBlue system
pumps the solution in the pipes back to the AdBlue
tank. Let this process finish before starting work in
order to reduce the amount of spillage.
CAUTION
AdBlue is very corrosive and creeping.
AdBlue is extremely aggressive towards wiring.
Wiring that has come into contact with AdBlue must
be replaced.
IMPORTANT
Do not spill AdBlue on the ground and in water.
Spillage on the ground must be absorbed with sand or
other absorbent non-combustible material.

Risks
AdBlue is very corrosive and creeping, spillage that is not cleaned up
can damage to wiring, equipment and tools. In the event of spillage
there is a risk AdBlue can cause oxidation which is impossible to
remove. Cleaning with compressed air and water is not enough as
AdBlue oxidises the metal itself.
Safety precautions
• Prior to working with the AdBlue system, turn off the engine and
wait for two minutes so that the AdBlue system has time to pump
the solution back to the tank.
• If a connector has been exposed to the AdBlue solution it must be
replaced immediately so that the AdBlue solution does not creep
further into the cable harness. Ad-Blue creeps at a rate of 0.6 m/h
in the cable harness.
• Clean the machine immediately in the event of spillage to prevent
damage.
• Clean tools after the service work to prevent damage.
• Protect all electrical connectors properly prior to working on the
AdBlue system's tank and pipes.
• Always plug the AdBlue system's hoses, pump unit, metering valve
and tank when these are disconnected to prevent spillage and to
protect the system against contamination that causes the AdBlue
solution to crystallise.
Clothing, etc.
Clothes should be in good repair. Remove loosely hanging garments
(e.g. tie, scarf). Do not wear clothes with wide sleeves, wide trouser
legs, etc.
Remove jewellery as it may conduct electricity and get caught in

moving parts.
Long hair should be adequately gathered since it can easily get caught
in moving parts. Exercise caution when working with welding or an
naked flame since hair easily catches on fire.

Several mechanics on the same machine
WARNING
If several mechanics are working on the same vehicle,
extra care must be taken so that accidental movements
do not injure any other person. Communicate so that
everyone knows where everyone is, and what they are
doing.
Risks
Operations controlled from the operator's station, e.g. all movement of
lifting equipment, may cause severe personal injury.
Safety precautions
• Make sure that the machine's lifting equipment is completely
lowered or secured in some other way.
• Move the battery disconnector to position zero and remove the key.
• Be aware of the risks when several persons are working around
the vehicle.
• Make your co-workers aware of what you are working with.
• Do not work with the drive wheels on both sides of the truck at the
same time if the drive wheels on both sides are raised.
Working under the machine

Working under cab
Working under cab

On machines with liftable cab, the cab must be secured in the raised
position with the intended locks.
Working under the frame

A raised vehicle may not, for any reason, be supported or raised in
parts that belong to the wheel suspension or steering. Do not support
under mudguards or tanks either. Always support under the frame or
drive axle.
Risks
A
Mechanical or hydraulic tools and lifting devices may fall over or
accidentally lower due to malfunctions or incorrect use.
001977
Safety precautions
Locks on lift mast for securing the liftable cab in the • Use axle stands and supports that stand securely.
raised position.
• Lifting tools should be inspected and type approved for use.

Lifting heavy components
WARNING
Careless handling of heavy components may lead to
serious personal injury and material damage.
Use type approved lifting tools or other tools to move
heavy components. Make sure that the device is sturdy
and intact.
Risks
Unsuitable lifting straps, etc. may break or slide.
The centre of gravity of the component may shift while work is in

progress, and the component may then make unexpected movements
which may cause severe personal injury and material damage.
A component lifted with lifting equipment may start to turn if the centre
of gravity shifts.
A component lifted using an overhead crane may start to swing back

and forth, which can cause severe crushing injuries or material damage.
Safety precautions
Lifting with lifting device. Use lifting tools or other tools, in particular
when there are such tools available adapted for specific work
operations.
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 often good protection to reduce crushing
and cutting injuries to fingers.
• Always use protective shoes.
Vibration
Use of vibrating tools, e.g. impact nut runner or grinder, for an extended
period of time may cause injuries as vibration is transmitted from the
tool to hands. In particular when fingers are cold.
Safety precautions
• Use heavy gloves that protect against the cold and the transfer of
vibrations.
• Switch between work duties to give the body time to rest.
• Vary your work position and grip so that your body is not affected in
only one position by the vibration.

Noise
Noise louder than 85 dB (A) that lasts for longer than 8 hours is
considered to damage hearing. (Limit values may differ between
different countries.) High pitches (high frequencies) do more damage
than low pitches with the same sound level. Noise in the form of
impulse sounds may also be damaging, e.g. hammer strikes.
Risks
At noise levels higher than the limit values hearing damage may occur.
In more severe cases, hearing damage can become permanent.
Safety precautions
• Use hearing protection. Make sure that it's tested and protects
against the right noise level.
• Limit noise with noise-absorbing screens, for example,
noise-absorbing materials in roof and on walls.
Dissolvent
Fluids that (as opposed to water) dissolve grease, paint, lacquer,
wax, oil, glue, rubber, etc. are called organic dissolvents.
Example: Petroleum spirits, petrol, thinner, alcohols, diesel, xylene,
trichloroethylene, toluene, etc. Many dissolvents are flammable.
Risks
Products with dissolvents give off fumes that may cause dizziness,
headache and nausea. They may also irritate mucous membranes
in the throat and bronchi.
If dissolvent comes into direct contact with the skin it can dry and crack.
Increased risk of skin allergies. Dissolvents may also cause injury if
they penetrate through the skin and are absorbed by the blood.
If the body is continuously exposed to dissolvents, there may be

damage to the central nervous system. This manifests itself in
sleeping problems, depression, nervousness, poor memory and
general tiredness. Continuous inhalation of petrol and diesel fumes is
suspected to cause cancer.
Safety precautions
• Avoid inhaling dissolvent 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 dissolvent container without tight-sealing lid.
• Use dissolvents with a low content of aromatic substances. This
reduces the risk of injury.
• Avoid skin contact.
• Use protective gloves.
• Make sure that work clothes are dissolvent-resistant.

Fire and explosion risk
DANGER
In the event of fire the operator's safety must not be
compromised.
If given the opportunity, take the following action at
the slightest sign of fire:
1. Stop the machine and turn the ignition key to stop
position.
2. Leave the cab.
3. Switch off the system voltage with the battery
disconnector.
4. Alert the rescue services.
5. Try to extinguish the fire.
If this is not possible, leave the machine and the
risk area.
DANGER
Smoke can be extremely toxic.
Smoke subdues, suffocates and can kill people!
Smoke can cause damage to lungs and respiratory
organs even in small quantities.
Avoid breathing fumes, do not stand in the smoke.
Use breathing apparatus for fire fighting and work
with burnt material.
DANGER
Tyres that have caught fire are difficult to extinguish
and can cause fires with explosive development.
Extreme danger!
Always seek safety if tyres catch fire.
Examples of fire and explosion prone substances are oils, petrol, diesel
fuel oil, organic solvents (paint, plastics, detergents), rust preventive
agents, welding gas, gas for heating (acetylene), high concentrations
of dust particles consisting of combustible materials. Rubber tyres that
have caught fire are difficult to extinguish and can cause fires with
explosive development.

Risks
Examples of the cause of ignition are welding, cutting with gas flame,
tobacco smoking, sparks when grinding with grinding machines, contact
between hot engine parts and flammable materials, heat generation
in rags soaked with oil or paint (linseed oil) and oxygen. Oxygen
containers, lines and valves must be kept clean of oil and grease.
Fumes from e.g. fuel are heavier than air and may "run" down a slope,
or down into a grease pit, where welding flames, grinding sparks or
cigarette embers may cause an explosion. Vaporised fuel has a very
powerful explosive effect.
Special cases
Diesel fuel oil with added petrol has a lower flashpoint. Risk of
explosion even at room temperature. The explosion risk for heated
diesel fuel oil is higher than for petrol.
When changing the oil in the engine, hydraulic system and transmission,
keep in mind that the oil may be hot and cause burn injuries.
Welding on or in the vicinity of the machine. If diesel or other oils

have leaked and soaked rags, Absol/absorbing agents, paper or other
porous material then glowing welding sparks can cause ignition and
the explosive spread of fire.
When a battery is being recharged the battery electrolyte water is

divided into oxygen and hydrogen gas. This mixture is highly explosive.
The risk of explosion is especially high when a booster battery or a
rapid-charge unit is used, as they increase the risk of sparks.
There is a lot of electronic equipment on today's machines. When

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

10 cm around the welding or cutting point). Use gloves, breathing
protection and protective glasses. Also, welding work must not be done
near plastic or rubber materials without first protecting them from the
heat. Paints, plastics and rubber develop a number of substances
when heated that may be hazardous to health. Exercise caution with
machines that have been exposed to intense heat or fire.

Safety precautions
DANGER
Residue from fuel, oils, grease or other flammable
materials on the engine or in the engine compartment
is a fire hazard.
Fire hazard!
Remove residue of flammable materials in the engine
compartment as soon as they are detected. Be extra
careful on hot surfaces such as exhaust systems,
manifolds or turbochargers. If leakage of oil, fuel or
coolant is detected, the reason should be investigated
and the fault corrected before starting the engine.
• Make it a habit to make a visual inspection of the engine and

engine compartment before starting the engine and after operation,
when the engine has been stopped. This helps to quickly detect
if anything abnormal has happened or is about to happen. Look
particularly closely for oil, fuel or coolant leakage, loose bolts, worn
or poorly tensioned drive belts, loose connections, damaged hoses
and electrical cables. The inspection only takes a few minutes and
can prevent serious faults and costly repairs.
• Store a hazardous substance in an approved and sealed container.
• Make sure that there is no ignition source near flammable or
explosive substances.
• Make sure that ventilation is adequate or there is an air extraction
unit when handling flammable substances.
• Always have a fire extinguisher close at hand.

Fluid or gas under pressure

Lines with high pressure may be damaged during work and fluid or
gas may jet out.
There may be high pressure in a line even if the pump has stopped.
Therefore, gas or fluid may leak out when the connection for the hose
is loosened.
A gas container that is subjected to external forces may explode, e.g. if

it falls against a hard surface. Gas may jet out from damaged valves.
Risks
Risk of damage/injury in connection with work on:
• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Tyre changing.
• Air conditioning.
• Cooling system.
Safety precautions
• Use protective goggles and protective gloves.
• Never work in a pressurised system.
• Never adjust a pressure relief valve to a higher pressure than the
manufacturer's recommendations.
• A hydraulic hose that swells, e.g. at a connection, shows evidence
that it is about to rupture. Replace it as soon as possible! Check
the connections thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• A discarded pressure accumulator must 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 to check for any leaks. A fine jet from a
hydraulic hose may have such high pressure that it easily cuts
through e.g. a hand and causes very severe injuries.
• First open the cooling system cap for the filling point slowly, so
that the high pressure is released. Exercise caution. Hot steam
and coolant may jet out.

Coolant
The coolant in the machine's cooling system consists of water,
anti-corrosion compound and anti-freeze fluid, for example, ethylene
glycol.
Coolant must not be drained into the sewer system or directly onto
the ground.
Risks
The cooling system is at high pressure when the engine is warm. Hot
coolant may jet out and cause scalding in the event of leaks or when
the cap on the expansion tank (filling point) is opened.
Ingesting glycol and anti-corrosion compound is dangerous and

hazardous to health.
Safety precautions
• Use protective gloves and protective safety glasses if there is a risk
of splashing or spraying.
• First open the cap for the filling point slowly, so that the high
pressure is released. Exercise caution. Hot steam and coolant
may jet out.
• If possible, avoid working on the cooling system when the coolant
is hot.
Refrigerant
Refrigerant is used in the machine's air conditioning system.
Work on the air conditioning system must be performed by

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

system), generates gases that are very dangerous to inhale.
Safety precautions
• Use special instructions and equipment for refrigerant according to
the manual when working on the air conditioning system. Special
certification and authorisation must often be held by the person
who may do the work. (Observe national legislation and local
regulations!)
• Use protective gloves and protective safety glasses if there is
a risk of leaks.
• Make sure, for example, that heat-producing sources or objects
are not close by (cigarette glow, welding flame).

Air pollution
Air pollutants are the impurities in the air around us and are regarded
as hazardous to health. Certain impurities are more prevalent in certain
environments.
The following health-hazardous air pollution is particularly prominent in

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

in aerosol) when cutting, grinding or welding. May cause mucous
membrane irritation with asthma-like symptoms and impaired lung
function. Even brief exposure to high concentrations may cause
problems with persistent hypersensitivity.
Safety precautions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are
formed.
• Use suitable protective gloves and breathing protection when there
is a risk of oil mist. Make sure that the protection is oil-resistant.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eyewash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine in the workshop.
Connect extraction equipment to the exhaust pipe so that exhausts
are routed out from the workshop.

Tensioned springs
Examples of tensioned springs:
1. Torque springs in, e.g. pedals
2. Thrust spring (cup springs) in parking brake cylinder
3. Lock rings
4. Gas springs
Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries amongst other things.
Parking brake springs are tensioned with high force and can cause very
severe accidents if they are accidentally released in an uncontrolled
manner.
Gas springs and gas-charged shock absorbers are tensioned with high
force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety precautions
• Use protective safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manuals when performing
maintenance and replacing parts and components.
• Always use the tools recommended.
Electrical system and electric motors

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

Examples of rotating components and tools:
• Cooling fan
• Drive belts
• Propeller shafts
• Drills
• Grinding machines
Risks
Rotating components, e.g. fans or shafts, can cause severe injury
if touched.
Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothing or hair gets caught and becomes wound
into the machine.

Safety precautions
• Do not use gloves when working with a drill.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or trouser legs.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair net or similar.
• Remove large or loose hanging jewellery from hands, arms and
neck.
Tyres and rims
DANGER
Tyres should be regarded as pressure reservoirs. If
handled incorrectly, they constitute fatal danger.
Parts could be thrown out with explosive force and
cause severe injuries.
Never repair damaged tyres, wheel rims or lock rings.
Tyre changes must be performed by authorised
personnel.
Risks
Dismantling of wheels: Tyres, rims and lock rings may be ejected.
Inflating tyres: Tyres, 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 are not damaged. Never
repair damaged wheel rims or lock rings.
• The tyres must be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected parts.
• Use protective screen and protective safety glasses.
Lifting equipment
When working on the machine in general, and with the machine's lifting
equipment in particular, the greatest caution must be exercised with
respect to securing the mast, boom, and attachment.
Therefore, always make a habit of having the boom fully lowered and
completely retracted when working on the machine.
Risks
If the machine's lifting equipment is not lowered or secured, there is a
risk of crushing.
Risk of crushing is particularly great when depressurising the hydraulic

system, see Hydraulic and brake systems, depressurising, page B:6.
Safety precautions
• If possible, do not start to work before the boom is completely
lowered and fully retracted.

Welding
DANGER
Contact Cargotec Support before welding on the
machine.
CAUTION
There is a lot of electronic equipment on today's
machines. Control units must be disconnected and the
electric power must be switched off with the battery
disconnector with all welding on the machine.
Powerful welding currents may otherwise short-circuit
the electronics, destroy expensive equipment or cause
an explosion or fire.

Spare parts
WARNING
For safety reasons, the following spare parts may only
be replaced with genuine spare parts:
• Brake valve
• Drive axle
• Valve for mini-wheel/joystick control
• Steering valve (Orbitrol)
• Control valve steering incl. priority valve
• Steering axle
• Steering cylinder
• Steering spindle
• Hub
• Rim
• Lift boom
• Boom nose extension
• Lift cylinder
• Valve block lift cylinder
• Extension cylinder
• Valve block extension cylinder
• Rotation motor unit
• Tilt cylinder
• Twistlock, lift shoe
• Attachment complete
• Lifting lugs
• Control breaker (for hydraulic function)
• Emergency stop
• Cab
• Frame
• Accumulator
• Accumulator charging valve
• All control units

Non-ionised radiation
WARNING
Optional equipment such as two-way radio, remote
controlled door openers, etc. may emit non-ionising
radiation. This type of equipment transmits within the
frequency band 100 - 500 MHz.
Danger of disruption to active medical products (e.g.
pacemaker).
Do not use communication radios, remote door
openers, etc. when persons with active implanted
medical devices are in the cab.
NOTE
Cargotec will not assume any responsibility for installed optional
equipment, which is not installed by Cargotec or an installer
approved by Cargotec.

B Safety – Environment B:27
Environment
General
The ever-increasing industrialisation of our world is having a significant
impact on our global environment. Nature, animals and people are
subjected daily to risks in connection with various forms of chemical
handling.
There are still no fully environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle, perform
service on or repair machines must use the tools, assisting devices and
methods necessary to protect the environment in an environmentally
sound manner.
By following the simple rules below, you will contribute to protecting
our environment.
Recycling
Conscientious recycling of the machine is the starting point for the life
cycle to come full circle, and for being able to recycle and make use of
material in new products. According to calculations by Cargotec, the
machine is more than 90% recyclable by weight.
Environmentally hazardous waste
Components such as batteries, oils, and various chemicals and other
items that may constitute environmentally hazardous waste must be
handled and taken care of in an environmentally safe and sound
manner.
Discarded batteries contain substances hazardous to personal health
and the environment. Therefore, handle batteries in an environmentally
safe manner and according to national regulations.
Oils and fluids
Oils freely discharged cause environmental damage and can also be a
fire hazard. Therefore, when emptying and draining oils or fuel, take
appropriate action to prevent unnecessary spills.
Waste oils and fluids should always be taken care of by an authorised
disposal company.
Pay close attention to oil leaks and other fluid leaks! Rectify leakage
immediately.
Air conditioning
The refrigerant in the air conditioning for the cab adds to the
"greenhouse effect" if released into the open air. Special training is
required for all service work on the air conditioning. Many countries
also require certification by a governing authority for such work. When
scrapping an air conditioning unit, the refrigerant shall be taken care
of by a certified company.
Working in a contaminated area
The machine must be equipped for work in contaminated areas
(environmentally polluted or health-hazardous area) before work is
started. Also, there are special local rules in force for such handling
and when servicing such a machine.
Declarations
The machine does not contain asbestos.
The machine contains lead in batteries and in electric cabling.
If the machine is equipped with air conditioning, use refrigerant type
R134a.

B:28

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

section A Foreword.

C:2

0:1
0 Complete machine
Contents 0 Complete machine

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

0:2

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

functions. Certain faults can be identified directly using function
descriptions. Sections 0–12 contain descriptions of the various
functions of the machine.
Troubleshooting procedure
1 Check that there is battery voltage available.
• Battery disconnector, must be in position 1.
• Battery voltage, should be 24–30 V.
• Fuses, check that they are intact.
2 Check that all oil and fluid levels are normal.
• Fuel
• Engine oil
• Transmission oil
• Hydraulic oil
• Coolant
• Washer fluid
3 Check if there are error codes.
4 If there are error codes, use the error code lists as a guide. See
Troubleshooting with an error code, example, page 0:5.
The error code lists contain recommended actions for every error
code. Error code lists are available in section D Error codes.
5 If there is no error code or the problem persists, read the
function description for the function affected in section 0–12. See
Troubleshooting without an error code, example, page 0:4
The function description contains information on which components
are involved in the function and how these components work
together. In some cases, there is information on what conditions
are required in order for it to be possible to activate the function.
Measuring points are marked with flags (C for measuring outlet,
D for diagnostic menu).
Use the diagnostic menus to read signal and sensor values as well
as to activate individual components in order to identify potential
sources of error. For a more detailed description, 8.4 Diagnostics,
page 8:26.

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

example
1 Choose suitable section 0–12 to locate the function and
subfunction that have caused the symptom.
2 Read the function description for the function in question to get
an overall understanding of which components are affected and
how these interact.
3 Use the function description and check the signals for the function
affected in order to locate where in the function chain that the
signal or reaction is incorrect.
Measuring points are marked with flags (C for measuring outlet, D
for diagnostic menu). Individual signal and sensor values can be
read with the diagnostic menus. In certain cases, it is also possible
to activate individual components. For a more detailed description
of the diagnostic menus, see 8.4 Diagnostics, page 8:26.
4 The fault is probably between the two units where the signal is
incorrect. Start by checking the component that should be sending
the signal.
5 If the component that is to send the signal seems to be intact,
check the transmission of the signal (electric cables or hydraulic
hoses).
For electric cables, see Troubleshooting cable harnesses, page
0:6.
For hydraulic hoses, see Troubleshooting hydraulic hoses, page
0:8.
6 If the cables or hoses between the components seem to be intact,
then check the component that receives the signal.

Troubleshooting with an error code,

example
Error codes are indicators of malfunctions detected by the control
system. Many error codes are connected to electrical malfunctions but
there are also error codes that interpret associations between one or
several signals that indicate a non-electrical malfunction. It is important
not to draw conclusions too hastily based on an error code.
1 Use the error code lists and search information about the error
code, see "Example of error code information in error code list"
below.
The error code lists are available in section D Error codes.
For detailed instructions for reading out error code, see section
D Error codes.
2 Follow the instructions in the field "Action".
3 Use diagnostic menus and circuit diagrams to determine if the
input signal to the control unit is correct; see section 8 Control
system, group 8.4 Diagnostics as well as section E Schematics.
4 Use the function group to find more information if needed.
In section 0–12 there is function description, the function's included
components and their position as well as, in certain cases, work
instructions for how components are checked, cleaned or adjusted.
5 If possible, eliminate component faults by testing the component
individually.
Electric components can sometimes be checked with resistance
measurements using a multimeter.
Hydraulic components are usually controlled by measuring the
pressure (which is described in the function group). Sometimes
valves can be activated mechanically in order to determine if the
malfunction is electric or hydraulic.
6 If the component's measurement values are correct, continue by
troubleshooting electric cables and hydraulic hoses.
For electric cables, see Troubleshooting cable harnesses, page
0:6.
For hydraulic hoses, see Troubleshooting hydraulic hoses, page
0:8.
7 If the wiring is not defective, then connect the cable to the control
unit.
NOTE
The system voltage must be switched off with the battery
disconnector!
8 Disconnect the cable harness from the component in question.

9 Switch on the system voltage with the battery disconnector.
10 Check that voltage reaches the component.

Tabell Example of error code information in error code list
Error codes machine
Connec-
tions
Lo- and Diag-
Ty- No- ca- Descrip- compo- nostic Refer-
pe SPN FMI de tion tion Limitation Action nents menu ence
B 7570 3 2 Sensor Incorrect Check the B7570 1.2 Fuel Sen-
fuel level display of cable harness D7971/C- System sor, fuel
(B7570), fuel volume between the 2:24 1/XX level, de-
high signal (empty or control unit and DIAG- scription,
voltage. full). the sensor using NOSE, page
the diagnostic page 1:26
menu. 8:28
Check the
sensor.
Troubleshooting cable harnesses
NOTE
Perform troubleshooting for all cables in the same way to avoid
damage to control units, components or measuring equipment.
1 Study the circuit diagram in question, check where the suspected

cable is connected and if, and if so where, it is spliced.
2 Turn off the system voltage with the battery disconnector.
3 Unplug the connector at the control unit or component in question.
CAUTION
Wipe and re-grease the connectors (applies to sealed
contacts).
Risk of corrosion on contact surfaces.
Clean all connectors loosened during troubleshooting
using electronic cleaner 923836.0826 and re-grease
them with connector grease 923836.0552.
IMPORTANT
AdBlue on wiring.
be replaced.

4 Check if there is an open circuit.
NOTE
Some components cannot be checked without power supply to
the component. In such an event, proceed to point 5.
a. Measure resistance between connections to the component in

the connector at the control unit or component.
b. The resistance must correspond with the component.
Otherwise there may be an open circuit or short circuit in cable
harness and/or component.
5 Check if there is a short circuit to the frame:
a. Unplug the connector at both the control unit and the
component in question.
b. Measure the resistance in one cable at a time. Measure
between the cable and a frame-connected part of the machine.
c. The multimeter should show infinite resistance.

Troubleshooting hydraulic hoses
WARNING
Hot and pressurised oil.
Always depressurise hydraulic and brake systems
before starting to work on the systems. The hydraulic
and brake systems are pressurised and the oil may
cause personal injuries.
Avoid skin contact with the oil, use protective gloves.
Hot oil can cause burn injuries, rashes and irritation!
The oil can act corrosive to eyes and skin, and mucous
membranes in the throat.
1 Depressurise the hydraulic and brake systems, see section B

Safety.
2 Study the hydraulic diagram in question, check between which
components the suspect hose is connected and if so where the
splice is located.
3 Locate the hose on the machine.
Start at one component and follow the hose to the next component.
4 Inspect the entire hose and splicing points with respect to chafing
damage, pinching damage and leaks.
Replace damaged hoses. Always check the O-rings on adapters
and couplings. Replace if necessary.

1:1
1 Engine
Contents 1 Engine
1 Engine................................................................................................................. 1:3
1.1 Controls and instruments ...............................................................................1:21
1.1.1 Ignition.......................................................................................................1:21
1.1.2 Accelerator pedal ......................................................................................1:22
Start button................................................................................................1:24
1.2 Fuel system....................................................................................................1:25
1.2.1 Fuel tank ...................................................................................................1:25
1.2.2 Sensor fuel level........................................................................................1:26
1.2.12 AdBlue tank ...............................................................................................1:26
1.6 Air intake and exhaust outlet..........................................................................1:27
1.6.1 Air cleaning system ...................................................................................1:27
1.6.3 Exhaust system .........................................................................................1:28
1.6.4 Intercooler .................................................................................................1:29
1.6.8 SCR system ..............................................................................................1:29
1.6.9 Pipes and hoses........................................................................................1:30
1.7 Cooling system ..............................................................................................1:31
1.7.4 Radiator and expansion tank ....................................................................1:32
1.7.8 Coolant level sensor..................................................................................1:33
1.7.10 Engine heater ............................................................................................1:33
1.9 Control system, engine ..................................................................................1:34
1.9.1 Engine control unit ....................................................................................1:34
1.10 Ignition/heating...............................................................................................1:35
1.11 Start/stop........................................................................................................1:36
1.11.1 Starter motor .............................................................................................1:36
1.11.2 Stopping device.........................................................................................1:36
1.11.3 Automatic stop of the engine a specific time after leaving the operator's
station .......................................................................................................1:37

1:2

1 Engine – Engine 1:3
1 Engine
Engine, general
Engine alternative
The engine provides power for propulsion and working hydraulics.
The engines are low-emission engines and meet emission requirements

from the U.S. (California) and Europe. The new engines offer a
significant improvement, not only of exhaust emissions, but also on the
power and torque curves.
The machine is equipped with one of the following engine alternatives:

• Volvo TAD1360VE Stage 3B/Tier 4i
• Cummins QSM11 Stage 3A/Tier 3
Component supplier documentation
The workshop manual only describes components and work
descriptions that concern installation in the machine. For descriptions
and instructions for the engine's components and systems, refer to the
relevant supplier documentation.
References to supplier documentation are only provided in exceptional

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

1:4 1 Engine – Engine
Engine alternative Volvo TAD1360VE,

function description
Condition Reference value Reference
Engine heater Disconnected (when cable is in start lock-out is Engine heater, description, page 1:33
activated)
Transmission In neutral position Transmission, function description, page 2:4
1 7 12
D1 D7 D12
2, 8, 13 6, 20, 33
D7902 D7950
D7901 D7971
19, 32, 34 D18
31 3, 5, 9, 14, 16, 29, 35 22, 26, 28

D7930 D7940 UDS D24 18
M
SENSORS M H2O NOx
30 4 15 21 24 25
11 10 27
016326
23
Pos Explanation Signal description Reference

1 The ignition switch (S1500) sends voltage U = 24 V Ignition key lock, description, page 1:21
signals to Control unit KCU (D7901) when D1: Diagnostic menu, see 11.5 Distr of
the start key is turned to position 1. Electr 1/XX DIAGNOSE, page 8:81
2 Control unit KCU (D7901) activates the Checked by control 11.5.3.1 KCU control unit (D7901), page
ignition voltage, which activates all the system, error shown 11:25
control units. with error code. D1: Diagnostic menu, see 11.5 Distr of
Electr 1/XX DIAGNOSE, page 8:81
3 If necessary, the intake air to the engine U = 24 V 11.5.3.6 Control unit, engine (D7940), page
is preheated. The Engine control 11:35
unit (D7940) controls the preheating
requirement and feeds voltage to the
preheater through a preheating relay.
4 The preheating element warms the engine Checked by control 11.5.3.6 Control unit, engine (D7940), page
intake air. system, error shown 11:35
with error code.
5 When preheating is activated, Control Checked by control 11.5.3.4 KFU control unit (D7971), page
unit engine (D7940) sends information system, error shown 11:31
on CAN bus drive-train to Control unit with error code.
KFU (D7971), which in turn sends the
information further on the CAN bus.
6 When preheating is activated, Control Checked by control 11.5.3.3 Control unit, KID (D7950), page
unit KID (D7950) shows Event menu system, error shown 11:29
preheating. with error code.


7 Start button (S1051) sends voltage signals U = 24 V Start button description, page 1:24
to Control unit KPU (D7902) when the D7: Diagnostic menu, see 1.11 Start & Stop
start button is activated. 2/XX DIAGNOSE, page 8:32
8 Control unit KPU (D7902) sends Checked by control 11.5.3.2 KPU control unit (D7902), page
messages a start signal on the CAN bus, system, error shown 11:27
via Control unit KFU (D7971), to Control with error code.
unit engine (D7940).
9 Control unit engine (D7940) supplies U = 24 V 11.5.3.4 KFU control unit (D7971), page
voltage to the starter motor (M6450). 11:31.
10 The starter motor (M6450) cranks the - Starter motor, description (engine
engine. alternative Volvo TAD1360VE), page 1:36
11 The engine's sensor sends signals to Checked by control 11.5.3.6 Control unit, engine (D7940), page
Control unit, engine (D7940) that controls system, error shown 11:35
the injectors so the engine starts. with error code.
12 The accelerator pedal (B6900) sends the U = 0.5-4.5 V Accelerator pedal description, page 1:22
KPU control unit (D7902) a voltage signal Lower voltage than 0.5 D12: Diagnostic menu, see 1.1 Controls &
proportional to the pedal actuation. V and higher voltage Instr 1/XX DIAGNOSE, page 8:28
than 4.5 V is used to
detect faults in cable
harnesses and controls.
13 Control unit KPU (D7902) sends a Checked by control 11.5.3.2 KPU control unit (D7902), page
message with engine speed request system, error shown 11:27
on the CAN bus, via Control unit KFU with error code.
(D7971), to Control unit engine (D7940).
14 Control unit, engine (D7940) increases the Checked by control 11.5.3.6 Control unit, engine (D7940), page
engine speed. system, error shown 11:35
with error code.
15 Make-contact (closing switch) coolant U = 24 V Sensor coolant level, description, page 1:33
level sends a voltage signal to Control
unit, engine (D7940) if the coolant level is
low in the expansion tank.
16 Control unit, engine (D7940) sends engine Checked by control 11.5.3.6 Control unit, engine (D7940), page
data and warning messages on the CAN system, error shown 11:35
bus. with error code. Diagnostic menus engine: 8.4.1 Engine,
page 8:28
17 Control unit KID (D7950) shows engine Checked by control 11.5.3.3 Control unit, KID (D7950), page
data on the display. system, error shown 11:29.
with error code.
18 The fuel level sensor (B7570) sends a U = 0.5-4.5 V Sensor, fuel level, description, page 1:26
voltage signal proportional to the fuel level Lower voltage than 0.5 D18: Diagnostic menu, see 1.2 Fuel
in the tank to the KFU control unit (D7971). V and higher voltage System 1/XX DIAGNOSE, page 8:28
19 Control unit KFU (D7971) sends fuel level Checked by control 11.5.3.4 KFU control unit (D7971), page
on the CAN bus. system, error shown 11:31
with error code.
20 Control unit KID (D7950) shows the fuel - 11.5.3.3 Control unit, KID (D7950), page
level in the operating menu for the engine. 11:29
Event menu for low fuel level is shown in
the display if the fuel level is below 10%
for more than 10 seconds.
21 Exhaust cleaning U = 0.5-4.5 V SCR system, description, page 1:29
AdBlue level and temperature sensor
sends Control unit SCR (UDS) a voltage
signal proportional to the AdBlue level and
temperature in the tank.


22 In the event of cold AdBlue, Control unit U = 24 V SCR system, description, page 1:29
SCR (UDS) voltage feeds the water valve.
23 The water valve leads warm water to the - SCR system, description, page 1:29
AdBlue tank to heat it.
24 Exhaust gas temperature sensor sends U = 0.5-4.5 V SCR system, description, page 1:29
Control unit SCR (UDS) a voltage signal
proportional to the temperature of the
exhaust gases.
There is a damper located after the
intercooler that helps to increase the
temperature of the exhaust gas when
necessary.
25 The NOx sensor continuously measures U = 0.5-4.5 V SCR system, description, page 1:29
the amount of nitrogen oxide in exhaust
gases and sends the voltage signal to the
Control unit SCR (UDS).
26 The Control unit SCR (UDS) voltage feeds U = 24 V SCR system, description, page 1:29
the AdBlue pump.
27 The AdBlue pump pumps AdBlue from - SCR system, description, page 1:29
the AdBlue tank. The right amount of
AdBlue is injected into the silencer inlet
depending on the amount of nitrogen
oxides in exhaust gases. AdBlue and
exhaust gases are mixed before passing
the catalytic converter (SCR), which is
located centrally in the silencer.
28 If the levels of nitrogen oxides in the - SCR system, description, page 1:29
exhaust gases are too high, the Control
unit SCR (UDS) sends a request to the
engine Control unit (D7940) on the CAN
bus to restrict the engine speed.
29 Control unit, engine (D7940) limits the Checked by control 11.5.3.6 Control unit, engine (D7940), page
with error code.
30 Speed limitation Checked by control Transmission, function description, page
The output shaft speed sensor system, error shown 2:4
(B7580) sends the transmission control with error code.
unit (D7930) pulses with frequency
proportional to output shaft rpm.
31 The transmission control unit (D7930) Checked by control 11.5.3.7 Control unit, transmission (D7930),
transmits speed on CAN bus. system, error shown page 11:37
with error code.
32 Control unit KFU (D7971) recalculates Checked by control 11.5.3.4 KFU control unit (D7971), page
the rotation speed of the output shaft to system, error shown 11:31
machine speed and sends the speed on with error code.
the CAN bus.
33 The KID control unit (D7950) shows the Checked by control 11.5.3.3 Control unit, KID (D7950), page
machine's speed. system, error shown 11:29
with error code.
34 If the limit for the machine's speed limit Checked by control 11.5.3.4 KFU control unit (D7971), page
is exceeded, Control unit KFU (D7971) system, error shown 11:31
sends reduce engine speed on the CAN with error code.
bus.
35 Control unit, engine (D7940) reduces Checked by control 11.5.3.6 Control unit, engine (D7940), page
engine speed until it is correct. system, error shown 11:35
with error code.

Engine alternative Cummins QSM11,

Engine heater Disconnected (when cable is in start lock-out is Engine heater, description, page 1:33
activated)
Transmission In neutral position Transmission, function description, page 2:4
1 7 13
D1 D7 D13
2, 5, 8, 14 6, 18, 21, 25
D7902 D7950
D7901 D7971
9, 20, 24, 26
D19
10 3, 5, 15, 17, 27
D7940 D7930
23
19
M SENSORS H2O
016325
4 16 22
11 12

1 The ignition switch (S1500) sends voltage U = 24 V Ignition key lock, description, page 1:21
signals to Control unit KCU (D7901) when D1: Diagnostic menu, see 11.5 Distr of
the start key is turned to position 1. Electr 1/XX DIAGNOSE, page 8:81
2 Control unit KCU (D7901) activates the Checked by control D1: Diagnostic menu, see 11.5 Distr of
ignition voltage, which activates all the system, error shown Electr 1/XX DIAGNOSE, page 8:81
control units. with error code.
3 If necessary, the intake air to the engine U = 24 V 11.5.3.6 Control unit, engine (D7940), page
is preheated. The Engine control 11:35
unit (D7940) controls the preheating
requirement and feeds voltage to the
preheater through a preheating relay.
4 The preheating element warms the engine Checked by control 11.5.3.6 Control unit, engine (D7940), page
intake air. system, error shown 11:35
with error code.
5 When preheating is activated, Control Checked by control 11.5.3.4 KFU control unit (D7971), page
unit engine (D7940) sends information system, error shown 11:31
on CAN bus drive-train to Control unit with error code.
KFU (D7971), which in turn sends the
information further on the CAN bus.
6 When preheating is activated, Control Checked by control 11.5.3.3 Control unit, KID (D7950), page
unit KID (D7950) shows Event menu system, error shown 11:29
preheating with error code.
7 Start button (S1051) sends voltage signals U = 24 V Start button description, page 1:24
to Control unit KPU (D7902) when the D6: Diagnostic menu, see 1.11 Start & Stop
start button is activated. 1/XX DIAGNOSE, page 8:32


messages a start signal on the CAN bus, system, error shown 11:27
via Control unit KFU (D7971), to Control with error code.
unit engine (D7940).
9 Control unit KFU (D7971 sends control U = 24 V 11.5.3.4 KFU control unit (D7971), page
current to Relay starter motor (K3600). 11:31
10 Relay starter motor (K3600) supplies U = 24 V Starter motor, description (engine
voltage to the starter motor (M6450). alternative Cummins QSM11), page 1:36
11 The starter motor (M6450) cranks the - Starter motor, description (engine
engine. alternative Cummins QSM11), page 1:36
12 The engine's sensor sends signals to Checked by control 11.5.3.6 Control unit, engine (D7940), page
Control unit, engine (D7940) that controls system, error shown 11:35
the injectors so the engine starts. with error code.
13 The accelerator pedal (B6900) sends the U = 0.5-4.5 V Accelerator pedal description, page 1:22
KPU control unit (D7902) a voltage signal Lower voltage than 0.5 D13: Diagnostic menu, see 1.1 Controls &
proportional to the pedal actuation. V and higher voltage Instr 1/XX DIAGNOSE, page 8:28
14 Control unit KPU (D7902) sends a Checked by control 11.5.3.2 KPU control unit (D7902), page
message with engine speed request system, error shown 11:27
on the CAN bus, via Control unit KFU with error code. 11.5.3.4 KFU control unit (D7971), page
(D7971), to Control unit engine (D7940). 11:31
15 Control unit, engine (D7940) increases the Checked by control 11.5.3.6 Control unit, engine (D7940), page
with error code.
16 Make-contact (closing switch) coolant Low coolant level: U = Sensor coolant level, description, page 1:33
level sends a ground signal to Control unit, 0V
engine (D7940) if the coolant level is low
in the expansion tank.
17 Control unit, engine (D7940) sends engine Checked by control 11.5.3.6 Control unit, engine (D7940), page
data and warning messages on the CAN system, error shown 11:35
bus. with error code. Diagnostic menus engine: 8.4.1 Engine,
page 8:28
18 Control unit KID (D7950) shows engine Checked by control 11.5.3.3 Control unit, KID (D7950), page
data on the display. system, error shown 11:29
with error code.
19 The fuel level sensor (B7570) sends a U = 0.5-4.5 V Sensor, fuel level, description, page 1:26
voltage signal proportional to the fuel level Lower voltage than 0.5 D18: Diagnostic menu, see 1.2 Fuel
in the tank to the KFU control unit (D7971). V and higher voltage System 1/XX DIAGNOSE, page 8:28
20 Control unit KFU (D7971) sends fuel level Checked by control 11.5.3.4 KFU control unit (D7971), page
on the CAN bus. system, error shown 11:31
with error code.
21 Control unit KID (D7950) shows the fuel Checked by control 11.5.3.3 Control unit, KID (D7950), page
level in the operating menu for the engine. system, error shown 11:29
Event menu for low fuel level is shown in with error code.
the display if the fuel level is below 10%
for more than 10 seconds.
22 Speed limitation Checked by control Transmission, function description, page
The output shaft speed sensor system, error shown 2:4
(B7580) sends the transmission control with error code.
unit (D7930) pulses with frequency
proportional to output shaft rpm.


23 The transmission control unit (D7930) Checked by control 11.5.3.7 Control unit, transmission (D7930),
transmits speed on CAN bus. system, error shown page 11:37
with error code.
24 Control unit KFU (D7971) recalculates Checked by control 11.5.3.4 KFU control unit (D7971), page
the rotation speed of the output shaft to system, error shown 11:31
machine speed and sends the speed on with error code.
the CAN bus.
25 The KID control unit (D7950) shows the Checked by control 11.5.3.3 Control unit, KID (D7950), page
machine's speed. system, error shown 11:29
with error code.
26 If the limit for the machine's speed limit Checked by control 11.5.3.4 KFU control unit (D7971), page
is exceeded, Control unit KFU (D7971) system, error shown 11:31
sends reduce engine speed on the CAN with error code.
bus.
27 Control unit, engine (D7940) reduces Checked by control 11.5.3.6 Control unit, engine (D7940), page
engine speed until it is correct. system, error shown 11:35
with error code.

Engine alternative Volvo TAD1360VE,

component location
1 2 3 4
17
16
15
5
6
8 7
9
10
11
016824
13 12
14
Engine right-hand side (in the machine's direction of travel)
1. Preheating element 9. Fuel filter
2. Oil separator crankcase ventilation 10. Oil level/oil temperature sensor
3. Control unit, engine (D7940) 11. Dipstick
4. Charge air pressure and charge air temperature 12. AC compressor
sensors 13. Alternator
5. Fuel pump 14. Transmission oil cooler
6. Make-contact (closing switch), fuel pressure 15. Water cooler
7. Fuel prefilter 16. Condenser air conditioning unit
8. Water separator with water-in-fuel sensor 17. Intercooler

1 2 3 4 5
14
6
13 8
016823
12 11 10 9
Engine left-hand side (in the machine's direction of travel)
1. Camshaft speed sensor 8. Sensor oil pressure
2. Turbocharger 9. Water pump
3. Sensor, coolant level (B7590) 10. Oil filter (full flow)
4. Sight glass coolant level 11. Oil filter (bypass)
5. Expansion tank 12. Starter motor
6. Thermostat 13. Sensor flywheel speed
7. Sensor coolant temperature 14. Engine oil filling point
Exhaust system, see SCR system, component location (engine

alternative Volvo TAD1360VE), page 1:30

Engine alternative Cummins QSM11,

component positions
1 2 3 4
13
12
11
10
5
6
7
8
9
017438
Engine alternative Cummins, right side (in the machine's travel direction)
1. Expansion tank 8. Sensor crankshaft position
2. AC compressor 9. Sensor oil pressure and oil temperature
3. Sensor fuel pressure 10. Transmission oil cooler
4. Control unit, engine (D7940) 11. Water cooler
5. Starter motor 12. Condenser air conditioning unit
6. Fuel filter 13. Intercooler
7. Fuel pump

4 5
3
2
1
15
6
14
8
017438
13 12 11 10 9
Engine alternative Cummins, left side (in the machine's travel direction)
1. Sensor inlet temperature 9. Alternator
2. Turbocharger 10. Water pump
3. Sensor, coolant level (B7590) 11. Oil filter
4. Sight glass coolant level 12. Coolant filter
5. Expansion tank 13. Shut-off valve coolant
6. Sensor boost pressure 14. Dipstick engine oil
7. Thermostat housing 15. Engine oil filling point
8. Sensor coolant temperature

Components on the machine, component

location
1 2 3 4 5
13
7
12
016328
11 10
1. Control unit, transmission (D7930) 7. Control unit KFU (D7971)
2. Diagnostic socket, engine, VODIA (engine alternative 8. Ignition key lock (S1500)
Volvo TAD1360VE)
9. Start button (S1501)
3. Diagnostic socket, engine, (engine alternative
10. Control unit, KID (D7950)
Cummins QSM11)
11. Accelerator pedal (B6900)
4. Control unit SCR (UDS) (engine alternative Volvo
TAD1360VE) 12. KPU control unit (D7902)
5. Sensor fuel level (B7570) 13. KCU control unit (D7901)
6. Fuel tank

Engine and transmission, separation

Separation
1 Machine in service position, see section B Safety.
2 Mark up and disconnect the requisite hoses and cables before
separating engine and transmission.
NOTE
Drain and collect liquids before detaching hoses.
3 Attach hoisting equipment to the engine.
4 Use a jack to secure the transmission.
5 Remove the cover plate over the flywheel on the left-hand side.

6 Remove the cover washer on the right-hand side.
014344
7 Remove the flex plate's fastening bolts (x12). Turn over the engine
(use the Volvo special tool 999 3590), until the flex plate's screws
are visible in the opening on the left-hand side.
8 Take up the slack in the hoisting equipment.
NOTE
Do not lift the engine or transmission.
014343

9 Remove the screws (12 pcs) between the engine and the
transmission.
10 Loosen the engine or transmission mounts and separate the
engine and transmission.
Assembly
11 Insert two studs into the flywheel housing as a guide when the
engine is installed.
12 Clean the contact faces on the flywheel and flex plates. Check
that the flex plates are flat and not worn. Damaged or worn parts
must be replaced.
13 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 twelve attachment points to be connected with
the flywheel on the engine.
014940
14 Install the engine or transmission mounts.

Tighten to a torque of 330 Nm.
15 Carefully connect the engine to the transmission.
014844

16 Remove the stud bolts. Fit the bolts (x12) between the engine and
the transmission. Tighten to a torque of 40 Nm.
17 Slide the converter in toward the flywheel and check that they mate
correctly, use a fitter's bar if necessary. Check to ensure that the
flex plates rest against the flywheel.
18 Fit the nuts that attach the flex plates at the flywheel in two steps.
First fit the nuts without tightening. Then rotate the flywheel one
more revolution and tighten the nuts to 46 Nm (oiled screw).
19 Refit the cover washer behind the flywheel on the right-hand side
of the engine.
20 Refit the cover plate over the flywheel on the left-hand side of the
engine.
21 Remove the hoisting equipment from the engine.
22 Remove the jack from underneath the transmission.
23 Connect the requisite hoses and cables for the engine and
transmission. Check and fill fluids as required.
24 Bleed air from the engine's fuel system before starting.

Engine and transmission, separating

(engine alternative Cummins QSM11 )
Separation
2 Attach hoisting equipment to the engine.
3 Mark up and disconnect the requisite hoses and cables before
separating engine and transmission.
NOTE
Drain and collect liquids before detaching hoses.
4 Use a jack to secure the transmission.
5 Remove the cover washer.
6 Rotate the engine for each bolt in the flex plate that has to be
removed.
7 Remove the bolts for 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 screws to the engine mounts and transmission brackets.
Tighten to a torque of 330 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 cover washer 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
transmission. Check and fill fluids as required.

1 Engine – Controls and instruments 1:21
1.1 Controls and instruments

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

1 2 2 Remove the cover.

015784
1. Cover
2. Ignition

1:22 1 Engine – Accelerator pedal
3 Remove the screw.

4 Remove the nut.
5 Disconnect the connector.
6 Replace the ignition key lock.
7 Fit in the reverse order.
1 2 3 015785
1. Contact
2. Screw
3. Nut
1.1.2 Accelerator pedal

Accelerator pedal description
The accelerator pedal actuates a sensor via a linkage in the pedal
assembly, see Cab overview, page 9:5. Sensor accelerator pedal
(B6900) sends two voltage signals (for increased safety) proportional
to the pedal's position to Control unit KPU (D7902).
The signals can be checked with the diagnostic menu, see 1.1 Controls
& Instr 1/XX DIAGNOSE, page 8:28.
016898
Pedal rubber, replacement

2 Drill out the pop rivets.
3 Remove the pedal rubber.
4 Replace the pedal rubber.
015787

1 Engine – Accelerator pedal 1:23
Accelerator potentiometer, replacement

2 Remove the screws and lift off the cover.
1 2 1
015856
1. Screws
2. Cover
3 Remove the split pin and pin.
2
017448
1. Split pin
2. Pin
4 Turn the link arms and the potentiometer so that the stop screw
is accessible.
5 Loosen the stop screw on the link arm and remove the link arms.
017449
Stop screw

1:24 1 Engine – Start button
6 Remove the screws which secure the potentiometer.

7 Cut the cable ties and split the contact.
8 Replace the accelerator's potentiometer.
9 Fit in reverse order. Use new split pins.
017450
Start button
Start button description
The start button (S1051) is fitted on the steering panel, see Cab
overview, page 9:5. The start button controls the starting and stopping
of the engine. The signal can be checked with the diagnostic menu,
for engine alternative Volvo TAD1360VE 1.11 Start & Stop 2/XX
DIAGNOSE, page 8:32 applies, and for engine alternative Cummins
QSM11 1.11 Start & Stop 1/XX DIAGNOSE, page 8:32 applies.
016899

1 Engine – Fuel system 1:25
1.2 Fuel system

Fuel system, description
The fuel system distributes fuel between the cylinders and by doing so
controls the engine output power and rpm.
The fuel tank is located on the left-hand side of the machine and is
equipped with a sensor for the fuel level. The amount of fuel in the tank
is shown in an operating menu on the display in the cab. Fuel prefilter
with water separator and fuel filter are fitted on the engine.
When the engine is started, the fuel pump draws fuel from the tank
through the fuel filter and forces it to the unit injectors. The unit injectors
spray in the fuel and atomises the fuel to the engine's combustion
chamber.
Engine alternative Volvo TAD1360VE: The water separator is

equipped with electrical indication, an error code is generated when
the water separator must be drained of water.
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
injure the skin, resulting in severe injuries.
Use protective gloves and protective safety glasses,
avoid skin contact with fuel. If a component is being
loosened then hold a rag over the connection as
protection and collect the fuel. Fuel acts corrosive to
eyes and skin, and mucous membranes in the throat.
1.2.1 Fuel tank

Fuel tank, description
3 The fuel tank is located on the left-hand side of the machine.

2
1
4
016958
1. Fuel filling
2. Manhole cover for cleaning
3. Sensor fuel level (B7570)
4. Drain plug, under tank

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

Sensor, fuel level, description
3 The fuel level sensor is inserted in the fuel tank from above.
2 The fuel level sensor (B7570) sends a voltage signal proportional to
1 the fuel level in the tank to the KFU control unit (D7971). An event
menu is shown in the display if the fuel level is below 10 % for more
than 10 seconds.
4
016958
1. Fuel filling
Fuel level sensor, replacement
3 1 Machine in service position, see section B Safety.

2 2 Disconnect the cable harness from the sensor. Note the cable's
1 clamping.
3 Unscrew the level sensor.
The sensor is threaded into the tank.
4 Screw in a new level sensor.
5 Connect the cable harness to the sensor and attach the cable in
the same way as before.
4
016958
1. Fuel filling
1.2.12 AdBlue tank

AdBlue tank, description
See SCR system, component location (engine alternative Volvo
TAD1360VE), page 1:30.

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

Air intake and exhaust outlet, description
There is an air cleaner fitted on the machine. The air cleaner is
equipped with an indicator that indicates when the air filters need
replacing. The air cleaner has two filter inserts, one main insert and
a safety insert. The air cleaner is connected to the engine by the
turbocharger.
Volvo Stage 3B/Tier 4i engines are equipped with SCR technology

in order to reduce nitrogen oxides (NOx) in exhaust gases. SCR
technology means that AdBlue is injected into the exhaust gases before
reaching the SCR catalyst. A sensor measures the NOx levels in the
exhaust gases. The SCR is located under the machine.
AdBlue contains deionised water mixed with 32.5% urea. The urea
decomposes to ammonia which reacts with NOx so that harmless
nitrogen and water vapour are formed.
1.6.1 Air cleaning system

Air cleaning system, description
1 2 3 4 5 The air cleaning system consists of an air cleaner with filter, filter
indicator, pipes and hoses. There are two filters in the air cleaner that
purify the air and a dust reservoir that collects larger particles. The dust
reservoir can be emptied without opening the air cleaner.
Combustion in the engine requires air. Free unobstructed flow for

fresh air and exhaust gases is essential for efficient engine operation.
Particles are collected in the filter material when the air filters clean the
air to the engine. Over time, a great deal of particle matter is collected
and the filter does not let through sufficient air for efficient combustion,
the filter must then be changed. The filter indicator measures the
negative pressure on the engine side of the filter. When the filter is
clogged the negative pressure is higher and the indicator indicates
that it is time to replace the filter.
001357
Air cleaning system, overview As an option the machine can be equipped with a raised air intake with
pre-cleaner. It consists of an extension of the inlet to the air filter and
1. Intake hose
a pre-cleaner that sorts out larger particles by creating vortices in the
2. Filter indicator air intake. The pre-cleaner does not contain any parts that need to
3. Air cleaner be replaced. During operation in dirty environments this means that
less dusty air is sucked into the air cleaner, and in this way the service
4. Intake
life of the air filters is extended.
5. Dust reservoir

1:28 1 Engine – Exhaust system
1.6.3 Exhaust system

Exhaust system, description (engine alternative Volvo
TAD1360VE)
The exhaust system is mounted in the frame. A heat shield is installed
1 between the engine and the exhaust system to protect wiring, etc. Flex
2 pipes between the turbo, silencer and end pipe absorb movements in
3 the system. On the outside of the machine, there is heat protection
4 fitted over the exhaust system.
5
WARNING
Hot exhaust system!
Risk of burn injuries!
017423
Never touch hot components, e.g. turbo, exhaust pipe,

silencer or catalytic converters when the machine is
1. Connection to turbocharger running or just after it has been turned off!
2. Flex pipe
3. Exhaust pipe
4. Silencer with catalytic converter WARNING
5. End pipe
Warm particle filter and warm exhaust gases!
Never touch the particle filter or stand by the exhaust
outlet when the machine is running or has just been
shut down!
Exhaust system, description (engine alternative

Cummins QSM11 )
The exhaust system is mounted in the frame. Heat protection is fitted
between the engine and exhaust system to protect cables, etc. A flex
pipe between the turbo and silencer takes up engine movement. On
the outside of the machine, there is heat protection fitted over the
exhaust system.
WARNING
Hot exhaust system!
Never touch hot components, e.g. turbo, exhaust pipe,
silencer or catalytic converters when the machine is
running or just after it has been turned off!
017422
1 2 3 4
1. End pipe
2. Silencer
3. Flex pipe
4. Exhaust pipe

1 Engine – Intercooler 1:29
1.6.4 Intercooler
Intercooler, description
The charge air is cooled by an air-air intercooler in the upper part of
the cooler unit.
1
See also Cooling system, description, page 1:31.
4
014293
Cooling unit
1. Intercooler
2. Radiator, engine
3. Radiator, transmission oil
4. Thermostat transmission oil
5. Drain point coolant
6. Mounting condenser (to AC)
1.6.8 SCR system

SCR system, description
SCR system, description (engine alternative Volvo

TAD1360VE)
SCR technology (Selective Catalytic Reduction) - catalytic exhaust
cleaning - is used to meet statutory emission requirements.
Diesel engines with even more efficient combustion in combination

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

the addition of AdBlue solution which is injected into the exhaust gases
before they pass through the SCR catalyst. This addition converts
nitrogen oxides into nitrogen and water vapour, natural substances
in our environment.
Diesel engines have been developed toward more efficient combustion

levels and its control unit calculates the optimum amount of AdBlue
solution to be injected in relation to the current load and engine speed.
For more information, see supplier documentation, engine.

1:30 1 Engine – Pipes and hoses
SCR system, component location (engine alternative

Volvo TAD1360VE)
1
2
3
4
5
8
7
6
017421
1. Sensor level and temperature AdBlue 5. End pipe
2. Water valve 6. Injection unit
3. NOx sensor 7. Control unit SCR (UDS) with AdBlue pump and filter
4. SCR catalyst 8. AdBlue tank
1.6.9 Pipes and hoses

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

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

1 Engine – Cooling system 1:31
1.7 Cooling system

Cooling system, description
The engine is water-cooled and has cooling ducts through which the
coolant from the radiator flows around a closed system.
Main parts of the cooling system:

• Coolant pump, located in the engine
• Expansion tank, located in the engine compartment
• Sensor coolant level (B7590) fitted in the expansion tank
• Thermostat, located in the engine
• Cooling fan, located in front of the radiator
• Engine oil cooler, located in the engine
• Transmission oil cooler, part of cooling unit (middle)
• Water cooler, part of cooling unit
• Intercooler, part of cooling unit
Engine cooling work as follows:

1. The coolant pump pumps coolant through the engine block, oil
cooler and cylinder head.
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
temperature the thermostat directs it back through the engine.
When the coolant is warmer than the thermostat opening
temperature the thermostat directs it through the radiator and then
back to the coolant pump.
4. The expansion tank allows the coolant to expand without escaping
from the engine.

1:32 1 Engine – Radiator and expansion tank
1.7.4 Radiator and expansion tank

Radiator and expansion tank, description
The radiator for the engine is located in the cooling unit which is
located on the engine.
1
The function of the cooler unit is to cool:
• Engine coolant
• Transmission oil (cooled in the lower part of the cooler unit), see
also section 2 Transmission, group 2.6.3 Oil cooler.
2 • Charge air (cooled in the upper part of the cooler unit), see also
Intercooler, description, page 1:29.
See also Cooling system, description, page 1:31.

5
4
014293
Cooling unit
1. Intercooler
2. Radiator, engine
Radiator, replacement
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.

2 Drain the coolant from the engine, see Maintenance manual.
3 Drain the transmission oil from the transmission, see Maintenance
Manual.
4 Detach the condenser from the cooling unit and hang it up so that
it is not damaged when the cooling unit is lifted away.
5 Detach the hoses for intercooler, engine and transmission cooling
and for the radiator's expansion tank.
6 Remove the screws that secure the cooler unit to the frame.
7 Connect lifting eyes and lifting equipment to the threaded holes in
the top of the cooling unit.
8 Carefully lift the cooler unit out of the frame.
10 Fit the condenser on the cooling unit.
11 Fill with transmission oil, see Maintenance manual.
12 Fill with coolant, see Maintenance manual.
13 Check and top up fluids as necessary.

1 Engine – Coolant level sensor 1:33
1.7.8 Coolant level sensor

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

control unit (D7940).
Sensor coolant level, replacement

2 Drain the coolant out of the expansion tank.
3 Unplug the connector for the switch.
4 Unscrew the sensor from the expansion tank.
6 Fill the system with coolant. Check the level.
1.7.10 Engine heater

Engine heater, description
See supplier documentation, engine.
The engine heater used to warm up the engine and facilitate starting
when the machine has been switched off for a long time.
The engine heater is connected via an external power connector. The

connector is located above the left-hand footstep. The heater has a
start-inhibitor function that prevents the engine from starting when the
power cable is plugged in.
CAUTION
The engine heater is connected to high voltage (110
- 400 V).
High voltage.
Installation and reconnection of the engine heater may
only be performed by personnel authorised for work
with high voltage.

1:34 1 Engine – Control system, engine
1.9 Control system, engine

Control system engine, description (engine
alternative Volvo TAD1360VE)
The engine is controlled by a control system whose central unit is a
control unit.
The system consists of sensors, control unit (D7940) and electric

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

engine, then engine power is limited to protect the engine from further
damage.
When one of the following limits is exceeded, engine performance is

limited:
• coolant temperature above 107 °C
• intake temperature above 85 °C
• oil temperature above 127 °C
• charge air pressure above 285 kPa
• exhaust gas temperature above 550 °C
Control system engine, description (engine

alternative Cummins QSM11 )
The engine is controlled by a control system whose central unit is a
control unit.
The system consists of sensors, control unit (D7940) and electric

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

engine, then engine power is limited to protect the engine from further
damage.
When one of the following limits is exceeded, engine performance is

limited:
• coolant temperature above 107 °C
• intake temperature above 93 °C
• oil pressure below 55 kPa
• low coolant level longer than 20 seconds
1.9.1 Engine control unit

Control unit, engine, general
See 11.5.3.6 Control unit, engine (D7940), page 11:35 and supplier
documentation, engine.

1 Engine – Ignition/heating 1:35
1.10 Ignition/heating
Ignition/heating, description (engine alternative
Volvo TAD1360VE)
The engine is equipped with preheating of the induction air, for faster
start at low temperatures. The preheating is activated automatically
when the ignition is switched on and the engine's management system
detects that there is a need for preheating. When preheating is
activated, the event menu for preheating is shown in the display.
Ignition/heating, description (engine alternative

Cummins QSM11 )
The engine is equipped with preheating of the induction air, for faster
start at low temperatures. The preheating is activated automatically
when the ignition is switched on and the engine's management system
detects that there is a need for preheating. Preheating is activated by
Control unit engine (D7940) when required.

1:36 1 Engine – Start/stop
1.11 Start/stop
1.11.1 Starter motor
Starter motor, description (engine alternative Volvo
TAD1360VE)
The engine is started and stopped with the start button. The start button
sends signals to Control unit dashboard panel (D7902) which, via
Control unit frame (D7971), sends messages via CAN bus drive-train
to Control unit engine (D7940). Starter motor (M6540) is supplied with
voltage directly from the starter batteries. A relay on the starter motor
(solenoid) is activated by Control unit, engine (D7940).
On machines with engine and hydraulic oil heater, engine start is

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

Cummins QSM11)
The engine is started and stopped with the start button. The start button
sends signals to Control unit dashboard panel (D7902) which, via
Control unit frame (D7971), sends messages via CAN bus drive-train
to Control unit engine (D7940). Starter motor (M6540) is supplied with
voltage directly from the starter batteries. A relay on the starter motor
(solenoid) is activated by Control unit frame (D7971) via Relay starter
motor (K3600).
On machines with engine and hydraulic oil heater, engine start is

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

Stopping device, description (engine alternative Volvo
TAD1360VE)
The engines have electrically regulated injectors that stop delivering
fuel when the voltage is cut off, which means that the engine stops.
The engine is stopped by means of pushing the start button or switching

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

emergency to stop the engine, e.g. if the engine cannot be stopped
by other means.
NOTE
The battery disconnector must not be used for emergency stop!
Automatic engine shutdown is available as an option. This means

that the engine is shut off automatically after 3-30 minutes (settable via
menus in the machine) regardless of whether the operator is sitting in
the seat. The conditions are that the machine is stationary and idling.

1 Engine – Automatic stop of the engine a specific time after leaving the operator's station 1:37
Stopping device, description (engine alternative

Cummins QSM11 )
The engines have electrically regulated injectors that stop delivering
fuel when the voltage is cut off, which means that the engine stops.
The engine is stopped by means of pushing the start button or switching

off the ignition on the ignition key lock.
NOTE
The battery disconnector must not be used for emergency stop!
Automatic engine shutdown is available as an option. This means

that the engine is shut off automatically after 3-30 minutes (settable via
menus in the machine) regardless of whether the operator is sitting
in the seat. The conditions are that the machine is stationary and
idling. During the programming of the control system, automatic engine
shutdown is blocked in order to ensure that the battery voltage does
not become too low.
1.11.3 Automatic stop of the engine a specific

time after leaving the operator's station
Automatic stop of the engine a specific time after
leaving the operator's station, description
The machine is equipped with a function that turns off the engine if the
operator leaves the cab for more than a specific time set on delivery
of the machine. During the programming of the control system, the
engine is not shut down automatically in order to ensure the voltage
feed to the control units.
Five minutes is the normal standard setting, the time can however be
altered by a Cargotec industries authorised service technician.

1:38

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

2:2

2 Transmission – Transmission 2:3
2 Transmission
Transmission, general
The transmission transfers the engine's power to the drive wheels
(drive axle), via the universal drive shaft and power to drive the
hydraulic oil pumps for the hydraulic system.
The transmission is fully automatic with torque converter. It has five

forward gears and three reverse.
The torque converter and gearbox work together via a common

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

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


2:4 2 Transmission – Transmission
Transmission, function description

Parking brake Released Parking brake system, function description,
page 4:35
Sensor, Not activated Sensor operator in seat, description, page
operator-in-seat 9:23
3
2
1, 4 5 25 6
D1
D3
D6
7, 8 22
D7902 D7950
D26 D7971 D7901

23, 27
D7940 D7930 9, 13, 14, 28

26 24
S ENS ORS 11, 16-20, 21,
10
V
A
9 L 12
15 V
E
016237
S

1 Travel direction selector (S1310) Neutral: US1310:5 = 24 V Travel direction selector and parking brake,
sends a voltage signal to the Forward: US1310:2 = 24 V description, page 2:9
KPU control unit (D7902). D1: Diagnostic menu, see 2.1 Controls & Instr
Reverse: US1310:3 = 24 V
1/XX DIAGNOSE, page 8:33
2 Travel direction selector on Neutral: US1310-2:8 = 24 V Control lever, description, page 7:6
Control lever (S8150) Forward: US1310-2:7 = 24 V D2: Diagnostic menu, see 2.1 Controls & Instr
Gear selector (S1310-2) sends Reverse: US1310-2:10 = 24 V 1/XX DIAGNOSE, page 8:33.
voltage signals to Control unit
KPU (D7901).
3 Travel direction selector on Neutral: US1310-3:6 = 24 V Mini-wheel, description, page 5:5 or Joystick,
joystick control/mini-wheel Forward: US1310-3:5 = 24 V description, page 5:6
Travel direction selector Reverse: US1310-3:7 = 24 V D3: Diagnostic menu, see 2.1 Controls & Instr
(S1310-3) sends voltage signals 2/XX DIAGNOSE, page 8:33
to Control unit KPU (D7901).
4 If the travel direction selector is Parking brake applied: US1310: Travel direction selector and parking brake,
in position for activated parking 4= 24 V description, page 2:9
brake (S1310) then a voltage Parking brake released: US1310: D1: Diagnostic menu, see 2.1 Controls & Instr
signal is sent to Control unit =0V 1/XX DIAGNOSE, page 8:33
4
KPU (D7902), upon which,
neutral position is selected in
the transmission.


5 Switch on steering panel Checked by control system, Cab overview, page 9:5
Switches for manual shifting up, error shown with error code. D5: Diagnostic menu, see 2.1 Controls & Instr
manual shifting down and for 4/XX DIAGNOSE, page 8:33
automatic shifting send voltage
signals to Control unit KPU
(D7902).
6 Accelerator pedal (B6900) U = 0.5-4.5 V Accelerator pedal description, page 1:22
sends voltage signals to Control D6: Diagnostic menu, see 1.1 Controls & Instr
unit KPU (D7902). 1/XX DIAGNOSE, page 8:28
7 The KPU control unit (D7902) Checked by control system, 11.5.3.2 KPU control unit (D7902), page 11:27.
sends the required throttle on error shown with error code. 11.5.3.4 KFU control unit (D7971), page 11:31
the CAN bus to the Engine
control unit (D7940) via KFU
(D7971).
8 Control unit KPU (D7902) sends Checked by control system, 11.5.3.2 KPU control unit (D7902), page 11:27.
the selected shifting program error shown with error code. 11.5.3.4 KFU control unit (D7971), page 11:31
(neutral, forward, backward
or gear 1-5) on the CAN bus D6: Diagnostic menu, see 2.1 Controls & Instr
via Control unit KFU (D7971), 4/XX DIAGNOSE, page 8:33.
to Control unit transmission
(D7930).
9 The transmission's oil pump - Lubrication system, description, page 2:13
pumps oil when the engine is
running.
10 The transmission's oil filter - Lubrication system, description, page 2:13
cleans the oil from impurities.
11 The oil filter differential pressure Normal: R = 510 Ohm Transmission, component location, page 2:7
sensor (B7551) sends signals Contaminated: R = Open circuit
to the Transmission control
unit (D7930) if the oil filter is
contaminated.
12 The oil cooler cools the - Oil cooler, description, page 2:13
transmission oil.
13 The transmission control unit Checked by Control unit, 11.5.3.7 Control unit, transmission (D7930),
(D7930) transmits temperature transmission, error shown with page 11:37
information on the CAN bus. error code.
14 Control unit transmission Checked by Control unit, 11.5.3.7 Control unit, transmission (D7930),
(D7930) supplies voltage to transmission, error shown with page 11:37
valve block transmission control error code.
(A3) in order to obtain the
desired function.
15 Solenoid valves for travel Checked by Control unit, Transmission, component location, page 2:7
direction and gear position transmission, error shown with
in valve block transmission error code.
control (A3) activate gears in the
transmission and the engine's
power is transmitted to the
transmission's output shaft.
16 Sensor, turbine speed (B7510) Checked by Control unit, Transmission, component location, page 2:7
sends Control unit, transmission transmission, error shown with
(D7930) a pulse signal with error code.
frequency proportional to turbine
speed.
17 Sensor, engine speed (B7530) Checked by Control unit, Transmission, component location, page 2:7
sends a pulse signal with transmission, error shown with
frequency proportional to the error code.
engine speed to Control unit,
transmission (D7930).


18 The inner transfer axle speed Checked by Control unit, Transmission, component location, page 2:7
sensor (B7520) sends a transmission, error shown with
pulse signal with a frequency error code.
proportional to the inner transfer
axle speed to the Transmission
19 The output shaft speed Checked by Control unit, Transmission, component location, page 2:7
sensor (B7580) sends the transmission, error shown with
transmission control unit error code.
(D7930) a pulse signal with
frequency proportional to output
shaft speed.
20 The oil temperature converter Checked by Control unit Transmission, component location, page 2:7
sensor (B7660) sends a voltage transmission and sent to D7950 D20: Diagnostic menu, see 2.6 Lubrication Sys
signal proportional to the oil for display. Error code is sent if 1/XX DIAGNOSE, page 8:34
temperature to Transmission the oil temperature is too high.
21 Control unit, transmission Checked by Control unit, 11.5.3.7 Control unit, transmission (D7930),
(D7930) controls gear shifting transmission, error shown with page 11:37
according to selected shifting error code.
program.
22 Control unit KID (D7950) shows Checked by Control unit, 11.5.3.3 Control unit, KID (D7950), page 11:29
transmission information in transmission, error shown with
operating menus. error code.
23 If the signal from Sensor rotation Checked by Control unit, 11.5.3.4 KFU control unit (D7971), page 11:31
speed output shaft (B7580) transmission, error shown with
indicates that the speed of the error code.
machine exceeds the speed
limitation, then Control unit KFU
(D7971) sends a request for
reduced engine speed on CAN
bus drive-train.
24 Control unit, engine (D7940) Checked by Control unit, 11.5.3.6 Control unit, engine (D7940), page
reduces the engine speed. transmission, error shown with 11:35
error code.
25 Declutch U = 0.5-4.5 V Brake pressure sensor, description, page 4:31
The brake pressure sensor D26: Diagnostic menu, see 4.3 Power Assisted
(B7681) sends a voltage signal 3/XX DIAGNOSE, page 8:36 or 2.2 Torq Conv
corresponding to the brake Clutch 1/XX DIAGNOSE, page 8:34
pressure to the KFU control unit
(D7971).
26 Control unit KFU (D7971) sends Checked by Control unit, 11.5.3.4 KFU control unit (D7971), page 11:31
brake pressure information on transmission, error shown with
CAN bus drive-train. error code.
27 Control unit transmission Checked by Control unit, 11.5.3.7 Control unit, transmission (D7930),
(D7930) supplies voltage to transmission, error shown with page 11:37
Valve block transmission control error code.
in order to declutch the drive if
criteria for declutch are fulfilled.

Transmission, component location
9
3
4
10
11
5
12
14 13 1
6
7
014043
1. Power take-off 9. Sensor turbine speed (B7510)
2. Oil dipstick and filling point for transmission oil 10. Sensor, drum rpm (B7520)
3. Transmission oil cooler 11. Make-contact (closing switch) transmission oil filter
(S2710)
4. Thermostat
12. Oil filter transmission
5. Sensor engine speed (B7530)
13. Sensor rpm output shaft (B7580)
6. Coarse strainer transmission oil
14. Output shaft
7. Sensor oil temperature sump (B7660)
8. Valve unit transmission (A3)

Components in the machine, component

location
1 2
3
4
12
6
11
9
10
016329
8
1. Control unit, transmission (D7930) 7. Switch, shifting program
2. Diagnostic socket, transmission 8. Control unit, KID (D7950)
3. Travel direction selector (S1310-3) 9. Travel direction selector (S1310-2)
4. Travel direction selector (S1310) 10. Accelerator pedal (B6900)
5. KFU control unit (D7971) 11. KCU control unit (D7901)
6. Brake pressure sensor (B7681) 12. KPU control unit (D7902)
Engine and transmission, separation

See section 1 Engine, group 1 Engine and transmission, separation.

2 Transmission – Controls and instruments 2:9

2.1.1 Gear selector and multi-function lever
Travel direction selector and parking brake,
description
Travel direction selector and parking brake control both selection of
travel direction and activation of the parking brake.
The travel direction selector and parking brake (S1310) send voltage
signals to Control unit KPU (D7902), which in turn provides information
about the selected gear via the CAN bus to the Control unit KFU
(D7971). Control unit KFU (D7971) sends information about selected
gear to Control unit transmission (D7930) on CAN bus drive-train.
The signals can be checked with the diagnostic menu, see 2.1 Controls
& Instr 1/XX DIAGNOSE, page 8:33.
1
015215
1. Travel direction selector and parking brake
Travel direction selector and parking brake,

replacement
2 Remove the screws and the cover.
015776
3 Remove the screws and adjuster lever.

4 Remove the cover.
Let the gaiter over the travel direction selector and parking brake
remain in place.
015780
1 2 3
1. Cover
2. Adjuster lever
3. Screw, adjuster lever

2:10 2 Transmission – Gear selector and multi-function lever
5 Remove the cover.

6 Remove the screws that hold the travel direction selector and
parking brake.
015782
1 2 3
1. Cover
2. Screw
7 Disconnect the contact.

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

See Control lever, description, page 7:6.
Travel direction selector, joystick control/mini-wheel,

general
On machines with joystick control or mini-wheel, there is an additional

travel direction selector in the left-hand arm rest, see Mini-wheel,
description, page 5:5 or Joystick, description, page 5:6.

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

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

Flex plates, changing
Before the flex plate can be replaced, the engine and transmission
must be split, see Engine and transmission, separation, page 2:8
2 Remove the bolts holding the flex plate to the transmission.
3 Fit the transmission, see Engine and transmission, separation,
page 2:8.
4 Before the machine is taken into service, the transmission must be
calibrated, see Maintenance manual.
Flex plate attachment.

2:12 2 Transmission – Mechanical transmission
2.3 Mechanical transmission

Mechanical transmission, description
The transmission is built with all gears constantly in mesh. It is shifted
by means of hydraulic pressurising of clutch plates for each of the
gears. The clutch plates connect the input shaft with the main shaft or
tubular shaft, depending on which gear has been selected. Shifting
takes place without the transmission being disengaged from the engine.
The transmission has five forward gears and three reverse. The
electrical shifting system is automatic but it is also possible to change
gear manually with the switch on the steering panel.
The FORWARD and REVERSE clutches are electro-hydraulically

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

engine speed to be increased without machine propulsion in order to
obtain more hydraulic power for the load handling functions. Declutch
is activated at a specific brake pressure.
High modulation (i.e. smooth driving/intense slipping between gears)

results in high wear on the transmission and high oil temperature.
The sensor for oil temperature gives a warning when the oil is hotter
than 120 °C. If the sensor for oil temperature indicates 125 °C then
transmission function is stopped.

2 Transmission – Lubrication system 2:13
2.6 Lubrication system

Lubrication system, description
The transmission has a separate lubrication system that is used for
lubrication, control and cooling of the transmission. The transmission
oil cooler is at the bottom of the cooling unit behind the engine, a
thermostat in the cooler means that the oil comes up to operating
temperature more quickly. In the event of high oil temperature, a
warning is activated in Control unit KID (D7950) and performance is
reduced, if the oil temperature continues to increase then error codes
are generated and the transmission is disengaged.
During operation of the engine, the oil pump draws oil from the
transmission's oil sump through a strainer, and it then pumps it through
two oil filters to a control valve. The control valve provides oil at the
correct pressure to the transmission's valve housing for activation of
disc clutches for FORWARD (gears 1, 2, 3, 4 or 5) or BACKWARD
(gears 1, 2 or 3). The disc clutches require only a small part of the oil
flow supplied by the pump. The remainder of the oil is pumped through
the torque converter circuit to the transmission oil cooler and then back
to the transmission for lubrication.
See also supplier documentation, transmission.
2.6.3 Oil cooler

Oil cooler, description
The transmission oil is cooled in the lower section of the cooler unit.
1 A temperature-controlled bypass valve, which only acts on the

transmission oil cooling circuit, is fitted in a pipe on the underside of
the radiator (engine side). The valve closes when the oil starts to
reach operating temperature. This means that the oil reaches normal
operating temperature more quickly.
2 For more information, see supplier documentation, transmission.
4
014293
1. Intercooler
2. Radiator, engine

2:14 2 Transmission – Oil cooler
Thermostat transmission oil cooler, replacement
NOTE
Read the safety instructions for oil before working, see section B
Safety.

2 Drain the oil from the transmission, see Maintenance manual.
3 Loosen the cover plug and remove the thermostat.
4 Check the O-ring and the spring in the bottom, replace as
necessary.
5 Install the new thermostat, and the cover plug.
IMPORTANT
It is very important that the thermostat is turned with
the temperature bulb facing out as shown.
6 Fill with transmission oil, see Maintenance manual.

7 Start the engine and check for leaks.
8 Check the transmission oil level, see Maintenance manual.
014294
Thermostat transmission oil cooler for engine option

TAD1360VE

2 Transmission – Cooling system 2:15
2.7 Cooling system

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

Oil cooler, description, page 2:13.

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

Transmission control system, description
The transmission is electronic with five forward gears and three reverse
gears and electronically controlled disc clutches. The transmission has
functions for manual shifting as standard and automatic shifting and
electronic declutch via the brake pedal.
Control unit transmission controls shifting based on signals from the

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

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

the safety system, for more detailed information, see section 8 Control
system, group 8.2.2 Bypass.
WARNING
Safety interlocks are blocked.
No safety system is engaged! Risk of tipping and
rolling over!
Use only bypass in emergency situations!
1 Unload the load.

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

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

Control unit transmission, general
See 11.5.3.7 Control unit, transmission (D7930), page 11:37.
2.8.2 Brake pressure sensor

Sensor brake pressure, general
See Brake pressure sensor, description, page 4:31
2.8.3 Transmission cable harness

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

2:18

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

3:2

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

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

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

4 Fit the propeller shaft's attaching bolts.
Tightening torque 156 Nm. Retighten the attaching bolts after 50h
operating time.

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

Drive axle, general
The drive axle transmits the engine power to the wheels. A differential
1
is fitted after the drive axle's input shaft, which changes the reduction
3 ratio, distributes the power between right and left-hand drive wheels
and also makes it possible for the drive wheels to rotate at different
4 speeds during cornering. The half shaft transmits the power from the
2 differential to the wheel hubs. Hub reductions are fitted at the wheel
hubs that change the reduction ratio between wheel and engine in
1 order to reduce the stress on the half shaft.
and instructions for the drive axle's components and systems, refer to
the relevant supplier documentation.

016258
1. Hub reduction
2. Half shaft (internal)
3. Differential (internal)
4. Drive axle housing
Drive axle, replacement
DANGER
Drive axle and machine are very heavy.
Risk of crushing!
It is forbidden to go under a machine which has been
lifted by a jack etc. For machine weight, see section F
Technical data.
1 Park the machine with blocks behind the steering wheels.

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

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

(position 2) from the distribution block.
NOTE
Plug all connections immediately to protect the hydraulic system
from impurities.
1. Hydraulic hoses
2. Cable harness
6 Remove the cover (position 3) on the parking brake.

3
004505
3. Cover, parking brake

7 Loosen the lock nut (position 4) and screw in the screw (position
5), this compresses the brake spring. Screw until the brake pads
release from the brake disc. Refit the cover on the parking brake
(position 3).
6
8 Detach the hydraulic hose (position 6) from the parking brake.
NOTE
5 Plug all connections immediately to protect the hydraulic system
from impurities.
4
004506
4. Lock nut
5. Release screw
6. Hydraulic hose, parking brake
9 Detach the propeller shaft from the drive axle. Secure the propeller
shaft, otherwise there is a risk that it will be pulled apart.
Securing the propeller shaft
10 Lift the machine so that the wheels are off the ground.
11 Remove the drive wheels from the drive axle.
12 Support the drive axle under the hubs.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away
Lifting machine uncontrollably.

3 Driveline/Axle – Drive axle 3:7
13 Remove the bolts that secure the drive axle in the frame.
14 Lift away the drive axle.
CAUTION
Crushing injury!
uncontrollably.
15 Transfer parts from the old drive axle to the new one.
NOTE
Attaching bolts drive axle Plug all connections immediately to protect the hydraulic system
from impurities.
16 Clean contact surfaces on drive axle and frame. Also clean the
contact surface for the bolts on the underside of the drive axle.
17 Remove the nuts for attaching the drive axle, blow clean and refit
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.
CAUTION
Crushing injury!
uncontrollably.
20 Lower the frame toward the drive axle. Check that the guide pins
fit in the frame.
21 Install the new bolts that secure the drive axle in the frame. Tighten
the bolts with a torque of 2820 Nm.
22 Install the drive wheels on the new axle.
23 Rustproof the bolts with suitable paint.

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

(position 2) to the distribution block on the drive axle.
25 Connect the hydraulic hose to the parking brake, adjust the
parking brake.
26 Connect the drive shaft to the drive axle, tighten the bolts with
a torque of 156 Nm. (Check-tighten the attaching bolts after 50
operating hours.)
27 Check the oil level in the drive axle.
28 Close the valves that were opened for draining the pressure in the
hydraulic system.
1. Hydraulic hoses
2. Cable harness NOTE
the lock ring.
29 Start the machine and bleed the brakes, see section 4 Brakes,
group 4.3.9 Wheel brake.
30 Check for leaks.

4:1
4 Brakes
Contents 4 Brakes
4 Brakes................................................................................................................. 4:3
4.1.1 Brake pedal .................................................................................................4:4
4.1.2 Switch parking brake ...................................................................................4:9
4.3 Power-assisted brake system ........................................................................4:10
4.3.1 Oil pump brake system..............................................................................4:12
4.3.2 Oil filter brake system................................................................................4:15
4.3.3 Accumulator charging valve ......................................................................4:16
4.3.4 Accumulator ..............................................................................................4:19
4.3.5 Brake valve ...............................................................................................4:22
4.3.6 Drive axle block .........................................................................................4:25
4.3.9 Wheel brakes ............................................................................................4:25
4.3.10 Pipes and hoses........................................................................................4:27
4.3.11 Accumulator pressure sensor....................................................................4:28
4.3.12 Brake pressure sensor ..............................................................................4:31
4.5 Parking brake system ....................................................................................4:35
4.5.3 Solenoid valve parking brake ....................................................................4:37
4.5.4 Parking brake unit .....................................................................................4:38
4.5.6 Pipes and hoses........................................................................................4:41
4.5.10 Sensor parking brake pressure .................................................................4:42
4.8 Temperature control, cleaning and oil brake system......................................4:46
4.8.1 Oil tank brake system................................................................................4:48
4.8.2 Tank heater ...............................................................................................4:48
4.8.4 Accumulator charging valve ......................................................................4:49
4.8.5 Drive axle block .........................................................................................4:49
4.8.6 Wheel brakes ............................................................................................4:49
4.8.7 Oil cooler ...................................................................................................4:49
4.8.8 Cooling fan ................................................................................................4:50
4.8.9 Thermal bypass valve ...............................................................................4:51
4.8.10 Sensor, oil temperature brake system.......................................................4:52
4.8.11 Breather filter.............................................................................................4:53
4.8.13 Pipes and hoses........................................................................................4:53
4.8.14 Oil, brake system ......................................................................................4:53

4:2

4 Brakes – Brakes 4:3
4 Brakes
Brakes, general
Brakes are designed to facilitate stopping the machine. The brakes act
on the drive axle (the steering axle has no brakes).
The brake system is divided into three functions:

• Power-assisted brake system, description, page 4:10
• Parking brake system, description, page 4:35
• Temperature control, cleaning and oil brake system, description,
page 4:46

4:4 4 Brakes – Controls and instruments

4.1.1 Brake pedal
Brake pedal, description
The brake pedal (1) acts on the brake valve via a lever. A spring
causes the pedal to automatically return to rest position. It is important
to keep the area around the pedal clean. Dust and dirt can cause the
pedal to jam or not become fully depressed.
1
015745
1
1. Brake pedal
Brake pedal, replacement
NOTE
Safety.

NOTE

1 2 1
015856
1. Screws
2. Cover
4 Release the brake valve from the pedal assembly from below
the cab.
5 Carefully fold back the floor mat so the pedal assembly's mounting
in the floor is accessible.
The mat has a slot that is sufficiently large for access to the pedal.
016391

4 Brakes – Brake pedal 4:5
6 Loosen the tab washers and remove the screws that fasten the
pedal assembly to the floor. Lift out the pedal assembly.
016178
1 2 3 4 3 5 7 Remove the circlip.

8 Remove the stop screws.
9 Pull out the brake pedal's axle.
10 Loosen the nut securing the accelerator pedal axle.
11 Pull out the accelerator pedal's axle.
12 Loosen the brace to the brake valve.
13 Replace the brake pedal.
016055
1. Axle, brake pedal

2. Circlip
3. Stop screw
4. Nut, accelerator pedal axle
5. Brace, brake valve

4:6 4 Brakes – Brake pedal

Use new split pins. If required, replace the tab washers for the
screws that attach the pedal assembly to the floor.
15 Adjust the pedal assembly, see Pedal assembly, adjusting, page
4:6.
hydraulic system.
NOTE
the lock ring.
016179
Pedal assembly, adjusting
Checking the pump pressure
0:00pm
1 Operate and warm up the machine so that the oil in the brake
a system reaches operating temperature, at least 50 °C.
Use Operating menu transmission and hydraulics in order to check
the oil temperature.
75° C 50%
b c
50° C 50° C
016372
Operating menu, transmission and hydraulic system

a. Oil temperature transmission
b. Oil temperature hydraulic system
c. Oil temperature brake system

1 2 1
015856
1. Screws
2. Cover

4 Brakes – Brake pedal 4:7
3 Check that the distance (A) between the adjusting device and the
adjusting screw is 2.6 mm.
On newer machines, the distance is designed so that the clearance
is correct when the adjusting screws are tightened to the bottom.
A
A 016567
4 Connect a pressure gauge (0-25 MPa) to the measuring outlet for

brake pressure on the drive axle block.
5 Start the engine and run the engine at idling speed in order to
ensure that the brake system has working pressure.
016319
Measuring outlet, brake pressure
6 Fully depress the centre pedal and check that the distance between
the bottom of the brake pedal and the floor mat is at least 10 mm.
If necessary, adjust the adjusting screw for bottom position until
the correct measurement is obtained.
DANGER
Inadequate clearance may result in reduced braking
performance.
017454
Extreme danger.
Adjusting screw, centre pedal bottom position. Ensure that the clearance between brake pedal and
floor in fully depressed position is correct.

4:8 4 Brakes – Brake pedal
7 Fully depress the centre pedal and check that the brake pressure
corresponds with the brake pressure on the pressure plate.
If necessary, adjust the push rod until the correct pressure is
obtained.
8 Fully release the centre pedal and check that the brake pressure
falls to 0 kPa.
017457
Adjusting screw, brake pressure.
9 Check that there is a small amount of play in the centre pedal

before the brakes are pressurised.
If necessary, adjust the adjusting screw for top position until there
is some play.
017455
Adjusting screw, centre pedal top position
10 Check that the accelerator pedal has the same height as the
centre pedal in released position.
If necessary, adjust the position with the adjusting screw for the
accelerator pedal's top position.
11 Check that the accelerator pedal does not travel lower down to the
floor than the fully depressed position of the centre pedal.
accelerator pedal's bottom position.
017458
1 2
1. Adjusting screw, accelerator pedal bottom
position
2. Adjusting screw, accelerator pedal top position

4 Brakes – Switch parking brake 4:9
12 Check that there is clearance for the linkage between accelerator

pedal and potentiometer.
13 Depress the accelerator pedal and check that the linkage does not
bind or make contact against other parts.
014778
Clearance, linkage accelerator pedal
14 Check that the left-hand brake pedal has the same height as the
centre pedal.
left-hand brake pedal.
15 Fully depress the left-hand brake pedal and check that the brake
pressure corresponds with the brake pressure on the pressure
plate.
16 Fully release the left-hand brake pedal and check that the brake
pressure falls to 0 kPa.
17 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
017456
18 Test drive the machine and check the function of the brakes and
Adjusting screw, left-hand brake pedal the sensitivity in the pedals.
Pedal rubber, replacement

See Pedal rubber, replacement, page 1:22.
4.1.2 Switch parking brake

Switch, parking brake, general
The parking brake is controlled with gear and multi-function lever, see
Travel direction selector and parking brake, description, page 2:9.

4:10 4 Brakes – Power-assisted brake system
4.3 Power-assisted brake system

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

routes oil through the drive axle's brake units and cools the brakes.
The oil passes through the cooler back to the tank. An electric cooling
fan increases the air flow through the cooler when the temperature
needs to be lowered. A thermal bypass valve routes the oil past the
cooler if the oil temperature is low. The temperature sensor controls
fan activation and temperature warning in the display.
Power-assisted brake system, function

description
15 5
D7902 D7950 P
B
T
D11 D7971 D7901
10 9
11 C
Pa
13
D7930 D9
D14
6
4
14 8 8
Pa
ACC
C H
P 3 7 7
2 T
B
1
016395

1 Oil pump brake system pumps oil from P = 20.5±1.0 MPa (when the Oil tank brake system, description, page
oil tank brake system. accumulators are charged) 4:48
Oil pump brake system, description, page
4:12
2 Oil filter brake system cleans the oil. - Oil filter brake system, description, page
4:53
3 The accumulator charging valve directs - Accumulator charging valve, description,
oil to charging of accumulators or page 4:16
through the brake system's cooling
circuit.

4 Brakes – Power-assisted brake system 4:11

4 The accumulators store oil pressure. See the pressure plate, Accumulator, description, page 4:19
Accumulator pressure brake
system, on the left frame
member.
5 The brake valve directs pressure from - Brake valve, description, page 4:22
the accumulators to the distribution
block in proportion to pedal depression.
6 The drive axle block shares the pressure See the pressure plate, Drive axle block, description, page 4:25
to right and left brake cylinder. Brake pressure, on the left
frame member.
7 The brake cylinders compress the discs - Wheel brakes, description, page 4:25
in the wheel brakes.
8 The wheel brakes brake the machine. - Wheel brakes, description, page 4:25
9 The brake pressure sensor (B7681) U = 0.5-4.5 V Brake pressure sensor, description, page
sends a voltage signal corresponding to 4:31
the brake pressure to the KFU control D9: Diagnostic menu, see 4.3 Power
unit (D7971). Assisted 3/XX DIAGNOSE, page 8:36
10 If the voltage signal from Sensor brake U = 24 V 11.5.3.4 KFU control unit (D7971), page
pressure (B7681) is equivalent to brake 11:31
pressure above 0.2 MPa: D10: Diagnostic menu, see 9.6 Lighting
Control unit KFU (D7971) activates Sys 5/XX DIAGNOSE, page 8:67
voltage feed to Brake lights (H4110-LE
and H4110-RI).
11 Brake lights (H4110-LE and H4110-RI) - Brake lights, description, page 9:62
are switched on. D10: Diagnostic menu, see 9.6 Lighting
Sys 5/XX DIAGNOSE, page 8:67
12 If the voltage signal from Sensor brake Checked by control system, 11.5.3.4 KFU control unit (D7971), page
pressure (B7681) is equivalent to brake error shown with error code. 11:31
pressure above the limit for transmission
declutch:
Control unit KFU (D7971) sends
declutch on CAN bus drive-train.
It is also possible to set it so that there
is a requirement for the engine speed
to be above a certain limit in order that
declutch should be activated.
13 The transmission control unit (D7930) Checked by control system, 11.5.3.7 Control unit, transmission
disengages the engine drive. error shown with error code. (D7930), page 11:37
14 The accumulator pressure sensor U = 0.5-4.5 V Accumulator pressure sensor, description,
(B7683) sends a voltage signal page 4:28
equivalent to the pressure in the D14: Diagnostic menu, see 4.3 Power
accumulators to Control unit KFU Assisted 3/XX DIAGNOSE, page 8:36
(D7971).
15 If the voltage signal from Sensor Checked by control system, 11.5.3.4 KFU control unit (D7971), page
accumulator pressure (B7683) is error shown with error code. 11:31
equivalent to pressure below 15 MPa: D14: Diagnostic menu, see 4.3 Power
Control unit KFU (D7971) sends a Assisted 3/XX DIAGNOSE, page 8:36
warning about low pressure on the CAN
bus.
15 KID control unit (D7950) activates the Checked by control system, 11.5.3.3 Control unit, KID (D7950), page
event menu low accumulator pressure. error shown with error code. 11:29
16 Control unit, engine (D7940) limits the Checked by control system, 11.5.3.6 Control unit, engine (D7940),
engine speed error shown with error code. page 11:35
Hydraulic diagram, basic machine, see Hydraulic diagram brake

system, page E:4.

4:12 4 Brakes – Oil pump brake system
4.3.1 Oil pump brake system

Oil pump brake system, description
The brake system has a gear pump with fixed displacement. Oil pump
1 5 3 2 4 brake system is located at the front of the right-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
4:16.
Oil pump brake system is driven by the main pump's shaft from the
transmission's power take-off. The pump's rotation speed is directly
dependent on engine speed. The pump flow rate increases with engine
speed and varies with the rotation speed of the input shaft.
NOTE
It is very important that the clearance between the gears and
between the gear and the housing is correct. Clearance that is too
small creates wear damage. Clearance that is too large reduces
016339
the pump's power output.
1. Hydraulic oil pump 1

4. Hydraulic oil pump cooling and cleaning
5. Oil pump brake system
Oil pump brake system, checking
NOTE
Safety.
Checking the pump pressure
0:00pm
1 Operate and warm up the machine so that the oil in the brake
a system reaches operating temperature, at least 50 °C.
75° C 50%
b c 3 Open the drain valve on the accumulator charging valve.
50° C 50° C
016372


4 Brakes – Oil pump brake system 4:13
4 Connect a pressure gauge (0-25 MPa) to the pump measuring

outlet on the accumulator charging valve.
5 Start the engine and run it at idle.
6 Close the drain valve on the accumulator charging valve and check
the pump pressure during charging.
During charging the pressure should increase to 20.5±1.0 MPa
before the accumulator charging valve switches to cooling. When
the accumulator charging valve switches to cooling, the pressure
drops.
7 Check the pressure during cooling.
During cooling the pressure should be max. 0.10–0.15 MPa at
max. engine rpm.
8 Switch off the engine.
measuring outlet.
Checking the accumulator charging

10 Open the drain valve on the accumulator charging valve.
016290
Measuring outlet, pump pressure
11 Connect a pressure gauge (0-25 MPa) to the accumulator

measuring outlet on the accumulator charging valve.
13 Close the drain valve on the accumulator charging valve.
NOTE
the lock ring.
14 Check that the pressure increases slowly to 20.5±1.0 MPa.

15 Check that Sensor accumulator pressure shows the correct
pressure in the display, see Sensor accumulator pressure,
checking, page 4:28.
16 Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve must switch to charging at 15.5±0.5 MPa.
016291
measuring outlet.
Measuring outlet, accumulator pressure

Oil pump brake system, replacement
NOTE
Safety.
1 Machine in service position, section B Safety.

NOTE
3 Mark up and detach the hydraulic hoses from the pump.
NOTE
Plug all connections immediately to protect the brake system
from impurities.
016836
4 Remove the attaching bolts, pull the pump out backwards and
lift it away.
5 Transfer the connection adapters to the new pump.
016835
6 Remove the spacer ring from the brake pump.

Clean the O rings' contact surfaces on the spacer ring.
7 Install the spacer ring on the main pump.

4 Brakes – Oil filter brake system 4:15
8 Brush sealing silicone on the sealing face of the brake pump, see
section F Technical data.
9 Fit the brake pump on the main pump.
Install the pump and check that the pump's splines engage in the
shaft in the main pump.
Fit the pump's attaching bolts.
10 Connect the hydraulic hoses to the brake pump.
016868
The illustration shows a separate pump. NOTE
Change the O-rings. Check that the O-rings are positioned
correctly.
hydraulic system.
NOTE
the lock ring.
12 Switch on the system voltage and start the engine.

13 Check that the hose connections and seal between the hydraulic
oil pump and brake pump seal tight.
Check the feed pressure from the brake pump, see Oil pump brake
system, checking, page 4:12.
14 Check the oil level in the brake system, fill if necessary.
NOTE
If the pump is replaced due to malfunction, change the oil and
filter in the brake system as well.
4.3.2 Oil filter brake system

Oil filter brake system, general
See Oil filter brake system, description, page 4:53.

4:16 4 Brakes – Accumulator charging valve
4.3.3 Accumulator charging valve

Accumulator charging valve, description
The accumulator charging valve distributes the oil from the pump
1 2 3
between pressure storage and cooling of the wheel brakes. The
accumulator charging valve is fitted on the beam in front of the
4 transmission in the engine compartment.
14
5 The accumulator charging valve stores pressure by directing the oil to
the accumulators. The wheel brakes are cooled by oil being directed to
6 the drive axle cooling circuit and then on to the brake system's cooler.
The accumulator charging valve prioritises charging of the accumulators

above cooling. A restriction of the charging means that a small quantity
13 7 of oil also flows to cooling during accumulator charging. At idle the flow
12 from the pump is so small that all oil flows to pressure storage.
11 8 The drain valve (position 5) is used to relieve the pressure in the
accumulators to the tank. The valve opens a connection between the
10 9 accumulators 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 pump pressure (position

11) and accumulator pressure (position 12) on the accumulator
charging valve. The pressures are individual to each machine and
016820
the values are specified on the pressure plate on the left-hand frame
member, see section 10 Common hydraulics. Also fitted on the
1. Connection, parking brake caliper (HB) accumulator charging valve is Solenoid valve parking brake (Y6420)
(position 13), Sensor parking brake (B7682) (position 2) and Sensor
2. Sensor parking brake (B7682) (LB)
accumulator pressure (B7683) (position 4).
3. Connection, accumulators (ACC)
• Solenoid valve parking brake, description, page 4:37
4. Accumulator pressure sensor (B7683)
• Accumulator pressure sensor, description, page 4:28
5. Drain valve
• Sensor parking brake pressure, description, page 4:42
6. Pressure relief valve
7. Main valve, charging
8. Safety valve
9. Connection from pump (P)
10. Connection, wheel brake (T)
11. Measuring outlet, pump pressure (P)
12. Measuring outlet, accumulator pressure (M)
13. Solenoid valve parking brake (Y6420)
14. Connection, brake valve (B)

4 Brakes – Accumulator charging valve 4:17
Accumulator charging, checking and adjustment
NOTE
Safety.

2 Check the accumulator's charging, see Oil pump brake system,
3 If necessary, adjust the accumulator charging pressure on the
pressure relief slide.
Undo the lock nut and adjust the pressure by turning the adjusting
screw.
Clockwise: reduce pressure.
Anticlockwise: increase pressure.
4 Open the drain valve on the accumulator charging valve so that
the accumulators are drained and the valve switches to charging.
Close the drain valve and check the max. pressure again.
5 Repeat steps 3 and 4 until the pressure is correct.
6 Close the drain valve on the accumulator charging valve.
NOTE
the lock ring.
016814
Adjusting screw accumulator charging pressure

4:18 4 Brakes – Accumulator charging valve
Accumulator charging valve, replacement
NOTE
Safety.

NOTE
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
from impurities.
6 Remove the accumulator charging valve.

7 Transfer the connection adapters and sensors to the new
accumulator charging valve.
8 Fit the new valve.
9 Connect the hoses to the accumulator charging valve in
accordance with the marking.
NOTE
016985

correctly.
10 Install the parking brake valve and break contact (opening switch)
parking brake.
11 Connect the wiring to the accumulator charging valve.
hydraulic system.
NOTE
the lock ring.

Check that the hydraulic connections are sealed tightly.
14 Check the charging and switching function, see Accumulator
charging, checking and adjustment, page 4:17.

4 Brakes – Accumulator 4:19
4.3.4 Accumulator
Accumulator, description
The accumulators store pressure so that there is a pressure reserve in
the event of engine or brake system malfunction. The brake system
has four accumulators connected in parallel. These are fitted at the
front in the engine compartment, above the drive axle.
The accumulators are of the diaphragm type. Each accumulator is

divided into two compartments by a diaphragm. One side of the
diaphragm is pressurised by nitrogen gas. The other side is pressurised
by the hydraulic oil, which compresses the nitrogen gas.
The accumulator has pressure check connections for checking the gas
pressure on the opposite side of the pressure connection.
016340
Accumulator, checking
NOTE
Safety.

NOTE
3 The accumulators can be tested with separate test equipment or in

the machine. Primarily, separate test equipment should be used
since it is faster and more accurate.
Test equipment can be ordered from Cargotec.
• Checking with test equipment: continue with step 4.
• Checking in machine: continue with step 6.

4:20 4 Brakes – Accumulator
Checking with test equipment

4 Remove the accumulators and test them with the test equipment
designed for the purpose.
The accumulators' gas pressure must match with the pressure
plate.
5 Continue with step 17.
Checking in the machine

6 Detach one of the accumulators from the distribution block. Plug
the distribution block connections with plugs that can withstand the
system pressure. Plug the connections on the accumulators to
protect against impurities.
016834
Pressure plate, gas pressure brake accumulators

7 Connect a pressure gauge (0-25 MPa) to the accumulator
measuring outlet on the accumulator charging valve.
9 Close the drain valve on the accumulator charging valve and
charge the accumulator until the accumulator charging valve
changes to cooling.
10 Check that the plugs seal properly.
12 Lower the pressure by means of braking carefully several times
while checking the pressure on the pressure gauge.
When the pressure reaches approx. 10 MPa the pressure must
decrease immediately to 0 MPa.
If the pressure drops immediately when the engine is switched off
then the accumulator does not have any precharge pressure. This
indicates internal leakage and the accumulator must be replaced.
If the pressure can be reduced slowly to a pressure below 10 MPa
then the pre-charge pressure is too low and the accumulator must
be replaced or given to authorised personnel for maintenance.
13 Depressurise the brake and hydraulic systems, see section B
016291
Safety.
14 Mark up and disconnect the tested accumulator. Plug the

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

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

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

4 Brakes – Accumulator 4:21
21 When the accumulators are fully charged, switch off the engine
and turn the start key to position I.
22 Check that at least 8 brake applications (pedal depressions) can
be performed before the pressure drops to 10 MPa.
At 11.5 MPa the warning lamp for low brake pressure must be
switched on.
Accumulator, replacement
NOTE
Safety.

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

5 Detach the accumulator from the distribution block.
NOTE
Hold the block firmly so that the other accumulator does not work
loose.
6 Bend the clamp away and remove the accumulator.

4:22 4 Brakes – Brake valve
7 Fit the new accumulator.
NOTE
Check that the seal is intact, clean and fitted in the correct
position.
8 Secure the accumulator's clamp and tighten the bolt.

hydraulic system.
NOTE
the lock ring.

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

Brake valve, description
The brake valve controls the hydraulic pressure to the brakes and is
pressurised by the accumulator. The brake valve is mounted under
the cab floor, a lever transmits the pedal force from the brake pedal
to the valve.
The foot brake valve is a mechanically activated pressure reducing

valve. With the brake pedal depressed halfway the brake pressure is
around 3 MPa, then pedal resistance increases more steeply. When
the pedal is depressed to the bottom, the brake pressure is up to
15 MPa (depending on machine version). This provides optimum pedal
responsiveness as well as increased safety as the operator can easily
016392
1 2 sense if no brake pressure is being built up (no resistance in the pedal).

1. Brake valve
2. Lever from the brake pedal

4 Brakes – Brake valve 4:23
Brake valve, checking
NOTE
Safety.
0:00pm
1 Operate and warm up the machine so that the hydraulic oil reaches
a operating temperature, at least 50 °C.
75° C 50%
b c
50° C 50° C
016372

a. Temperature transmission
b. Temperature hydraulic system
c. Temperature brake system

4 Start the machine and run it at idling speed until the accumulator is
charged and the accumulator charging valve changes to cooling.
016319
5 Press down the pedal completely and read off the pressure.
Compare with the value specified on the pressure plate.
7 Depress the pedal fully and keep it pressed down, check the
pressure.
The brake pressure must correspond with the value specified on
the pressure plate and must not decrease from this value for 15
seconds.
016389
Pressure plate, brake pressure

4:24 4 Brakes – Brake valve
8 Release the pedal. The brake pressure must decrease to 0 MPa

immediately.
If the brake pressure does not go down all the way to 0 MPa then
the pedal's zero position may have to be adjusted. The pedal's
zero position is adjusted with the screw under the pedal.
If the brake pedal is correctly adjusted and the pressure does not
fall to 0 MPa, the brake valve is not sealed and can cause the
brakes to remain applied and then overheat during operation.
Replace the brake valve if it is not sealed.
015817
measuring outlet.
Adjuster screw brake
Brake valve, replacement
NOTE
Safety.

NOTE
3 Mark up and detach the hydraulic hoses from the brake valve.
NOTE
from impurities.
016393
4 Remove the brake valve attaching bolts.

5 Remove the brake valve.
6 Transfer the connection adapters to the new brake valve.
7 Fit the new brake valve.
8 Connect the hydraulic hoses to the brake valve in accordance
with the marking.
016391
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.
10 Switch on the system voltage and start the engine. Let the engine
run at idle speed.
11 Test the brakes a couple of times.
12 Check that the brake valve's connections are sealed tightly.
13 Bleed the wheel brakes' brake cylinders, see Wheel brakes,
bleeding, page 4:26

4 Brakes – Drive axle block 4:25
4.3.6 Drive axle block

Drive axle block, description
1 2 The drive axle block distributes oil flow and brake pressure to the right
and left-hand wheel brakes. The drive axle block is fitted on a bracket
3 above the drive axle differential.
1
9 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 leads oil directly from
8 4 the cooling circuit intake to the cooling circuit return if the resistance
in the axle becomes too great. This protects the wheel brake seals,
e.g. when the oil is cold.
7
6 Sensor brake pressure (B7681) is fitted in the drive axle block, see
5
Brake pressure sensor, description, page 4:31.
016397
1. Connection brake cooling, return from wheel

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

Wheel brakes, description
The wheel brakes brake the machine during operation and are fitted on
the drive axle between the drive axle housing and hub reduction.
The wheel brake uses so-called wet disc brakes (WDB). Wet disc
brakes require minimal maintenance and have a long service life due
to efficient cooling. Maintenance requirements are minimised since oil
circulates in the brake system and prevents corrosion.
016806

4:26 4 Brakes – Wheel brakes
The wheel brakes have two main sections - disc pack and brake
1 2
cylinder. The disc pack performs the braking. The brake cylinder
presses the discs in the disc pack together during braking.
000016
Wheel hub and brake, cross-section

1. Disc pack
2. Brake cylinder
Wheel brakes, bleeding
NOTE
Safety.
IMPORTANT
Both the brake cylinder and disc brake must be bled
after work which involves the brake system being
opened or after work on the wheel brake.
Brake cylinder
2 Position a ring spanner on the bleed nipple and connect a
transparent hose to the bleed nipple.
Route the other end of the hose down into a receptacle.
3 Start the machine and depress the brake pedal, keep the pedal
depressed.
4 Open the bleed nipple and allow oil to run out of it until the oil is
free of air bubbles.
NOTE
The hydraulic hose between the brake pedal and brake is long.
So allow at least two litres of oil to pass through the bleed nipple
Bleed nipple, brake cylinder, on top of the drive axle when bleeding to ensure that no air pockets remain in the system.
at the wheel hub's inner short side (left-hand side).
5 Close the bleed nipple.
6 Move the spanner and hose and repeat steps 1-4 on the other side.
7 Check the oil level in the brake system, fill if necessary.
Wheel brake, replacement

See supplier documentation, drive axle.

4 Brakes – Pipes and hoses 4:27
4.3.9.1 Disc pack
Disc pack, description

The disc pack consists of several thin coated metal discs fixed
alternately to the wheel brake housing and to the hub reduction
housing. The discs are mounted on splines, which allows them to
move laterally.
Oil circulates between the discs cooling them, thus the name wet disc
brake. The oil is the same as in other parts of the brake system.
Braking takes place by means of the brake cylinder pressing together

the discs. This creates friction between the discs that are fixed to the
axle and those fixed to the hub reduction.
000008
Disc pack
4.3.9.2 Brake cylinder
Brake cylinder, description

The brake cylinder is integrated in the wheel brake and consists of a
metal ring (cylinder) with two seal rings. The seals have lateral support
from a bevel on the cylinder and a bevel on the wheel brake housing.
The space between the seal rings is pressurised through a channel in

the wheel brake housing. The pressure moves the metal ring sideways
and compresses the disc pack.
000007
Brake cylinder

See Pipes and hoses, general, page 10:23.

4:28 4 Brakes – Accumulator pressure sensor
4.3.11 Accumulator pressure sensor

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

sends proportional voltage signals to Control unit KFU (D7971).
The signal can be checked with the diagnostic menu, see 4.3 Power
Assisted 3/XX DIAGNOSE, page 8:36.
017451
Sensor accumulator pressure, checking
NOTE
Safety.
0:00pm
1 Operate and warm up the machine until the oil reaches operating
a temperature, at least 50 °C.
The temperature can be checked with Operating menu,
transmission and hydraulic system.
75° C 50%
b c
50° C 50° C
016372


4 Brakes – Accumulator pressure sensor 4:29

accumulator pressure on the accumulator charging valve.
016291
Measuring outlet, accumulator pressure
10:23
4 To be able to read the signal from the sensor, first navigate to the
CUSTOMER SETTI NGS menu for service and settings with or and confirm with .
0
014981
10:23 5 Enter diagnostic code 1111, with or . Confirm each figure

with .
0 WRI TE PI N CODE NOTE

The code determines which service menus should be activated.
0 0
015625
6 Select 4. BRAKES by scrolling with or and confirm with .

* SETTI NGS & DI AGNOSTI CS*
4 . BRAKES
016946

4:30 4 Brakes – Accumulator pressure sensor
7 Select 4.3 Power Assisted System by scrolling with or and

* 4 . BRAKES *
confirm with .
4.1 Controls & I n s t r ume nt s
4.2 ABS
4.3 Power Assist e d Sys t e m
4.4 Non Power As s i s t e d Sy s t e m
4.5 Parking Brak e
4.6 Speed Retard a t i o n Sys t e m
4.7 Trailer Brak e Co nn e c t i o n s
4.8 Brake Oil Te mp / Cl e a n
016947
8 Select DIAGNOSE by scrolling with or and confirm with .
* 4 . BRAKES *
DIAGNOSE INITIATE CALIBRATE
4.2 ABS
4.5 Parking Brak e
016948
9 Select 4.3 Power Assisted 3 by scrolling with or .

For a more detailed description, 4.3 Power Assisted 3/XX
DIAGNOSE, page 8:36.
10 Start the engine and compare the pressure in the diagnostics
menu with the measured pressure on the pressure gauge.
11 Stop the engine and turn the start key to position I.
measuring outlet.
Accumulator pressure sensor, replacement
NOTE
Safety.

NOTE

4 Brakes – Brake pressure sensor 4:31
3 Disconnect the electrical connections and replace the sensor.

hydraulic system.
NOTE
the lock ring.
017451
4.3.12 Brake pressure sensor

Brake pressure sensor, description
Sensor brake pressure (B7681) controls activation of the brake light
when the machine is braked. The sensor is fitted on the drive axle
block which is fitted on a bracket above the drive axle differential.
Sensor, brake pressure (B7681) is supplied with voltage by, and sends
voltage signals proportional to the brake pressure to Control unit KFU
(D7971).
The signal can be checked with the diagnostic menu, see 4.3 Power
016398

4:32 4 Brakes – Brake pressure sensor
Sensor brake pressure, checking
NOTE
Safety.
0:00pm
1 Operate and warm up the machine until the oil in the brake system
a reaches operating temperature, at least 50 °C.
75° C 50%
b c
50° C 50° C 016372


016319
10:23
0
014981

4 Brakes – Brake pressure sensor 4:33

with .

0 0
015625
0

4 . BRAKES
016946
7 Select 4.3 Power Assisted System by scrolling with or and

* 4 . BRAKES *
confirm with .
4.2 ABS
4.5 Parking Brak e
016947

* 4 . BRAKES *
4.2 ABS
4.5 Parking Brak e
016948
9 Scroll to diagnostic menu 4.3 Power Assisted 3, with or .

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

4:34 4 Brakes – Brake pressure sensor
Brake pressure sensor, replacement
NOTE
Safety.

NOTE

hydraulic system.
NOTE
the lock ring.
016398

4 Brakes – Parking brake system 4:35
4.5 Parking brake system

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

Accumulator pressure Above limit for warning Power-assisted brake system, function description, page 4:10
Service brake Activated Power-assisted brake system, function description, page 4:10
D5
5
6, 12
D7902
D7971
4 D8 7, 11, 13
8 10 D10
Pa
C C
ACC
H
P 3
2 T
B
1
9
016394
1 Oil pump brake system pumps oil from P = 19±0.5 MPa Oil tank brake system, description, page 4:48
oil tank brake system. Oil pump brake system, description, page
4:12
2 Oil filter brake system cleans the oil. - Oil filter brake system, description, page 4:53
3 The accumulator charging valve directs - Accumulator charging valve, description,
oil to charging of accumulators or page 4:16
through the brake system's cooling
circuit.
4 The accumulators store oil pressure. See the pressure plate on Accumulator, description, page 4:19
the left-hand frame beam.
5 The travel direction selector in position U = 24 V Travel direction selector and parking brake,
for activated parking brake (S1310) description, page 2:9
sends a voltage signal to the KPU D5: Diagnostic menu, see 4.5 Park Brake
control unit (D7902). Sys 3/XX DIAGNOSE, page 8:37
The service brake must be actuated to
release the parking brake before the
travel direction selector is moved to the
released parking brake position (S1310).


6 The KPU control unit (D7902) sends Checked by control 11.5.3.4 KFU control unit (D7971), page
release the parking brake on the CAN system, error shown with 11:31
bus. error code.
7 KFU control unit (D7971) activates the U = 24 V 11.5.3.4 KFU control unit (D7971), page
parking brake solenoid valve (Y6420). 11:31
D8: Diagnostic menu, see 4.5 Park Brake
8 Solenoid valve parking brake (Y6420) Pump pressure. Solenoid valve parking brake, description,
acts on the valve slide which drains page 4:37
pressure in the parking brake's brake
caliper to tank.
9 The brake caliper is drained of pressure 0 MPa Parking brake unit, description, page 4:38
and the spring applies the parking brake.
10 Sensor parking brake pressure (B7682) U = 0.5-4.5 V Sensor parking brake pressure, description,
sends voltage signals equivalent to the page 4:42
pressure for the parking brake caliper to D10: Diagnostic menu, see 4.5 Park Brake
Control unit KFU (D7971). Sys 3/XX DIAGNOSE, page 8:37
The pressure indicates that the parking
brake is released.
11 The KFU control unit (D7971) sends Checked by control 11.5.3.4 KFU control unit (D7971), page
parking brake applied on the CAN bus. system, error shown with 11:31
error code.
12 KPU control unit (D7902) activates Checked by control 11.5.3.2 KPU control unit (D7902), page
indicator light, parking brake. system, error shown with 11:27
error code.
13 Control unit KFU (D7971) sends a signal U = 24 V 11.5.3.4 KFU control unit (D7971), page
over the CAN bus to allow declutch of 11:31
the transmission.
Hydraulic diagram brake system, see Hydraulic diagram brake system,

page E:4.

Oil pump brake system, general
See Oil pump brake system, description, page 4:12.

Oil filter brake system, general
See Oil filter brake system, description, page 4:53.

4 Brakes – Solenoid valve parking brake 4:37
4.5.3 Solenoid valve parking brake

Solenoid valve parking brake, description
Solenoid valve parking brake (Y6420) activates the parking brake.
The solenoid valve is fitted on the accumulator charging valve, which
is fitted on the lifting beam in front of the transmission in the engine
compartment, see Accumulator charging valve, description, page 4:16.
The solenoid valve opens a connection between the accumulators and

the parking brake caliper on activation. This means that the parking
brake caliper is pressurised and the parking brake is released. When
the voltage feed to the solenoid valve is cut off, the connection between
the accumulators and parking brake caliper is closed. Instead, a
connection between the parking brake caliper and tank is opened and
the parking brake is applied. This means that the parking brake is
applied if the machine becomes de-energised or if the brake system
becomes depressurised.
The solenoid valve is voltage fed by the KFU control unit (D7971) on
activation.
The signal can be checked with the diagnostic menu, see 4.5 Park
Brake Sys 3/XX DIAGNOSE, page 8:37.
016817
Solenoid valve parking brake, checking
DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to
roll when the parking brake is released.
1 Start the engine and run it at idling speed until the accumulator
charging valve changes to cooling.
2 Switch off the engine. Let the ignition key lock be in the I position.
3 Release the parking brake with the travel direction selector and
check that the parking brake's brake caliper releases. The brake
caliper should be able to move.
4 Actuate the service brake pedal, apply the parking brake with the
travel direction selector and check that the parking brake's calipers
are applied.

4:38 4 Brakes – Parking brake unit
Solenoid valve parking brake, replacement

NOTE
3 Detach the electrical connection from the solenoid valve.

4 Remove the nut that attaches the solenoid to the valve.
5 Remove the solenoid from the valve.
6 Unscrew the valve from the accumulator charging valve.
7 Replace the valve. Tighten to a torque of 30 Nm.
8 Fit the solenoid coil. Tighten to a torque of 4.1 Nm.
9 Fit the remaining components in the reverse order.
hydraulic system.
NOTE
the lock ring.
11 Switch on the system voltage and start the engine. Let the engine
run at idle speed.
12 Test the parking brake a couple of times.
016817
4.5.4 Parking brake unit

Parking brake unit, description
The parking brake unit keeps the machine stationary when parked.
The parking brake unit is fitted on the drive axle input shaft between
the propeller shaft and drive axle.
The parking brake acts on the propeller shaft via a disc mounted on the
drive axle input shaft and a brake caliper with dry brake pads mounted
1 in a bracket on the drive axle.
2 NOTE
If the hydraulic pressure in the feed circuit drops, a warning is
3 activated before the pressure drops so low that the parking brake
is applied. If the parking brake is applied while the machine is in
motion, the brake disc and brake pads must be replaced.
016815
1. Parking brake pad

2. Parking brake caliper
3. Brake disc parking brake

4 Brakes – Parking brake unit 4:39
Parking brake unit, checking and adjustment
DANGER
Risk of crushing.
1 Start the engine and run up hydraulic pressure until the

accumulators are fully charged and the accumulator charging
valve switches to cooling.
2 Switch off the engine and turn the start key to position I.
3 Release the parking brake.
The parking brake is applied with springs and is released with
accumulator pressure that is controlled electrically with a solenoid
valve.
4 Check that the parking brake caliper can move on the bracket.
5 Check that the brake disc is free from oil and dirt.
6 Remove the cover from the brake caliper.
Check that there is no oil inside the cover.
016318
Cover brake caliper
7 Loosen the lock nut.

8 Adjust the adjusting screw so that the brakes are applied.
9 Turn back the adjusting screw so that the clearance between pad
and disc is 0.5±0.1 mm.
10 Tighten the lock nut.
NOTE
To avoid turning the adjusting screw as well it must be held still
when tightening the lock nut.
11 Refit the cover to the caliper.

12 Test the function of the parking brake.

4:40 4 Brakes – Parking brake unit
4.5.4.1 Parking brake caliper

Brake caliper, description
The brake caliper has a spring section and a hydraulic section. The
1 2 3 4 5
spring section applies the brake while the hydraulic section is used to
release the brake. This means that the parking brake is applied if the
brake system loses pressure. This, in turn, means that the machine
is braked if a serious fault arises.
000020
1. Brake pads
2. Release cylinder
3. Thrust spring
4. Slackening screw
5. Adjusting washer
4.5.4.2 Parking brake pads

Brake pads, description
The brake pads consist of a metal plate with friction material (lining).
Brake pads, replacement
DANGER
Risk of crushing.
1 Machine in service position and wheels blocked, see section B

Safety.
2 Remove the cover from the brake caliper.

4 Brakes – Pipes and hoses 4:41
3 Loosen the lock nut.

4 Slacken the adjusting screw to release the brake pads.
5 Remove the split pin and undo the nut on one of the attaching bolts
holding the parking brake calliper in place.
6 Pull the attaching bolt out so that the brake pads can be angled
out and removed.
NOTE
The bolt does not need to be removed.
7 Remove the parking brake pads.

8 Clean the brake disc with methylated spirit.
9 Fit new parking brake pads.
10 Press back the attaching bolt.
11 Fit the nut and a new split pin.
12 Adjust the parking brake, see Parking brake unit, checking and
adjustment, page 4:39.
4.5.4.3 Parking brake disc
Brake disc, description

The brake disc is fitted on the drive axle input shaft. The drive axle's
gear ratio amplifies the braking force.


4:42 4 Brakes – Sensor parking brake pressure
4.5.10 Sensor parking brake pressure

Sensor parking brake pressure, description
Sensor parking brake pressure (B7682) detects the pressure to the
parking brake caliper. The sensor is fitted on the accumulator charging
valve on the lifting beam in front of the transmission in the engine
compartment.
Sensor parking brake pressure (B7682) is supplied with voltage by, and
sends proportional voltage signals to Control unit KFU (D7971).
The signal can be checked with the diagnostic menu, see 4.5 Park
Brake Sys 3/XX DIAGNOSE, page 8:37.
016816
Sensor parking brake pressure, checking
NOTE
Safety.
0:00pm
1 Operate and warm up the machine until the oil reaches operating
a temperature, at least 50 °C.
75° C 50%
b c
50° C 50° C
016372


4 Brakes – Sensor parking brake pressure 4:43

parking brake pressure on the accumulator charging valve.
016290
Measuring outlet parking brake pressure
10:23
0
014981

with .

0 0
015625

4 . BRAKES
016946

4:44 4 Brakes – Sensor parking brake pressure
7 Select 4.5 Parking Brake by scrolling with or and confirm

* 4 . BRAKES *
with .
4.2 ABS
4.5 Parking Brak e
017453
* 4 . BRAKES *
4.2 ABS
4.5 Parking Brak e
017452
9 Select 4.5 Park Brake Sys 3 by scrolling with or .

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

NOTE

4 Brakes – Sensor parking brake pressure 4:45

hydraulic system.
NOTE
the lock ring.
016816

4:46 4 Brakes – Temperature control, cleaning and oil brake system
4.8 Temperature control, cleaning

and oil brake system
Temperature control, cleaning and oil brake
system, description
The brake system is cooled by oil that is circulated through a cooler.
The cooler has a temperature-controlled electric fan that prevents
overheating.
The temperature control consists of oil tank brake system, oil pump
brake system, oil filter brake system, accumulator charging valve,
wheel brake units, cooler, cooling fan, sensor oil temperature brake
system and thermal bypass valve.
Oil pump brake system pumps oil (from the tank) that is cleaned in
the oil filter. When the accumulators are charged, the accumulator
charging valve routes oil through the drive axle's brake units and cools
the brakes. The oil passes through the cooler back to the tank. An
electric cooling fan increases the air flow through the cooler when the
temperature needs to be lowered. A thermal bypass valve routes the
hydraulic oil past the cooler if the oil temperature is low and through
the cooler if the oil temperature is too high. The temperature sensor
controls fan activation and temperature warning in the display.
If the temperature in the brake system becomes too high then the
speed of the machine is limited in order to protect the brakes.
Temperature control, cleaning and oil brake

system, function description
15
D7902 D7950
C
D7971 D7901
10
13
D7930
Pa
ACC
C H
P 3
B
T
2
1
M
016395

1 Oil pump brake system pumps oil from P = 20.5±1.0 MPa Oil pump brake system, description, page
oil tank brake system. 4:12
Oil tank brake system, description, page
4:48
2 Oil filter brake system cleans the oil. - Oil filter brake system, description, page
4:53
3 The accumulator charging valve routes Max. 0.1 MPa Accumulator charging valve, description,
oil to charging of the accumulators or page 4:16
the drive axle block.

4 Brakes – Temperature control, cleaning and oil brake system 4:47

4 The drive axle block distributes the oil to Drive axle block, description, page 4:25
both cooling circuits of the wheel brakes.
The bypass valve in the distribution
block leads oil past the drive axle if the
back pressure through the wheel brake
is too great.
5 The oil cools the wheel brake. - Wheel brakes, description, page 4:25
6 The cooler cools the oil. - Oil cooler, description, page 4:49
7 The thermal bypass valve routes oil past approx. 50 °C Thermal bypass valve, description, page
the cooler if the oil temperature is low. 4:51
8 The temperature sensor (B7720) detects R = 25 kΩ at 20 °C Sensor, oil temperature brake system,
the oil temperature and sends a voltage description, page 4:52
signal proportional to the oil temperature D8: 4.8 Oil Temp/Clean 1/XX DIAGNOSE,
to Control unit KFU (D7971). page 8:38
9 Control unit KFU (D7971) sends oil Checked by control system, 11.5.3.4 KFU control unit (D7971), page
temperature information on the CAN error shown with error code. 11:31
bus.
10 When the oil is hot, Control unit KFU Activated fan: U = 24 V 11.5.3.4 KFU control unit (D7971), page
(D7971) activates voltage feed to Activates at 65 °C. 11:31
Cooling fan (M6740). D10: 4.8 Oil Temp/Clean 2/XX
Deactivates at 55 °C.
DIAGNOSE, page 8:38
11 Cooling fan (M6740) and increases air - Cooling fan, description, page 4:50
flow through the cooler.
12 If the oil temperature increases Checked by control system, 11.5.3.3 Control unit, KID (D7950), page
above 85 °C then Control unit KID error shown with error code. 11:29
(D7950) activates a warning for high oil
temperature in the display.
13 If the oil temperature increases above Checked by control system, 11.5.3.4 KFU control unit (D7971), page
90 °C then Control unit transmission error shown with error code. 11:31
(D7930) limits the speed of the machine
in order to protect the brakes.
Hydraulic diagram brake system, see Hydraulic diagram brake system,

page E:4.

4:48 4 Brakes – Oil tank brake system
4.8.1 Oil tank brake system

Oil tank brake system, description
1 2 3 The oil tank brake system stores oil in the brake system and is fitted on
the left-hand 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 specify the oil in the brake
system so that additives can be avoided.
Filling oil takes place directly to the tank. There is a drain plug 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

changes in the tank, due to temperature variations and use. See
Breather filter, description, page 4:53.
The tank has a sight glass for checking oil level.

016324
1. Sight glass
2. Filling oil, brake system
3. Breather filter, brake oil tank
4.8.2 Tank heater

Tank heater, description
Oil tank brake system can be equipped with a tank heater. The tank
heater, which is fitted in a flange on the front short side of the tank,
heats the oil in the oil tank. The tank heater is designed for use in
cold climates.
The tank heater is powered by high voltage. Heater output is adapted

through different connections and adaptation to different operating
voltages - 110, 230 or 400 V AC. Higher voltage generates higher
heater output. The heater is mounted in a hole in the connection cover
at the bottom of the tank's short side.
016818
The tank heater has an adjustable thermostat that keeps the

temperature at a constant level. The thermostat is fitted on the heating
element and is adjusted with a knob on the junction box.
The recommended temperature setting is 20-30 °C.
CAUTION
The tank heater is connected to high voltage (110 - 400
V).
High voltage.
Installation and reconnection of the tank heater may
with high voltage.

4 Brakes – Oil pump brake system 4:49

Oil pump brake system, general
See Oil pump brake system, description, page 4:12.
4.8.4 Accumulator charging valve

Accumulator charging valve, general
See Accumulator charging valve, description, page 4:16.
4.8.5 Drive axle block

Drive axle block, description
See Drive axle block, description, page 4:25.
4.8.6 Wheel brakes

Wheel brake, general
See Wheel brakes, description, page 4:25 and supplier documentation,
drive axle.
4.8.7 Oil cooler

The oil cooler cools the oil in the brake system in order to maintain
brake performance. The oil cooler is fitted inside the side panel on the
left-hand side behind the front wing.
The brake system uses a flow-through cooler with electric cooling fan.
The brake system's oil is cooled as it passes the cooler. Openings in
the side cover allow air to pass through the cooler.
The cooling fan is screwed onto the cooler. See Cooling fan,
description, page 4:50.
016830

4:50 4 Brakes – Cooling fan
Oil cooler brake system, replacement
NOTE
Safety.

2 Drain the oil from the oil tank, see Maintenance manual.
3 Mark up and detach the hydraulic hoses from the cooler. Let the
oil in the cooler drain into the receptacle.
NOTE
from impurities.
4 Disconnect the cable harness from the cooling fan.

5 Remove the attaching bolts and lift away the cooler.
6 Transfer the cooling fan to the new cooler.
7 Fit the cooler.
8 Connect the cable harness to the cooling fan.
9 Connect the hydraulic hoses to the cooler.
NOTE
1. Cooling fan
2. Connector correctly.
3. Radiator
10 Fill oil in the oil tank, see Maintenance manual.
4.8.8 Cooling fan

Cooling fan, description
The cooling fan (M6740) is a suctioning electric fan. The fan draws air
from the outside of the machine through the cooler and increases the
airflow through the oil cooler as required. The cooling fan is mounted
on the inside of the cooler inside the side panel behind the left-hand
drive wheel.
The cooling fan (M6740) is supplied with voltage by Control unit KFU
(D7971). The cooling fan is activated when oil temperature is 65
°C in the oil tank brake system and the fan is deactivated when oil
temperature is 55 °C.
The signal can be checked with the diagnostic menu, see 4.8 Oil
Temp/Clean 2/XX DIAGNOSE, page 8:38.
016831

4 Brakes – Thermal bypass valve 4:51
4.8.9 Thermal bypass valve

Thermal bypass valve, description
When the oil is cold, the thermal bypass valve directs the oil past the
cooler directly to the tank. The thermal bypass valve is fitted inside the
oil tank adjacent to the hose connections to and from the cooler.
The thermal bypass valve is a temperature-regulated bimetal valve.

The valve is open at low temperatures and completely closed at 50 °C.
016832
Thermal bypass valve, replacement
NOTE
Safety.

Safety.
4 Remove the thermal bypass valve that is installed in the hydraulic
oil tank.
NOTE
Note how the valve is fitted.

4:52 4 Brakes – Sensor, oil temperature brake system
4.8.10 Sensor, oil temperature brake system

Sensor, oil temperature brake system, description
Sensor, oil temperature brake system (B7720) detects the temperature
of the oil in the brake system. The sensor is fitted on the rear short
side of the oil tank and therefore takes into account the accumulated
heat in the brake system oil.
Sensor, oil temperature brake system (B7720) is supplied with voltage

by, and sends voltage signals proportional to the temperature to Control
unit KFU (D7971).
016833
Sensor, oil temperature brake system, replacement
NOTE
Safety.

3 Disconnect the cable harness from the oil temperature sensor.
4 Replace the oil temperature sensor.
NOTE
correctly.
5 Connect the cable harness to the sensor.

6 Fill oil in the oil tank, see Maintenance manual.
016833

4 Brakes – Breather filter 4:53
4.8.11 Breather filter

Breather filter, description
1 2 3 The breather filter cleans the air that passes through the tank's breather
in the event of volume changes arising due to temperature variations
and use. The breather filter is fitted in a holder on the top of the oil tank.
The breather filter is a paper insert filter. The filter cleans moisture and
dust from the air passing through the tank's breather.
016324
1. Sight glass
2. Filling oil, brake system

Oil filter brake system, description
The oil filter brake system cleans impurities from the oil in the brake
system. The filter is fitted on a bracket in front of the transmission
under the lifting beam.
The brake system's oil filter is a high-pressure filter with removable
filter insert. It is fitted between the pump and accumulator charging
valve. The oil is cleaned when it is forced through the filter insert's
filter material (which is glass fibre) before reaching the accumulator
charging valve.
A bypass valve located between the intake and outlet protects the
insert. If resistance through the filter surface becomes too great, the
bypass valve opens a passage past the insert. The bypass function
opens if the oil is viscous (cold or too low/high viscosity) or if the filter
insert is clogged with dirt.
NOTE
When the filter is clogged, the oil is directed past the filter without
cleaning. It is therefore very important to replace the filter at the
016259
prescribed interval.

4.8.14 Oil, brake system

Oil brake system, general
See section F Technical data.

4:54

5:1
5 Steering
Contents 5 Steering
5 Steering .............................................................................................................. 5:3
5.1.1 Steering wheel ............................................................................................5:4
5.1.2 Mini-wheel ...................................................................................................5:5
5.1.3 Joystick .......................................................................................................5:6
5.2 Power assisted system ....................................................................................5:9
5.2.1 Hydraulic oil pump.....................................................................................5:14
5.2.2 Priority valve..............................................................................................5:14
5.2.3 Steering valve ...........................................................................................5:16
5.2.4 Steering cylinder .......................................................................................5:19
5.2.5 Steering axle cradle ..................................................................................5:21
5.2.6 Link arm ....................................................................................................5:21
5.2.7 Wheel spindle............................................................................................5:21
5.2.8 Wheel hub .................................................................................................5:21
5.2.12 Sensor steering wheel movement .............................................................5:22
5.2.13 Pipes and hoses........................................................................................5:22
5.2.14 Control valve steering ...............................................................................5:23
5.2.21 Arm rest in position sensor .......................................................................5:28
5.2.22 Valve block servo pressure, general .........................................................5:29

5:2

5 Steering – Steering 5:3
5 Steering
Steering, general
The steering function means steering the machine during operation.
The machine is steered with the rear wheels by a power assisted
system.
Joystick control and mini-wheel are available as options, which means

that the machine is steered electrically with a control on the driver's
seat arm rest.

5:4 5 Steering – Controls and instruments

5.1.1 Steering wheel
Steering wheel, description
The steering wheel is used for steering the machine. The steering
wheel is fitted with splines and nut screwed directly onto the steering
valve.
016812
Steering wheel, replacement

2 Remove the steering wheel cover plate.
015788
3 Unscrew the nut counter holding the with an Allen key.

4 Replace the steering wheel.
Tighten the nut to a torque of 25 Nm.
015786

5 Steering – Mini-wheel 5:5
5.1.2 Mini-wheel
Mini-wheel, description
3 An electric control is used to steer machines equipped with a

mini-wheel. A directional control valve pressurises the steering cylinder.
2
The mini-wheel's control is integrated in the left-hand armrest.
1
4 NOTE
The mini-wheel is deactivated if the standard steering wheel is used.
5
Mini-wheel or joystick control can only be activated at speeds
below 3 km/h.
Switch, direction indicators

Switch direction indicators (S1470) activates the direction indicators
when the machine is steered with the mini-wheel. The switch is
supplied with voltage by, and sends voltage signals to Control unit
KCU (D7901).
The signals can be read with the diagnostic menu, see 9.6 Lighting
Sys 6/XX DIAGNOSE, page 8:68.
6 Mini-wheel
The control is connected to two rotary potentiometers (R8250-1 and
R8250-2), each potentiometer provides a signal of 0-5 V during one
revolution. The potentiometers are phase shifted in order to determine
the direction of rotation. The rotary potentiometers are supplied with
voltage by, and send voltage signals to Control unit KCU (D7901),
proportional to the rotation in order to indicate steering deflection.
The signals can be read with the diagnostic menu, see 5.2 Power
The ratio between the mini-wheel's and the wheels' deflection can be
015422
adjusted in 10 different positions, from linear to very progressive. The

steering angle can also be adjusted according to machine speed.
1. Switch direction indicators (S1470) This is performed with the menu system in the machine, see 8.5.5.2
2. Mini-wheel (R8250-1 & R8250-2) Initiation menus, Power assisted system, page 8:104.
3. Switch, mini-wheel activation (S1130) Switch, mini-wheel activation

4. Switch, travel direction selector (S1310-3) Switch activation of mini-wheel (S1130) activates steering with the
5. Switch, light signal (S1992) mini-wheel. The switch is supplied with voltage by, and sends voltage
6. Arm rest signals to Control unit KCU (D7901).
Switch, travel direction selector
Switch, travel direction selector (S1310-3) is used to select the travel
direction (forward or backward) when the mini-wheel is activated. The
switch is supplied with voltage by, and sends voltage signals to Control
unit KCU (D7901).
The signals can be read with the diagnostic menu, see 2.1 Controls &
Instr 2/XX DIAGNOSE, page 8:33.
Switch, light signal
Switch, light signal (S1992) activates either high beam flash, when
the lighting is switched off or switching between high and low beam,
when the service lighting is activated. The switch only works when the
mini-wheel is activated. The switch is supplied with voltage by, and
sends voltage signals to Control unit KCU (D7901).

5:6 5 Steering – Joystick
5.1.3 Joystick
Joystick, description
1 2 3
4 An electric control is used to steer machines equipped with a joystick.

A directional control valve actuates the steering cylinder.
The joystick is integrated in the left-hand armrest.
NOTE
5
below 3 km/h.
Joystick
016849
Joystick (R8250-1) controls steering wheel angle. The sliding

1. Joystick potentiometer is supplied with voltage by, and sends voltage signals
2. Switch direction indicators (S1470) to Control unit KCU (D7901), proportional to the movement in order to
indicate steering deflection.
3. Travel direction selector (F / N / R)
4. Switch, light signal (S1992) The signals can be read with the diagnostic menu, see 5.2 Power
Assisted 2/XX DIAGNOSE, page 8:38, menu 1.
5. Switch, joystick activation (S1130)
The ratio between the joystick's and the wheels' deflection can be
adjusted in 10 different positions, from linear to very progressive. The
steering angle can also be adjusted according to machine speed.
This is performed from the menu system in the machine, see 8.5.5.2
Initiation menus, Power assisted system, page 8:104.
Joystick positions (left, centre, right) can be calibrated with the menu
system in the machine, see Lever steering, calibration, page 5:7.
Switch, direction indicators
Switch direction indicators (S1470) activates the direction indicators
when the machine is steered with the mini-wheel. The switch is
supplied with voltage by, and sends voltage signals to Control unit
KCU (D7901).
Switch, travel direction selector
Switch, travel direction selector (S1310-3) is used to select the travel
direction (forward or backward) when the mini-wheel is activated. The
switch is supplied with voltage by, and sends voltage signals to Control
unit KCU (D7901).
The signals can be read with the diagnostic menu, see 2.1 Controls &
Instr 2/XX DIAGNOSE, page 8:33.
Switch, light signal
Switch, light signal (S1992) activates either high beam flash, when
the lighting is switched off or switching between high and low beam,
when the service lighting is activated. The switch only works when the
mini-wheel is activated. The switch is supplied with voltage by, and
sends voltage signals to Control unit KCU (D7901).

5 Steering – Joystick 5:7
Switch, mini-wheel/joystick activation

Switch activation of mini-wheel (S1130) activates steering with the
mini-wheel. The switch is supplied with voltage by, and sends voltage
signals to Control unit KCU (D7901).
Lever steering, calibration
NOTE
Calibration does not need to be performed in one process but each
step can be performed separately, independently of other steps.
1 Machine in service position.

2 Start key in operating position.
10:23
3 To be able to select the function to calibrate, first navigate to the
0
014981
10:23 4 Enter the code for calibration with or . Confirm each figure
with .
Code is obtained from Cargotec Support.
0 WRI TE PI N CODE
NOTE
0 0 The code determines which service menus should be activated.
015625
5 Select 5. STEERING by scrolling with or and confirm with .

5 . STEERI NG
016949

5:8 5 Steering – Joystick
6 Select 5.2 Power steering by scrolling with or and confirm

* 5 . STEERI NG *
with .
016950
7 Select CALIBRATE by scrolling with or and confirm with .
* 5 . STEERI NG *
016986
8 Navigate to the calibration menu 5.2 POWER ASSISTED, menu 1

with / . See Navigation to a menu, work instruction, page 8:98
for an explanation of navigation.
Row 1 shows the joystick position.
Row 2 shows the saved value for the joystick position.
9 Move the joystick to the desired centre position to set the centre
position for joystick control. Press Save to store this value.
The value on row 1, Comfort steering lever middle position,
is saved on row 2.
10 Navigate to the calibration menu 5.2 POWER ASSISTED, menu

2 with / .
11 Move the joystick to the desired position for max. deflection left to
set max deflection left for joystick control.
Press Save to store this position.
The value on row 1, Comfort steering lever left position, is
saved on row 2.
12 Navigate to the calibration menu 5.2 POWER ASSISTED, menu

3 with / .
13 Move the joystick to the desired position for max. deflection right
to set max deflection right for joystick control.
Press Save to store this position.
The value on row 1, Comfort steering lever right position, is
saved on row 2.

5 Steering – Power assisted system 5:9
5.2 Power assisted system

Power assisted system, description
The function of the power assisted system is to steer the machine.
Machine steering is servo assisted with pressure from hydraulic oil
pump 2.
The steering consists of steering wheel, steering axle, steering valve,

hydraulic oil pump, control valve steering, priority valve, steering
cylinder, link arms and wheel spindles.
The steering wheel acts on the steering valve (via the steering column)
which, via pilot pressure to Control valve steering, controls the oil
pressure from the hydraulic oil pump to the steering cylinder. The
priority valve is fitted on Control valve steering, and it prioritises the oil
supply to the steering valve above other functions, e.g. load handling.
The steering cylinder acts on the wheel spindles. The link arms are
located between steering cylinder and wheel spindles.
Power assisted system, function description
2 6
P
Ps P 5
EF
Ts T
3 LS L
LSP1 A H T
CL CR R
LSP2 LSPR
C LSP3 LSHY
LSP3X P T T P LSO
LSM
1
No.1 7
016399

1 Hydraulic oil pump 1 pumps oil to the See the pressure plate on Axial piston pump with variable
priority valve. the left-hand frame beam. displacement, description, page 10:10
2 The priority valve prioritises pressure Checked by control Priority valve, description, page 5:14
feed to the steering valve over the system, error shown with
working hydraulics. The priority valve error code.
also sends a control signal Valve block,
servo pressure.
3 Valve block servo pressure selects the Checked by control Valve block servo pressure, description,
strongest load signal with built-in shuttle system, error shown with page 10:25
valves if other hydraulic functions are error code.
activated while the steering wheel is
turned. The strongest signal is sent as a
control signal to hydraulic oil pump 1.
4 Hydraulic oil pump 1 increases the - Axial piston pump with variable
capacity displacement, description, page 10:10
5 The steering wheel is turned and acts on - Steering wheel, description, page 5:4
the steering valve\qs input shaft.

5:10 5 Steering – Power assisted system

6 The steering valve sends control signals - Steering valve, description, page 5:16
to control valve, steering.
7 Control valve steering routes pressurised - Control valve steering, description, page
oil to the steering cylinder and sends 5:23
load signals to hydraulic oil pump 1.
8 The steering cylinder turns the wheels. - Steering cylinder, description, page 5:19
Hydraulic diagram, basic machine, see Hydraulic diagram, basic

machine, page E:6.

Joystick control/mini-wheel, description
Mini-wheel or joystick control is a steering option that makes it possible

to steer the machine with an electric control on the left-hand arm rest
of the driver's seat. The electric control sends signals to the control
system. The steering cylinder is pressurised by a control valve, which
is also controlled by the control system.
Joystick control and mini-wheel work the same way, but with different
design of the steering control.
The ratio between the control's and the wheels' deflection can be
adjusted in different steps, from linear to very progressive. The steering
angle can also be adjusted according to machine speed. This is
performed with the initiation menus, see 8.5.5 Steering, page 8:104.
NOTE
below 3 km/h.
Joystick control/mini-wheel, function description

Joystick Voltage signal from the connection of mini-wheel/joystick Mini-wheel, description, page 5:5 or Joystick,
control/mini- control switch (S1130). description, page 5:6
wheel activated
Left-hand arm Voltage signal from the arm rest in position sensor Arm rest in position sensor, description,
rest lowered (D7250). page 5:28
Steering wheel The signals from Sensor steering wheel angle (B7700-1 Sensor, steering wheel movement,
stationary and B7700-2) must not detect movement (pulse train description, page 5:22
over a certain frequency).
Speed Below 3 km/h (at engagement) -
Control breaker Disengaged Control breaker voltage, function description,

page 11:19
Sensor, Not activated Sensor operator in seat, description, page
operator-in-seat 9:23

5:12 5 Steering – Power assisted system
D3
D5 5 3
2, 4, 6
D7950 D7901 D1
D7971 D7902 16
7, 18
1
17
17
8 D17
D5 10, 12 9, 14
P
Ps P 19
EF
Ts T
11 LS L
LSP1 A H T CL CR R
LSP2 LSPR
C LSP3 LSHY
LSP3X P T T P LSO
LSM
12
No.1 15
016801
1 Arm rest in position sensor (B7250) U = 24 V Arm rest in position sensor, description,
sends a voltage signal to the KCU page 5:28.
control unit (D7901). D1: Diagnostic menu, see:
• Joystick control: 5.2 Power Assisted
• Mini-wheel: 5.2 Power Assisted 3/XX
DIAGNOSE, page 8:39
2 Control unit KCU (D7901) permits Checked by the control 11.5.3.1 KCU control unit (D7901), page
engagement of mini-wheel or joystick system, error indicated 11:25
control. with error code.
3 Switch, engagement of U = 24 V Mini-wheel, description, page 5:5
mini-wheel/joystick control (S1130) Joystick, description, page 5:6
sends voltage signals to Control unit
KCU (D7901). D1: Diagnostic menu, see:
• Joystick control: 5.2 Power Assisted
• Mini-wheel: 5.2 Power Assisted 3/XX
DIAGNOSE, page 8:39
4 Control unit KCU (D7901) sends electric Checked by the control 11.5.3.1 KCU control unit (D7901), page
steering active on the CAN bus. system, error indicated 11:25
with error code.
5 Joystick control US8520-1 = 0.5 - 4.5 V Joystick, description, page 5:6
The potentiometer in the switch joystick D3: Diagnostic menu, see 5.2 Power
(R8250-1) sends a voltage signal to Assisted 2/XX DIAGNOSE, page 8:38
KCU control unit (D7901).
Mini-wheel US8520-1 = 0.5 - 4.5 V Mini-wheel, description, page 5:5
The 2-channel potentiometer in the US8520-2 = 0.5 - 4.5 V (only D3: Diagnostic menu, see 5.2 Power
mini-wheel switch (R8250-1 and mini-wheel) Assisted 3/XX DIAGNOSE, page 8:39
R8250-2) sends a voltage signal to
the KCU control unit (D7901), which
calculates the rotation speed of the
joystick.


6 Control unit KCU (D7901) sends steering Checked by the control 11.5.3.1 KCU control unit (D7901), page
angle on the CAN bus. system, error indicated 11:25
with error code.
7 Control unit KFU (D7971) supplies U = 0 V to battery voltage. 11.5.3.4 KFU control unit (D7971), page
voltage to Electric steering module Steering takes place 11:31
(Y6150). as set out below as a D5: Diagnostic menu, see 5.2 Power
When the voltage is 50% of the battery percentage of the battery Assisted 5/XX DIAGNOSE, page 8:39
voltage the valve is in the neutral voltage:
position. Lower voltage gives steering to 0-15% = error indication
the left and higher voltage gives steering
to the right. 25% = full steering right
approx. 45% = start
steering right
50% = neutral position
approx. 56% = start
steering left
76% = full steering left
85-100% = error indication
In the event of signal
error or internal fault in
the valve a signal is sent
from the steering valve
to Control unit, steering
(D7971) (24V).
8 Electric steering module (Y6150) - Control valve steering, description, page
pressurises the steering slide in Control 5:23
valve, steering.
9 Control valve steering sends a load Control valve steering, description, page
signal to the priority valve, which is 5:23
integrated with Control valve steering
and Valve block servo pressure.
10 Valve block servo pressure selects the - Valve block servo pressure, description,
strongest load signal with built-in shuttle page 10:25
valves and forwards it to Hydraulic
oil pump 1 if hydraulic functions are
activated while turning the steering
wheel.
11 Hydraulic oil pump 1 pumps oil from the See the pressure plate on Axial piston pump with variable
hydraulic oil tank. the left-hand frame beam. displacement, description, page 10:10
12 The priority valve prioritises pressure See the pressure plate on Priority valve, description, page 5:14
feed to Control valve steering over the the left-hand frame beam.
working hydraulics.
13 The steering slide in Control valve - Control valve steering, description, page
steering changes position and 5:23
pressurises the steering cylinder.
14 The steering cylinder turns the wheels. - Steering cylinder, description, page 5:19
15 The steering wheel is turned and acts on - Steering wheel, description, page 5:4
the steering valve\qs input shaft.
16 Steering wheel movement sensors U = 24 V Sensor, steering wheel movement,
(B7700-1 and B7700-2) send a voltage description, page 5:22
signal to the KPU control unit (D7902). D17: Diagnostic menu, see 11.5 Distr of
17 The KPU control unit (D7902) sends Checked by the control 11.5.3.2 KPU control unit (D7902), page
interrupt steering on the CAN bus. system, error indicated 11:27
with error code.

5:14 5 Steering – Hydraulic oil pump

18 Control unit KFU (D7971) sets Electric U = 12 V (50% of battery 11.5.3.4 KFU control unit (D7971), page
steering module (Y6150) in neutral voltage) 11:31
position. D5: Diagnostic menu, see 5.2 Power
Assisted 5/XX DIAGNOSE, page 8:39
19 The steering valve pressurises Control - Power assisted system, function description,
valve steering in the same way as for page 5:9
normal steering.

machine, page E:6.
5.2.1 Hydraulic oil pump

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

Priority valve, description
The priority valve divides the oil flow from hydraulic oil pump 1 so that
1
there is always oil to the steering valve. Residual flow goes to the
2 working hydraulics.
3 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.
5 The priority valve has a built-in pressure limiter on the load signal. The
4 pressure limiter maximises the load signal's pressure.
016804
1. Priority valve
2. Measuring outlet control pressure (PM)
3. Pressure feed from hydraulic oil pump 1 (P)
4. Pressure feed to control valve lift, lower and
extension (EF)
5. Control valve steering
Steering pressure, checking
NOTE
Safety.

5 Steering – Priority valve 5:15
0:00pm
a operating temperature, 50 °C.
The oil temperature can be checked with Operating menu,
transmission and hydraulics.
75° C 50%
b c
50° C 50° C
016372
Operating menu, transmission and hydraulics
a. Transmission oil temperature
b. Hydraulic oil temperature
3 Connect a pressure gauge (0 – 25 MPa) to the measuring outlet

for control pressure.
4 Start the engine and increase engine speed to approx. 1200 rpm.
016805
Measuring outlet control pressure
5 Turn the steering wheel fully and read pump pressure during the
steering wheel movement. Compare this to the steering pressure
on the hydraulics plate. The max. pressure must be 1.5 MPa
higher than the control pressure on the hydraulics plate.
7 Turn the start key to position 0 and switch off the system voltage.
measuring outlet.
016810

5:16 5 Steering – Steering valve
Priority valve, replacement
NOTE
Safety.
1 Remove Control valve steering and replace the priority valve, see
Control valve steering, replacement, page 5:24.
2 Start the engine and check that the hydraulic connections at the
priority valve are sealed.
3 Check the oil level in the hydraulic oil tank, see Maintenance
manual.
4 Check the steering pressure, see Steering pressure, checking,
page 5:14.
5.2.3 Steering valve

Steering valve, description
The control system consists of a pilot control valve that gives a signal
with low pressure and low flow (load signal) to the control valve
steering. Control valve steering acts as a pilot-controlled directional
control valve which can be supplemented by an electronic control unit
(option for joystick control/mini-wheel).
1
Control valve steering also has a built-in priority valve that gives priority
2 to oil to the steering function. For control valve steering, see Control
valve steering, description, page 5:23.
3
5
4
016802
1. Steering valve
2. Load signal steering left (L)
3. Tank return (T)
4. Pressure feed (P)
5. Load signal steering right (R)

5 Steering – Steering valve 5:17
Steering valve, replacement
NOTE
Safety.

NOTE
3 Remove the covers, see Travel direction selector and parking

brake, replacement, page 2:9, steps 2-5.
4 Remove the steering wheel, see Steering wheel, replacement,
page 5:4.
1
015789
1. Covers
5 Remove the screws and cover.

1
2
015791
1. Screw
2. Cover

5:18 5 Steering – Steering valve
1 2 6 Place a receptacle under the steering valve.

Mark up and detach the hydraulic hoses from the steering valve.
NOTE
from impurities.
015792
1. Hydraulic connections
2. Steering valve
7 Remove the steering valve's attaching bolts and remove the

steering valve.
8 Transfer the connections to the new steering valve.
NOTE
correctly.
NOTE
Transfer one connection at a time so that the marking is not
mixed up.
015790
9 Fit the new steering valve, tighten the attaching bolts crosswise
with increasing torque to 10±3 Nm.
Steering valve attaching bolts
CAUTION
Incorrectly assembled steering valve can impair the
function.
Uneven resistance in the steering wheel when driving.
Tighten the steering valve crosswise with increasing
torque in order to avoid tension in the valve.
10 Connect the hydraulic hoses in accordance with the marking.
NOTE
correctly.
11 Fit the covers and steering wheel.

hydraulic system.
NOTE
the lock ring.

5 Steering – Steering cylinder 5:19

14 Check the function.
15 If necessary, adjust the sensitivity of the steering wheel on the
throttle valve at the interface in the rear of the cab.
a) Fully close the throttle valve (turn clockwise).
b) Open the throttle valve one turn (turn anticlockwise).
c) Test the steering and check that it runs smoothly, both when
moving and when the machine is stationary.
d) Try opening the valve in steps of a half turn at a time to the position
where the throttle valve is fully open and the steering function is
correct.
e) The throttle valve may need to be adjusted after a period of
operation when the steering valve has been retracted. If the
steering starts to feel sluggish or jerky, perform a new adjustment.
manual.
017479
Throttle valve at the interface in the rear of the cab
5.2.4 Steering cylinder

Steering cylinder, description
1 2 3 4 5 The steering cylinder acts on the wheels via the link arms. The steering
cylinder is a double-acting hydraulic cylinder.
016311
9 8 7 6
1. Wheel hub
2. Steering axle cradle
3. Front suspension
4. Steering cylinder
5. Rear suspension
6. Counterweight
7. Link arm
8. Wheel spindle
9. Wheel bolt

5:20 5 Steering – Steering cylinder
Steering cylinder, replacement
NOTE
Safety.
1 Park the machine with the wheels fully turned so that the steering
cylinder can be lifted out to one side.
NOTE
4 Detach the link arms from the steering cylinder.

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

2. Hydraulic connection
6 Remove the steering cylinder's attaching bolts.

7 Replace the steering cylinder. Lift the steering cylinder aside.
NOTE
The steering cylinder is heavy, use lifting equipment.
8 Support the new steering cylinder so that the holes in the attaching
bolts are lined up directly opposite the holes in the steering axle.
9 Fit and lubricate the steering cylinder attaching bolts. Tighten the
bolts crosswise in steps until 680 Nm is achieved.
10 Transfer parts to the new steering cylinder.
Attaching bolts steering cylinder. NOTE

correctly.
11 Fit the link arms to the steering cylinder.

12 Connect the hydraulic hoses to the steering cylinder.
NOTE
correctly.

5 Steering – Steering axle cradle 5:21
hydraulic system.
NOTE
the lock ring.

manual.
Hydraulic cylinders, repairs

See Hydraulic cylinders, repairs, page 10:38.
5.2.5 Steering axle cradle

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

Link arm, description
1 2 3 4 5 The link arm transfers the lateral movement of the steering cylinder to
turning the wheel spindles.
The setting of the steering wheels cannot be adjusted. If the link arms
are deformed in a way that changes the setting of the steering wheels
then they must be replaced.
The link arms must be turned to the right direction, otherwise they can
be damaged by the rims with large wheel angles.
016311
9 8 7 6
1. Wheel hub
3. Front suspension
5. Rear suspension
6. Counterweight
7. Link arm
8. Wheel spindle
9. Wheel bolt
5.2.7 Wheel spindle

Wheel spindle, general
See Wheel hub, description, page 6:12.
5.2.8 Wheel hub

Wheel hub, general
See Wheel spindle, description, page 6:8.

5:22 5 Steering – Sensor steering wheel movement
5.2.12 Sensor steering wheel movement

Sensor, steering wheel movement, description
The steering wheel movement sensors (B7700-1 and B7700-2) detect

whether the steering wheel has been turned and sends a signal to
KPU control unit (D7902). This is used to disengage joystick control
or mini-wheel. The sensor is located by the steering axle inside the
panels.
The sensor is activated by a disc on the steering axle with several

cams. The location of the sensor and the spacing between the cams
means that small movements on the steering wheel can be detected.
Status for supply voltage can be read with the diagnosis menu, see
11.5 Distr of Electr 21/XX DIAGNOSE, page 8:86.
016803
Position sensor, checking and adjustment

See section 7 Load handling.
Sensor steering wheel movement, replacement

2 Remove the steering wheel and steering column cover, see
Steering wheel, replacement, page 5:4 and Interior plastic
components, replacement, page 9:104.
3 Remove the screws which secure the sensor.
1
4 Unplug the connector from the sensor.
2 5 Replace the sensor.
NOTE
Do not tighten the screws that hold the sensor too tightly. The
sensor could then break.
NOTE
The distance between the sensor and metal plate must not be
more than 1.5 mm.
3
016130
1. Sensor steering wheel movement

2. Screw, Steering wheel movement sensor
3. Connector, Steering wheel movement sensor


5 Steering – Control valve steering 5:23
5.2.14 Control valve steering

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

the steering valve. This means that both the size and direction of flow
1 from the valve can be adjusted and the valve also sends control signals
to hydraulic oil pump 1. The load signals control a spring-centred valve
slide that controls the pressure and flow for the current direction to
the steering cylinder.
Valve slide, steering
10 The valve slide controls the direction and steering angle by controlling
the hydraulic pressure to the steering cylinder.
The valve slide is controlled by servo signals from either the steering
9 valve or Servo valve steering (machines with joystick control or
2 mini-wheel).
8
3
4
5 7
6
016807
1. Priority valve
3. Load signal to Valve block servo pressure (LS)
4. Pressure feed to steering valve (PS)
5. Tank return (T)
6. Tank return from steering valve (TS)
7. Load signal steering left (L)
8. Connection steering cylinder (CL)
9. Connection steering cylinder (CR)
10. Load signal steering right (R)

5:24 5 Steering – Control valve steering
Electric steering module
Electric steering module
1 On machines with joystick control or mini-wheel, Electric steering

module (Y6150) is fitted on Control valve, steering. The steering
module is an electrically-operated pressure reducing valve that
converts electric current into servo pressure. The servo pressure then
controls the spring-centred valve slide, which controls the pressure and
flow for the current direction. The steering module controls the control
valve for steering via signals from the Control unit KFU (D7971).
Servo valve steering
The steering servo valve controls the servo pressure to valve slide
steering, so that it controls the oil pressure for steering right or left.
The steering servo valve is controlled electrically with Solenoid valve

steering (Y6150) which is activated by Control unit KFU (D7971).
016809
1. Electric steering module (Y6150)
Control valve steering, replacement
NOTE
Safety.

2 Turn the start key to position 0 and switch off the system voltage.
NOTE
4 Mark up the hydraulic hoses and detach the hoses from the priority
valve.
NOTE
2 from impurities.
1
3
2
2
014299

5 Mark and disconnect the hydraulic hoses from the control valve.
NOTE
from impurities.
6 Only machine with joystick control or mini-wheel

Mark and disconnect the cable harness from the control valve.
014302
7 Undo the screws and remove the control valve's mounting plate
from the body.
8 Move the control valve to a clean protected area.
017409
9 Remove the priority valve's attaching bolts (1) and release the
priority valve from Control valve, steering.
1
10 Remove the priority valve.
014300

5:26 5 Steering – Control valve steering
11 Undo the screws and remove the control valve from the mounting
plate. Place the valve on a clean and protected surface.
12 Fit the new control valve on the attaching plate.
13 Transfer parts to the new control valve.
NOTE
correctly.
NOTE
014304
mixed up.
14 Mark up the servo valves on the new control valve.

15 Fit the priority valve to Control valve, steering.
NOTE
correctly.
16 Fit the valve in the machine.

17 Connect the cable harness to the control valve according to the
marking.
18 Connect the hydraulic hoses to the control valve in according to
the marking.
NOTE
correctly.
014302
19 Connect the hydraulic hoses to the priority valve.
NOTE
correctly.
hydraulic system.
NOTE
017408
the lock ring.

CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the steering carefully and operate at the lowest
possible speed a couple of times to avoid cavitation.
manual.
Electric steering module, replacement
NOTE
Safety.

NOTE
3 Mark and release the cable harness from Electric steering module
(Y6150).
1
014305

5:28 5 Steering – Arm rest in position sensor
4 Loosen the screws and remove Electric steering module (Y6150)

from the control valve.
5 Fit a new Electric steering module (Y6150).
6 Connect the cable harness to Electric steering module (Y6150) in
hydraulic system.
NOTE
the lock ring.

014306 9 Check the function, try to steer with the steering wheel and with
the mini-wheel or joystick.
CAUTION
product damage.
10 Test drive the machine and check that the steering is working and
that steering with the steering wheel disengages steering with
mini-wheel or joystick.
manual.
5.2.21 Arm rest in position sensor

Arm rest in position sensor, description
Arm rest in position sensor (B7250) is located in the arm rest mounting
in the driver's seat and detects the angle of the arm rest. If the arm
rest is angled upward, the mini-wheel function is deactivated at a
specific angle and must be activated again using the connection of
mini steering wheel switch.
016136

5 Steering – Valve block servo pressure, general 5:29
Arm rest in position sensor, replacement

2 Unscrew the steering wheel on the arm rest joint.
3 Cut off the cable ties and split the connector.
016133
1 2 3
1. Steering wheel, arm rest joint
2. Cable ties
3. Connector
4 Remove the screws and cover plate.

016134
1 2
1. Cover plate
2. Screw
5 Remove the screw which secures the sensor.

6 Replace the arm rest in position sensor.
016135
1 2
1. Arm rest in position sensor
2. Screw
5.2.22 Valve block servo pressure, general

Valve block servo pressure, general
See Valve block servo pressure, description, page 10:25.

5:30

6:1
6 Suspension
Contents 6 Suspension
6 Suspension ........................................................................................................ 6:3
6.2 Suspension ......................................................................................................6:4
6.2.1 Steering axle cradle ....................................................................................6:6
6.2.2 Wheel spindle..............................................................................................6:8
6.2.3 Wheel hub .................................................................................................6:12
6.3 Tyres and rims ...............................................................................................6:17
6.3.1 Tyres .........................................................................................................6:19
6.3.2 Rim ............................................................................................................6:20
6.3.3 Nut, washer and clamp .............................................................................6:21

6:2

6 Suspension – Suspension 6:3
6 Suspension
Suspension, description
The machine's suspension consists of its tyres (with associated wheel
rim and screw), steering axle with hubs, wheel spindles and the
steering axle's suspension in the frame. The drive axle belongs to the
driveline/axle, see section 3 Driveline/Axle, group 3.3 Drive axle.

6:4 6 Suspension – Suspension
6.2 Suspension
Suspension, description
1 2 3 4 5 The steering axle cradle is attached into the frame with two bushings,
one in the front edge and one in the rear edge of the steering axle
cradle. Two wheel spindles are fitted in the steering axle cradle on
bearing-mounted axles. The wheel spindle is pivoted in order to
facilitate steering. Bearing-mounted wheel hubs are fitted on the wheel
spindles where the wheels are mounted.
Suspension refers to:

• Steering axle cradle
• Wheel spindle
016311 • Wheel hub
9 8 7 6
1. Wheel hub
2. Steering axle
3. Front suspension
5. Rear suspension
6. Counterweight
7. Link arm
8. Wheel spindle
9. Wheel stud
Bushing steering axle mounting, changing
DANGER
Steering axle and machine are very heavy.
Risk of crushing!
Technical data.

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

5 Attach hoisting equipment to the rear of the machine and take up
the slack so that the steering axle's mounts are relieved.
NOTE
Do not lift so much that the wheels are off the ground.

6 Suspension – Suspension 6:5
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 necessary, disconnect the cable harness for the sensors on
the steering axle.
The illustration shows rear mounting.
10 Remove the washers that hold the bushing in place.

11 Press out the bushing.
12 Clean the bearing surfaces on the steering axle.
The illustration shows front attachment.
13 Assemble the parts of the bushing and press in the new bushing.
Lubricate the bushing with grease in order to simplify installation.
CAUTION
The bearing halves must be mounted horizontally.
14 Fit the washers that hold the bushing in place.

Use locking fluid and tighten the bolts to a torque of 65 Nm.
15 Move the steering axle into place under the frame.
Bushing steering axle parts
1. Inner race
2. Bearing halves

6:6 6 Suspension – Steering axle cradle
16 Turn the eccentric bushings in the frame so that the axle holes in
1
the steering axle and the frame are aligned directly on front of
1 each other.
2 17 Lubricate and install the front and rear axles at the mounting for
the steering axle.
18 Remove the lifting equipment from the machine.
19 Fit the counterweights.
NOTE
Make sure that all counterweights are refitted and that they are
016960
fitted in the exact same location as before. The stability of the
Steering axle mounting machine is affected if the counterweights are changed.
1. Eccentric bushing
2. Shaft
6.2.1 Steering axle cradle

Steering axle cradle, description
1 2 3 4 5 The steering axle cradle provides the frame in the mounting of the
steering wheels. The steering axle cradle is pendulum-mounted in
the body at two points with maintenance-free elements. The wheel
spindles, steering cylinder and a counterweight are attached in the
steering axle cradle. The design comprises a minimum of moving parts
to minimise service points and simplify maintenance.
016311
9 8 7 6
1. Wheel hub
3. Front suspension
5. Rear suspension
6. Counterweight
7. Link arm
8. Wheel spindle
9. Wheel bolt
Steering axle cradle, replacement
DANGER
Steering axle and machine are very heavy.
Risk of crushing!
Technical data.
1 Clean the steering axle and the surrounding area.


6 Suspension – Steering axle cradle 6:7

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

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

1
12 Lift the machine up so that the frame is lifted away from the axle.
1
13 Lift out the steering axle.
2
CAUTION
The steering axle may start to roll.
Crushing injury!
016960
Make sure that the steering axle does not roll away
Steering axle mounting uncontrollably.
1. Eccentric bushing
14 Adjust the support so that the machine is secured in the new
2. Shaft
position.
15 Lift the steering axle into place under the frame.
16 Remove the support under the frame.
17 Lower the rear of the machine.
18 Turn the eccentric bushings in the frame so that the axle holes in
1
the steering axle and the frame are aligned directly on front of
1 each other.
2 19 Fit the pins at the steering axle mountings.
20 Connect the hydraulic hoses to the steering cylinder.
NOTE
correctly.
016960
21 Remove the lifting equipment from the machine.

22 Fit the counterweights.
Steering axle mounting
1. Eccentric bushing NOTE
2. Shaft
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.
23 Fit the steering wheel and retighten in accordance with the

instructions, see Maintenance Manual.

6:8 6 Suspension – Wheel spindle
6.2.2 Wheel spindle

Wheel spindle, description
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
016827
1. Wheel spindle
2. Spindle bolt
3. Seal
4. Slide bearing washer
5. Cover
6. Spindle bolt bearing
7. Thrust bearing
8. Lock screw
Spindle bolt bearing, replacement

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

6 Suspension – Wheel spindle 6:9
2 4 Detach the link arm from the wheel spindle.

Remove the lock screw and then remove the axle. Move the link
arm aside.
5 Position a lifting strap inside the hub to secure the spindle.
1
6 Remove the covers at the spindle bolt's upper and lower bearing.
7 Remove the grease between the cover and spindle bolt.
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.
10 Remove the spindle bolt.

Pull the spindle bolt up, using a sliding hammer or similar
connected to the threaded hole in the centre of the spindle bolt.
11 Remove the wheel spindle.
Place the wheel spindle on a soft surface.
1 12 Remove the thrust bearings from the steering axle.

13 Press out the old bearing bushings. Note how the old bearing
bushings are fitted so that the new ones can be positioned the
same way with the space between in the same place.
14 Clean the surfaces inside the steering axle.
15 Press in the new bearing bushings. Make sure that the space is
in the same location as before.
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
1. Wear washer, thrust bearings

6:10 6 Suspension – Wheel spindle
16 Fit new thrust washers on the steering axle. Only fit three bolts in
the manner illustrated. The fourth bolt cannot be fitted until the
wheel spindle is in place. Only tighten the bolts slightly (5-10 Nm)
so that the thrust bearings are secured in position.
Thoroughly coat the bearing bushings with lubricating grease. For
grade, see section F Technical data.
NOTE
Make sure the nuts are positioned as illustrated.
17 Fit new O-rings on the wheel spindle.

Pull the O-ring toward the hub.
011152
18 Lift the wheel spindle into place on the steering axle.
19 Apply lubricating grease onto the wear surface of the lower wear
washer, and align the bearing between the wheel spindle and the
lower thrust washer. Use a rubber mallet to get the bearing into
the right position. Check that the bearing is centred in the wheel
spindle by looking in the spindle from below.
20 Apply lubricating grease onto the wear surface of the upper wear
washer, and align the bearing between the wheel spindle and the
upper thrust washer. Use a rubber mallet to get the bearing into
the right position. Check that the bearing is centred in the wheel
spindle by looking in the spindle from above.
011163
21 Fit the spindle bolt.

Apply lubricating grease onto the spindle bolt and press it into
place.
NOTE
Check that the spindle bolt is turned so that the holes for the guide
screws align with the holes in the wheel spindle. It is important
that the spindle bolt is perfectly seated before the lock screws are
fitted. It is not possible to "tighten" the spindle bolt into place.
22 Fit the lock screws and tighten the lock nut. Tighten to a torque of
250 Nm (oiled screw).
23 Apply lubricating grease in the space between the wheel spindle
and steering axle.

6 Suspension – Wheel spindle 6:11
24 Position the O-rings.
1 25 Fit the remaining bolts to the thrust bearings' wear washers. Fit
the bolts in the manner illustrated. Tighten to a torque of 25 Nm
(oiled screw).
004517
1. Wear washer, thrust bearings
2 26 Fit the upper cover and the lower cover.

27 Lubricate the upper and lower bearings of the spindle bolt with
lubricating grease.
28 Turn the wheel spindle back and forth a few times to even out the
1
grease. Check that resistance is uniform.
29 Connect the link arm to the wheel spindle.
Lubricate the link arm bearings with lubricating grease.
31 Remove the support and lower the steering wheel.
004516
3 32 Test-operate the machine and test the steering. Check also that
the machine feels stable when driving straight ahead.
1. Shaft, link arm
2. Cover (upper)
3. Cover (lower)

6:12 6 Suspension – Wheel hub
6.2.3 Wheel hub

Wheel hub, description
1 2 3 4 5 6 The wheel hub holds the wheel in place and allows the wheel to rotate.
016828
1. Hub nut with locking washer

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

1 Raise the machine under the steering axle at the wheel in question.
Support under the steering axle in a safe way.
2 Remove the steering wheel in question.
3 Clean the hub cover and its surrounding area.

4 Remove the hub cover.
5 Wipe away grease from hub cover and hub nut. Handle it as
environmentally hazardous waste.

6 Suspension – Wheel hub 6:13
6 Secure the hub with a lifting strap.
7 Bend up the locking washer's tabs, remove the lock nut and
locking washer.
8 Tension the lifting equipment so that the hub is unloaded.
9 Remove the hub nut.
10 Lift the hub out from the spindle.

Remove the outer bearing's inner race and pull the hub from the
axle.
11 Remove the inner bearing from the wheel spindle.

12 Remove the seal from the hub.

13 Remove the bearings' outer races from the hub.
Use a drift and press out the bearing races.
14 Clean the hub and line the inside with universal grease "EP2".
15 Fit new outer races in the hub.
Use a drift and press in the bearing races. Never tap directly on
the bearings.
NOTE
Fit the outer races with the larger diameter outward.
16 Fit a new seal on the inside with the seal lip turned out.
Press in a new seal in the hub. Use a suitable round plate, the seal
does not tolerate impacts from a hammer.
NOTE
Turn the seal correctly.
17 Fit the inner bearing's inner race and rollers on the wheel spindle.
Pack the bearing with universal grease "EP2".
18 Fill the empty space in the hub with universal grease "EP2".

6 Suspension – Wheel hub 6:15
19 Fit the hub on the wheel spindle.
20 Install the outer bearing, protecting washer, and bearing nut.

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

A. Lubricate the thread and the side of the nut facing the bearing
with oil (SAE 80W/140).
B. Tighten the nut to a torque of 250 Nm (oiled screw).
C. Rotate the hub 10 revolutions.
D. Angle tighten the nut 45°.
E. Rotate the hub 10 revolutions.
F. Angle tighten the nut 45°.
23 Apply grease onto the locking washer and fit it.

24 Fit the lock nut and tighten to at least 250 Nm (oiled screw) or
then on to engage the locking washer in the closest groove. Lock
the bearing nut and lock nut with the locking washer.

25 Fill the bearing casing with grease and fit it.

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

6 Suspension – Tyres and rims 6:17
6.3 Tyres and rims

Tyres and rims, safety
DANGER
Always block the wheels on the side of the axle that
is not going to be worked on before positioning the
jack. Always secure the jack to prevent it from sliding
out of position.
Fully deflate the tyre before removal. Otherwise the
conical ring and locking clips can loosen and shoot
out when the pressure is changed. With double wheel
fitting both tyres must be fully deflated!
The air should always be released via the valve. If this
is not possible - loosen the valve in the wheel rim and
deflate. If this is not possible then break, cut or saw
off the valve stem. If it is not possible to release the
air through the valve connection then the tyre must be
deflated by drilling a hole in the tyre tread. Use a drill
bit with max. Ø 5 mm. Damaged tyres may explode.
Never stand directly in front of the wheel when
deflating or inflating. The conical ring and locking
clips can loosen and shoot out when the pressure is
changed.
Never fit damaged tyres or rims.
It is prohibited to repair rims with welding.
It is prohibited to operate the machine if one of the
tyres is flat.
Wheels, tyres and rims are dimensioned and selected
for each machine type so that maximum wheel loads
and travel speeds are not exceeded. For this reason it
is not permitted to change tyre dimension, tyre make,
tyre type, rim type, or rim make without approval from
Cargotec.

6:18 6 Suspension – Tyres and rims
CAUTION
When removing wheels, the wheel nuts should be left
in place after loosening. If the wheel nuts are removed
immediately, the wheel may release from the hub.
When removing drive wheels, make sure that the
wheels are secured in position when the spacer rings
are removed. If the wheels move they may displace the
spacer rings, with crushing injuries as a result.
When fitting drive wheels, ensure that the clamps
clamp straight on the spacer ring.
Wheel nuts should be check-tightened after 4-5
operating hours.
Always follow the tyre manufacturer's or other
approved instructions when changing tyres.
Never use a steel hammer to fit or remove rim
components. Use a lead, brass or plastic mallet
instead.
Keep the tyre pressures at the prescribed level.
Insufficient tyre pressure impairs stability and reduces
the machine's capacity.
Remove stuck objects such as crushed glass, pieces
of wood, metal filings, etc.
Check if tyre wear is abnormal. This could indicate
a mechanical fault. Rectify faults immediately and
change damaged tyres.
Tyres and rims, description

The tyres are the point of contact between the machine and the ground,
the tyres absorb unevenness and act as suspension.
The drive axle is subjected to major forces during operation, if the

rolling circumference of the drive wheels is different then the stress on
the drive axle increases. It is important that the tyres on the drive axle
are the same model, type and make and have equal wear and the
correct air pressure.

6 Suspension – Tyres 6:19
6.3.1 Tyres
Tyres, description
The tyres are the point of contact between the machine and the ground,
and they absorb unevenness and provide suspension.
The drive axle is subject to major forces during operation. If each tyre's
rolling circumference differs, the stresses on the drive axle increase.
For this reason it is important that the tyres on the drive axle have
equal wear and correct air pressure.
Spare and replacement tyres must be from a manufacturer approved

by Cargotec.
002027
Front wheels
002026
Rear wheels
Tyres, changing
DANGER
Changing tyres involves large risks.
Danger to life!
Tyre replacement should be performed by service
dept. with tyre handling expertise!
The rims must be checked when tyres are changed, see Maintenance
manual section 6 Suspension.

6:20 6 Suspension – Rim
6.3.2 Rim
Rim, description
1 2 3 4 5 6 The rim is split to make it possible to fit a tyre. The rim consists of
the following parts.
• Rim
• Rim bead seat
• Rim edge
• Lock ring
• Lock lugs
• Hub plate
7
016829
1. Lock ring
2. Rim edge
3. Tapered rim
4. O-ring
5. Rim
6. Rim edge
7. Wheel nut
8. Wheel clamp

6 Suspension – Nut, washer and clamp 6:21
6.3.3 Nut, washer and clamp

Nut, washer and clamp, description
1 2 3 4 5 6 The rim is attached to the wheel hub with nuts and clamps.
The number of nuts and clamps varies depending on the type of drive
axle and steering axle used.
7
016829
1. Lock ring
2. Rim edge
3. Tapered rim
4. O-ring
5. Rim
6. Rim edge
7. Wheel nut
8. Wheel clamp
Wheel bolt, replacement

2 Raise the machine with a jack positioned under the steering axle.
3 Remove the steering wheel, see Maintenance manual.

6:22 6 Suspension – Nut, washer and clamp
4 Knock out the bolt with a sledge hammer.

5 Replace the bolt.

7:1
7 Load handling
Contents 7 Load handling

7 Load handling .................................................................................................... 7:3
7.1.1 Control lever ................................................................................................7:6
7.1.2 Switch lock twistlocks ................................................................................7:10
7.1.3 Switch, automatic spreading ..................................................................... 7:11
7.1.5 Switch stop at 30' or 35' ............................................................................ 7:11
7.2 Lifting/lowering ...............................................................................................7:13
7.2.2 Servo filter .................................................................................................7:18
7.2.4 Accumulator servo circuit ..........................................................................7:18
7.2.5 Control valve lift, lower and extension.......................................................7:19
7.2.7 Valve block lift cylinder ..............................................................................7:20
7.2.8 Lift cylinder ................................................................................................7:23
7.2.9 Sensor hydraulic pressure lift cylinder.......................................................7:25
7.2.10 Lift boom ...................................................................................................7:26
7.2.11 Sensor boom angle ...................................................................................7:26
7.2.12 Pipes and hoses........................................................................................7:26
7.2.17 Valve block servo pressure .......................................................................7:27
7.3 Extension .......................................................................................................7:28
7.3.2 Servo filter .................................................................................................7:32
7.3.4 Accumulator servo circuit ..........................................................................7:32
7.3.5 Control valve lift, lower, and extension ......................................................7:33
7.3.7 Valve block extension cylinder ..................................................................7:34
7.3.8 Extension cylinder .....................................................................................7:36
7.3.10 Lift boom ...................................................................................................7:39
7.3.11 Sensor boom length ..................................................................................7:41
7.3.12 Pipes and hoses........................................................................................7:41
7.4 Side shift ........................................................................................................7:42
7.4.3 Control valve, attachment .........................................................................7:44
7.4.5 Side shift cylinder ......................................................................................7:47
7.4.6 Side shift frame .........................................................................................7:48
7.4.7 Main beam, attachment.............................................................................7:51
7.4.8 Relief valve top lift .....................................................................................7:52
7.4.9 Pipes and hoses........................................................................................7:52
7.5 Spreading (positioning) ..................................................................................7:53
7.5.5 Valve block spreader motor.......................................................................7:60
7.5.6 Spreader motor .........................................................................................7:61
7.5.7 Spreader chains ........................................................................................7:64
7.5.8 Spreader beam .........................................................................................7:69
7.5.9 Main beam, attachment.............................................................................7:71
7.5.10 Position sensor, spreading ........................................................................7:71
7.5.12 Pipes and hoses........................................................................................7:71
7.5.13 Buzzer, automatic spread 20'-40' ..............................................................7:72
7.6 Rotation..........................................................................................................7:73
7.6.5 Valve block rotation motor .........................................................................7:76

7:2 6 Suspension – Nut, washer and clamp
7.6.6 Rotation motor unit ....................................................................................7:77

7.6.7 Rotation yoke ............................................................................................7:79
7.6.8 Ring gear...................................................................................................7:81
7.6.9 Side shift frame .........................................................................................7:81
7.6.10 Sensor rotation stop ..................................................................................7:82
7.6.12 Pipes and hoses........................................................................................7:82
7.7 Tilt ..................................................................................................................7:83
7.7.3 Damping block tilt ......................................................................................7:90
7.7.4 Lock valve tilt.............................................................................................7:91
7.7.7 Tilt cylinder ................................................................................................7:92
7.7.8 Lift boom ...................................................................................................7:93
7.7.9 Rotation yoke ............................................................................................7:93
7.7.11 Pipes and hoses........................................................................................7:93
7.8 Levelling.........................................................................................................7:94
7.8.5 Overcentre valve levelling .......................................................................7:100
7.8.6 Valve block levelling cylinders .................................................................7:100
7.8.7 Levelling cylinders ...................................................................................7:101
7.8.8 Side shift frame .......................................................................................7:101
7.8.9 Relief valve top lift ...................................................................................7:101
7.8.10 Pipes and hoses......................................................................................7:101
7.8.12 Valve block servo pressure .....................................................................7:101
7.9 Load carrier..................................................................................................7:102
7.9.1 Twistlocks ................................................................................................7:102
7.10 Other functions............................................................................................. 7:110
7.10.1 Support jacks .......................................................................................... 7:110
7.10.2 Weight indicator....................................................................................... 7:118
7.10.3 Container counter.................................................................................... 7:118
7.10.4 Synchronised lift ...................................................................................... 7:118

7 Load handling – Load handling 7:3
7 Load handling
Load handling, general
The load handling function means e.g. to lift, lower, rotate, tilt and
secure the load. Load handling also includes auxiliary functions for
handling loads, e.g. support jacks.
Load handling is divided into different subfunctions:

• Lifting/lowering
015597
Lifting/lowering
• Extension
015598
Extension
• Side shift
001113
Side shift
• Spreading (positioning)
30'-stop
Automatic spreading 20' - 40'
001114
Spreading (positioning)
• Rotation
Rotation stop ±25°
016202
Rotation
• Tilt
Damping
Damping with tilt lock
Damping with controllable tilt and tilt lock
016203
Tilt

7:4 7 Load handling – Load handling
• Levelling ±5°
Hydraulic levelling
001117
Levelling
• Load securing
– Twistlocks
Overheight legs
004868
– Lift jacks
– Lifting hooks
Twistlock
• Other
– Support jacks
– Weight indicator
– Container counter
– Synchronised lift
– Height limitation
– LC limitation
Load handling is preferably controlled using the control lever while

certain functions have separate switches.

7 Load handling – Load handling 7:5
2
1
3 5 4 3
10, 11 9
6
9
017428
12
1. Sensor rotation stop 7. Sensor support jacks down

2. Sensor steering wheel movement 8. Sensor overheight jacks up
3. Sensor, contact 9. Sensor lift jacks
4. Sensor spreader 10. Sensor, contact
5. Sensor twistlocks 11. Sensor clamping position
6. Sensor support jacks up 12. Sensor knee
2 Check that the sensor in question is free of damage and dirt.
3 Check that the distance between the position sensor and the
indicator is 4±1 mm. Adjust if necessary.

7:6 7 Load handling – Controls and instruments

7.1.1 Control lever
Control lever, description
Lifting/lowering or straight lift
The control lever (S8150) is used to control boom and attachment. The
lever sends voltage signals to Control unit KCU (D7901).
1 Lifting/lowering or straight lift
8 7
Lifting/lowering is controlled by moving the control lever (position 1)
forward (lower boom) or backward (lift boom). See Lifting/lowering,
2 6 function description, page 7:14.
If the shift button (position 6) is depressed while the control lever

3 (position 1) is moved forward then lowering straight down is activated
(boom in and lower at the same time for a vertical movement). If the
4 shift button (position 6) is depressed while the control lever (position 1)
is moved backward then lifting straight up is activated (boom out and
5 lift at the same time for a vertical movement). See Synchronised lift,
function description, page 8:25.
The signal can be checked with the diagnostic menu, see 7.1 Controls
and Instr 5/XX DIAGNOSE, page 8:40.
016846
Extension or levelling
Extension is controlled by moving the control lever (position 1) right
1. Lift, lower, boom in and boom out (whole lever) (boom out) or left (boom in). See Extension, function description,
2. Side shift, spreading, rotation and tilt page 7:29.
3. Selection of travel direction and cab movement
4. Levelling lock
If the shift button (position 6) is depressed while the control lever
5. Tilt lock (position 1) is moved to the right then levelling anticlockwise is
6. Alternative function (Shift button) activated. If the shift button (position 6) is depressed while the control
lever (position 1) is moved to the left then levelling clockwise is
7. Opening the twistlocks
activated. See Hydraulic levelling, function description, page 7:95.
8. Horn
The signal from the control lever can be checked with the diagnostic
menu, see 7.1 Controls and Instr 5/XX DIAGNOSE, page 8:40. The
signal from the shift button can be checked with the diagnostic menu,
see 7.1 Controls and Instr 6/XX DIAGNOSE, page 8:41.
Side shift or spreading
When the thumb joystick (position 2) is moved to the right, side shift
right is activated and when the thumb joystick (position 2) is moved to
the left, side shift left is activated. See Side shift, function description,
page 7:42.
If the shift button (position 6) is depressed in at the same time as side

shift right (position 2), spreading out is activated. If the shift button
(position 6) is depressed in at the same time as side shift left (position
2), spreading in is activated. See Spreading, function description,
page 7:54.
The signal from the thumb joystick can be checked with the diagnostic

7 Load handling – Control lever 7:7
Rotation or tilt
When the thumb control (position 2) is moved back to the side, rotation
clockwise is activated and when the thumb control (position 2) is moved
forward, rotation anticlockwise is activated. See Rotation, function
If the shift button (position 6) is depressed at the same time as the

thumb control (position 2) is moved backward to the side then tilt
backwards is activated. If the shift button (position 6) is depressed at
the same time as the thumb control (position 2) is moved forward to the
side then tilt forwards is activated. See Tilt control, function description,
page 7:87.
The signal from the thumb control can be checked with the diagnostic
Selection of travel direction or cab movement
Gear selector (S1310-2) (position 3) can be used to change travel
direction and select neutral position when the parking brake is released.
Move the control forward to select travel direction forwards. Move the
control backward to select travel direction backwards. Move the control
up or down to select neutral position.
The control is connected in parallel with the travel direction selector on

the steering column. The signal can be checked with the diagnostic
menu, see 2.1 Controls & Instr 1/XX DIAGNOSE, page 8:33.
If the shift button (position 6) is depressed at the same time as Gear

selector (S1310-2) (position 3) is moved backward to the side then
cab movement backwards is activated. If the shift button (position 6)
is depressed at the same time as Gear selector (S1310-2) (position
3) is moved forward to the side then cab movement forwards is
activated. See Hydraulic sliding cab, function description , page 9:92.
The function is activated with the initiation menus, see 9.10 Cab
Suspension 8/XX INITIATE, page 8:137.
Levelling lock
Switch levelling lock (S7251) (position 4) activates levelling lock. The

indicator light in the switch illuminates when levelling lock is activated.
See Levelling lock, function description, page 7:97.
Tilt lock
Switch tilt lock (SW3) (position 5) activates tilt lock. The light in the
switch illuminates when tilt lock is activated. See Tilt lock, function
description , page 7:85.

7:8 7 Load handling – Control lever
Shift button
The shift button changes the function of other buttons on the control
lever.
If lift is activated while the shift button is depressed then synchronised

lift is activated. See Synchronised lift, function description, page 8:25.
If side shift is activated while the shift button is depressed then

spreading is activated. See Spreading, function description, page 7:54.
If extension is activated while the shift button is depressed then

levelling is activated. See Hydraulic levelling, function description,
page 7:95.
If rotation is activated while the shift button is depressed then tilt

control is activated. See Tilt control, function description, page 7:87.
If selection of travel direction is activated while the shift button is

depressed then cab movement is activated. See Hydraulic sliding cab,
function description , page 9:92.
Opening the twistlocks
Switch open twistlocks (S1020) (position 7) opens twistlocks if the
conditions for this are met. See Twistlocks, function description, page
7:103.
Horn
Switch horn (S8500-2) (position 8) activates the horn.

7 Load handling – Control lever 7:9
Control lever, adjusting the hand grip

2 Pull down the control lever's gaiter so that the bracket is accessible
3 Hold the base (2) firmly with a wrench and undo the lock nut (1).
1
CAUTION
2
Do not loosen the nut without counterhold.

Risk of product damage!
Always counterhold the base when the lock nut is
loosened or tightened.
4 Rotate the control lever to the desired position.

5 Hold the base (2) firmly with a wrench and tighten the lock nut (1).
016999
1. Lock nut
2. Base
Control lever, replacement

2 Remove the panel's screws.
3 Turn the panel round and undo the control lever attaching bolts, if
necessary.
4 Lift the control lever out from the panel.
5 Connect the new control lever in the same way as the old one.
6 Fit the new control lever.
If necessary, lift the gaiter and move the attaching bolts for the
new control lever.
Attaching bolts

7:10 7 Load handling – Switch lock twistlocks
7 Fit the upper section of the panel.
CAUTION
Exercise caution when the upper section of the panel
is fitted.
The panel may be damaged.
Position the cable harness in the panel so that the
upper section of the panel can be aligned correctly
without the cable harness being trapped.
7.1.2 Switch lock twistlocks

Switch lock twistlocks, description
The switch for lock twistlocks (S1003) controls locking the twistlocks.
The switch has three positions: two fixed and one rocker with the
following functions.
015587
1 0 2 1. Automatic locking of the twistlocks at full contact and released

parking brake.
0. Twistlocks open (off).
2. Manual locking of the twistlocks at full contact and released parking

brake (rocker switch).
Twistlocks are opened with the switch on the control lever, see Control
lever, description, page 7:6.
The switch is supplied with power by, and sends voltage signals to
Control unit (D7902).
The signal can be checked with the diagnostic menu, see 7.9 Load
Carrier 3/XX DIAGNOSE, page 8:49.
Switch right-hand dashboard panel centre section,

replacement
2 Remove the screws.
3 Carefully lift the panel and remove contacts.

7 Load handling – Switch, automatic spreading 7:11
4 Detach the connector from the switch.

5 Replace the switch.
CAUTION
Exercise caution when the upper section of the panel
is fitted.
The panel may be damaged.
Position the cable harness in the panel so that the
upper section of the panel can be aligned correctly
without the cable harness being trapped.
7.1.3 Switch, automatic spreading

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

When the switch is in position 1, spreading automatically moves to
015593
0 1 the next position (20, 30 or 40 feet) if spreading is activated with the

control lever.
The switch is supplied with voltage from, and sends a voltage signal to
Control unit (D7902) when the switch is activated.
The signal can be checked with the diagnostic menu, see 7.5 Spreading
7/XX DIAGNOSE, page 8:45.
WARNING
Risk of crushing and damage to the product!
Automatic spreading is stopped by activating
spreading in the opposite direction, or by deactivating
the function with the switch, or by applying the parking
brake.

replacement
See Switch right-hand dashboard panel centre section, replacement,
page 7:10.
7.1.5 Switch stop at 30' or 35'

Switch, stop at 30' or 35', description
Switch, stop at 30' or 35' (S1004) activates 30 and 35 feet stop. When
the switch is in position 1, the function for spreading is changed from
015590
0 1 20' – 40' to stop at 30'.
The switch is supplied with power by, and sends voltage signals to
Control unit (D7902).

7:12 7 Load handling – Switch stop at 30' or 35'

replacement
See Switch right-hand dashboard panel centre section, replacement,
page 7:10.

7 Load handling – Lifting/lowering 7:13
7.2 Lifting/lowering
Lifting/lowering, description
Damping
Lifting/lowering means angling the boom up and down so that the

attachment is lifted and lowered. The lift boom is angled by two
lift cylinders, which are pressurised by Control valve lift, lower and
extension. The lift function is controlled by Control lever (S8150).
Damping
015597
Damping means that the speed of functions is reduced automatically
approaching the end positions. This means that the mechanics are
loaded less when stopping in the end positions.
Angle sensors detect when damping should be activated. When

damping is activated, Control unit KFU (D7971) reduces the control
current to the solenoid valve for the function in question.
Regeneration
Regeneration
To increase the speed during lift, oil from the rod side (2) is re-used
1 2 for the piston side (1), this is called regeneration. Engagement of
regeneration is controlled by the control system.
000455

7:14 7 Load handling – Lifting/lowering
Lifting/lowering, function description

Control breaker Disengaged Control breaker voltage, function description,
page 11:19
Sensor, operator-in-seat Not activated Sensor operator in seat, description, page 9:23
Twistlocks Locked or unlocked, not intermediate position Twistlocks, description, page 7:107
(can be bypassed)
Overload system Boom up: passive Overload system, description, page 8:5
Boom down: passive or bypass activated Bypass, description, page 8:6
Contact Boom down: no contact Twistlocks, function description, page 7:103
Height limitation Bypassed or boom height lower than height Height limitation, description, page 8:7
limitation.
Combi attachment Boom up: Approved lift (contact within time -

limit)
Doors Machine with vertically adjustable cab: Doors, description, page 9:86
Boom up: Doors closed when cab in lower
position.
Boom down: Doors closed when cab is raised.
D1
1
2, 4
D7902 D7950
D7971
3, 5, 16, 21
4
D7940 D25
D20 >°
D7930 6 D5 6 17 22 25
D16
15 PSS PSL
D21
Pa
PP
A1 VA
C-M 19, 24
12 7
P C-
B1 T
C+
LS P D
C+M Pa
14 20
18, 23
LSP1 A H
LSP2
8, 813
LSPR EF CF 11
LSP3 LSHY C13 P
LSP3X P T T P LSO
LSM
12
C9
C9 C10
016338
9 9 10

7 Load handling – Lifting/lowering 7:15

1 Control lever (S8150-Y) sends voltage Lower: U = 0.5-2.0 V Control lever, description, page 7:6
signals to Control unit KPU (D7902) Zero position: U = 2.0-3.0 V D1: Diagnostic menu, see 7.1
proportional to lever movement. Controls and Instr 5/XX DIAGNOSE,
Lift: U = 3.0-4.5 V
page 8:40
0.5 V is the fastest lowering
speed and 4.5 V is the fastest
lift speed. Lower voltage than
0.5 V and higher voltage than
4.5 V is used to detect faults in
cable harnesses and controls.
2 Control unit KPU (D7902) sends request Checked by control system, 11.5.3.2 KPU control unit (D7902),
for Boom up or Boom down with the speed error shown with error code. page 11:27
information on the CAN bus.
3 If the transmission is in neutral position Checked by control system, 11.5.3.1 KCU control unit (D7901),
then Control unit KFU (D7971) sends a error shown with error code. page 11:25
request for increased engine speed on
CAN bus drive-train.
4 Control unit, engine (D7940) increases Checked by control system, 11.5.3.6 Control unit, engine (D7940),
the engine speed. error shown with error code. page 11:35
5 Control unit KFU (D7971) activates I = 320–650 mA 11.5.3.4 KFU control unit (D7971),
Solenoid valve lift (Y6005) or Solenoid page 11:31
valve lower (Y6004). D5: Diagnostic menu, see 7.2 Lifting
Lowering 6/XX DIAGNOSE, page
8:41 or 7.2 Lifting Lowering 7/XX
DIAGNOSE, page 8:42
6 Solenoid valve lift (Y6005) or Solenoid - 7.2.5 Control valve lift, lower and
valve lower (Y6004) pressurises the extension, page 7:19
control valve's lift slide with servo D5: Diagnostic menu, 7.2 Lifting
pressure. Lowering 6/XX DIAGNOSE, page
8:41 and 7.2 Lifting Lowering 7/XX
DIAGNOSE, page 8:42
7 The control valve's lift slide changes - 7.2.5 Control valve lift, lower and
position and pressurises Valve block lift extension, page 7:19
cylinder and sends load signals to Servo
valve load handling steering.
8 Servo valve load handling steering - Valve block servo pressure,
distributes the load signal to hydraulic oil description, page 10:25
pump 1 - 3. Shuttle valves in servo valves
select the strongest load signal if other
functions are activated at the same time.
9 Hydraulic oil pump 2 and 3 pump oil from See the pressure plate on the Axial piston pump with variable
the hydraulic oil tank. left-hand frame beam. displacement, description, page
10:10
10 Hydraulic oil pump 1 pumps oil from the See the pressure plate on the Axial piston pump with variable
hydraulic oil tank to the priority valve. left-hand frame beam. displacement, description, page
10:10
11 The priority valve leads feed pressure to - Priority valve, description, page 5:14
Control valve, lifting/lowering.
12 High-pressure filter - Hydraulic oil filter, description
(high-pressure filter), page 10:36
On machines with high-pressure filter, the
oil is cleaned after the hydraulic oil pumps.
13 The pressure reducer in Servo valve See the pressure plate on the Valve block servo pressure,
load handling steering reduces the oil left-hand frame beam. description, page 10:25
pressure from hydraulic oil pump 1 to
servo pressure for the control valve.
14 The accumulator stores servo pressure. See the pressure plate on the Accumulator servo circuit, description,
The non-return valve in the pressure left-hand frame beam. page 10:29
reducer makes it possible to store the
pressure when the engine is switched off.

7:16 7 Load handling – Lifting/lowering

15 The servo filter cleans the servo oil before - Servo filter, description, page 7:18
the control valve.
16 Boom down U = 24 V 11.5.3.4 KFU control unit (D7971),
Control unit KFU (D7971) activates page 11:31
Solenoid valve blocking right (Y6045-RI) D16: Diagnostic menu, see 7.2 Lifting
and Solenoid valve blocking left Lowering 8/XX DIAGNOSE, page
(Y6045-LE). 8:42
17 Boom down - Valve block lift cylinder, description,
Solenoid valve blocking right (Y6045-RI) page 7:20
and Solenoid valve blocking left D16: Diagnostic menu, see 7.2 Lifting
(Y6045-LE) act on the blocking valves in Lowering 8/XX DIAGNOSE, page
the valve blocks for the left and right-hand 8:42
lift cylinder respectively.
18 Boom up - Valve block lift cylinder, description,
The blocking valves in the valve blocks for page 7:20
left and right-hand lift cylinder respectively
are opened by the hydraulic pressure from
the control valve.
Boom down
The blocking valve is opened so that
the pressure from the lift cylinder can be
released.
19 The lift cylinders' piston side is pressurised - Lift cylinder, description, page 7:23
and the boom is lifted.
20 Regeneration U=5V Sensor hydraulic pressure lift cylinder,
Sensor, hydraulic pressure lift cylinder, U=0V description, page 8:16
piston side left (B7226-1) sends voltage U = 0.5-4.5 V D20: Diagnostic menu, see 8.2
signals to Control unit KFU (D7971) Monitoring 17/XX DIAGNOSE, page
proportional to the oil pressure. Regeneration is activated 8:55
when the pressure in the
lift cylinders is 8.5 MPa.
NOTE Regeneration is stopped if the
Regeneration is not possible near pressure reaches 18.5 MPa.
end-position or in case of overload.
21 Control unit KFU (D7971) activates U = 24 V 11.5.3.4 KFU control unit (D7971),
Solenoid valve, regeneration right page 11:31
(Y6051-LE) and Solenoid valve, D21: Diagnostic menu, see 7.2 Lifting
regeneration left (Y6051-RI) if the pressure Lowering 9/XX DIAGNOSE, page
is sufficiently low for regeneration. 8:42
22 Solenoid valve regeneration pressurises - Valve block lift cylinder, description,
the regeneration valve. page 7:20
23 The regeneration valve changes position - Valve block lift cylinder, description,
and leads oil from the rod side of the lift page 7:20
cylinder to the piston side.
24 Lift speed increases. - -
25 Damping Checked by control system, Sensor boom angle, description, page

When the boom is approx. 4° from an error shown with error code. 8:18
end-position, damping is activated. D25: Diagnostic menu, see 8.2
Sensor, boom angle (B7241) sends Monitoring 16/XX DIAGNOSE, page
voltage signals proportional to the boom 8:54
angle to Control unit KFU (D7971)
requesting damping on the CAN bus.

machine, page E:6.

7 Load handling – Hydraulic oil pump 7:17
Lowering speed, checking
DANGER
The lowering speed must be correct. If lowering speed
is too fast, there is a risk of tipping forward.
Extreme danger!
The machine must absolutely not be taken into service
before the lowering speed is verified after repair work
on functions or components that affect the lowering
function.
0:00pm
1 Operate the machine and hydraulics until the hydraulic oil reaches
a the operating temperature of 50 °C.
75° C 50%
2 Lift a container weighing 35-45 tonnes.
b c 3 Move the machine away to a level and a safe place.
50° C 50° C NOTE

016372
It is important that the ground is smooth, level, and without

gradient.
4 Fully retract the extension and lift the boom to maximum angle.
5 Note the time for how long it takes to lower from top position until
b. Oil temperature hydraulic system damping is activated.
c. Oil temperature brake system Lowering should take 22–26 seconds.
6 If the time is not correct then contact Cargotec for further
instructions.

See Axial piston pump with variable displacement, description, page
10:10.

7:18 7 Load handling – Servo filter
7.2.2 Servo filter

Servo filter, description
The servo filter protects the control valve's servo circuits against
impurities. The servo filter is fitted in the front edge of the lifting
beam on the right-hand side of the engine compartment, between the
pressure reducer and the control valve for lift, lower and extension.
The servo filter is a high-pressure filter with detachable filter insert. The
oil is cleaned when it passes through the filter insert's filter material.
1 The filter insert is pressed against the upper section of the filter housing
by a spring. Rubber gaskets seal between the insert and filter housing.
If the back pressure through the filter is too great then the insert is
pressed down so that the oil passes by the insert. This occurs if the oil
2 is viscous (cold or incorrect viscosity) or if the filter insert is clogged.
016299
1. Filter body
2. Drain plug
7.2.4 Accumulator servo circuit

Accumulator servo circuit, general
See Accumulator servo circuit, description, page 10:29.

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

Control valve lift, lower, and extension, description
Lift slide
The control valve controls the speed and direction of lift and extension.
The control valve is fitted on a bracket in the space between the lifting
1
beam and front axle.
2 The valve has two sections, one for the lift function and one for boom
9 extension. The sections have many similarities, but are described
separately under the respective function. For extension, see 7.3.5
8 3 Control valve lift, lower, and extension, page 7:33. Electric servo valves
control the flow from the valve.
7 4 The control valve is a proportional valve controlled by servo valves.
This means that both volume and direction of the flow from the valve
6 can be adjusted and that the valve also sends control signals to the
5 variable pumps.
Electrically controlled pressure reducing valves (servo valves) convert

electric current into a low hydraulic pressure that is proportional to
the current, so-called servo pressure. The servo pressure acts on
the spring-centred control slide in the control valve for the function in
016839
question and thereby controls the main flow.
The speed of the function is controlled by means of the flow being

1. Connection, rod side, extension cylinder [B1] regulated in proportion to the lever movement.
2. Solenoid valve, boom out (Y6006) Lift slide
3. Solenoid valve, lift (Y6005)
The lift slide controls the direction and flow of the oil to the lift cylinder.
4. Connection, rod side, right lift cylinder [B2]
5. Connection, piston side, right lift cylinder [A2] Servo valve, lift
6. Solenoid valve, lower (Y6004) Servo valve, lift controls servo pressure to the lift slide so that it controls
7. Solenoid valve, boom in (Y6007) oil pressure for lifting. The valve is controlled electrically with Solenoid
valve, lift (Y6005), which is activated by Control unit KFU (D7971).
8. Connection, feed from hydraulic oil pumps [P]
9. Connection, piston side, extension cylinder The signals can be checked with the diagnostic menu, see 7.2 Lifting
[A1] Lowering 6/XX DIAGNOSE, page 8:41.
Servo valve, lower
Servo valve, lower, controls servo pressure to the lift slide so that it
controls oil pressure for lowering. The valve is controlled electrically
with Solenoid valve, lower (Y6004), which is activated by Control unit
KFU (D7971).
The signals can be checked with the diagnostic menu, see 7.2 Lifting
Lowering 7/XX DIAGNOSE, page 8:42.

7:20 7 Load handling – Valve block lift cylinder
Control valve lift, lower, and extension, changing
DANGER
The lowering speed must be correct. If lowering speed
is too fast, there is a risk of tipping forward.
Extreme danger!
The machine must absolutely not be taken into service
before the lowering speed is verified after repair work
on functions or components that affect the lowering
function.
After replacing Control valve lift, lower, and extension, or parts of

the valve, lowering speed must be checked. See Lowering speed,
7.2.7 Valve block lift cylinder

Valve block lift cylinder, description
Blocking valve
Valve block lift cylinder directs oil to the lift cylinder and is bolted directly
1 2 3 on the lower part of the lift cylinder. The valve block contains the
blocking valve, regeneration valve, non-return valve and shock valve.
Blocking valve
4
8 The blocking valve prevents unwanted lowering and angling of the
lift cylinders. The blocking valve holds the load by ensuring that the
connection to the lift cylinder's piston side is closed. (The pressure
5 travels through a restriction as blocking pressure and holds the valve
slide closed.)
7
6 Solenoid valve blocking acts on the blocking valve. The servo valve
is controlled electrically with Solenoid valve blocking left (Y6045-LE)
and Solenoid valve blocking right (Y6045-RI), activated by Control
unit KFU (D7971).
The signal can be checked with the diagnostic menu, see 7.2 Lifting
Lowering 8/XX DIAGNOSE, page 8:42.
Regeneration valve
016900
The regeneration valve directs oil from the rod side of the cylinder
1. Connection, rod side, lift cylinder [C-] back to the piston side. This allows the oil to be re-used during lifting.
2. Connection tank [T] For more information on regeneration, see Lifting/lowering, function
description, page 7:14. The regeneration valve is regulated by servo
3. Connection, pressure feed [VA] valve regeneration.
4. Sensor hydraulic pressure lift cylinder piston
side (B7226-1 or B7226-3) [C+M] Solenoid valve regeneration acts on the regeneration valve. The servo
valve is controlled electrically with Solenoid valve regeneration right
5. Draining servo valves [D]
(Y6051-RI) and Solenoid valve regeneration left (Y6051-LE), activated
6. Solenoid valve blocking (Y6045-LE or by Control unit KFU (D7971).
Y6045-RI)
7. Sensor hydraulic pressure lift cylinder piston The signal can be checked with the diagnostic menu, see 7.2 Lifting
side (B7226-2 or B7226-4) [C-M] Lowering 9/XX DIAGNOSE, page 8:42.
8. Solenoid valve regeneration (Y6051 or Y6052) Shock valve
The shock valve protects the hydraulic system against pressure surges
which can occur when operating with a load. The shock valve opens
a connection between the lift cylinder's piston side and the tank if the
pressure becomes too high.

7 Load handling – Valve block lift cylinder 7:21
Non-return valve
The non-return valve prevents oil from flowing the wrong way during
regeneration.
Valve block lift cylinder, changing
NOTE
Safety.

NOTE
4 Mark and disconnect the cable harness from the valve block.
Remove the cable harness's clamping at the valve block.
5 Mark up and detach the hydraulic hoses from the valve block.
NOTE
from impurities.
016901
6 Remove the valve block from the lift cylinder.

Remove the attaching bolts and lift away the valve block.
7 Transfer the connection adapters, sensors, and servo valves to
the new valve block.
NOTE
correctly.
016927
NOTE
mixed up.

7:22 7 Load handling – Valve block lift cylinder
8 Install the new valve on the lift cylinder.
NOTE
correctly.
9 Connect the hydraulic hoses to the valve block according to the

marking.
NOTE
correctly.
10 Connect the cable harness to the valve block according to the

marking.
Clamp the cable harness as before.
hydraulic system.
NOTE
016901
the lock ring.
12 Turn on the main electric power and start the engine.

13 Activate the lift carefully.
CAUTION
product damage.
Activate the functions carefully and operate at the
lowest possible speed a couple of times to avoid
cavitation.
14 Check for leaks.

manual.
16 Check the lowering speed, see Lowering speed, checking, page
7:17.

7 Load handling – Lift cylinder 7:23
7.2.8 Lift cylinder

Lift cylinder, description
The lift cylinders lift and lower (angle) the lift boom. The lift cylinders
are fitted between boom and frame in the front edge of the machine,
one on the right and one on the left-hand side.
A valve block that controls pressurising and regeneration of the lift

cylinder is installed on each 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
control valve for lift, lower, and extension, see 7.2.5 Control valve lift,
lower and extension, page 7:19.
001096
Lift cylinder, changing
DANGER
A lift cylinder weighs approx. 2 tonnes.
Extreme danger!
Exercise caution when handling so that personal
injury and equipment damage are avoided.
WARNING
The boom may move when the pins are removed.
Risk of personal injury!
Make sure that the shafts are unloaded. Stand to
the side of the boom mounting so that it provides
protection in the event of any movement.
CAUTION
The boom may drop.
Be certain to compensate for the lift cylinder's support
of the boom by lifting the boom's leading edge with
the lifting equipment.
1 Move the cab into the front position.

NOTE

7:24 7 Load handling – Lift cylinder
4 Connect lifting equipment at the front edge of the boom.

5 Lift the boom at the front edge so that the bearings on the lift
cylinders are unloaded.
6 Mark and release the hydraulic hoses and the cable harness from
Valve block lift cylinder.
016901
7 Connect the lifting equipment to the lift cylinder.
8 Remove the upper pin for the lift cylinder.

9 Unload the lower bearing of the lift cylinder.
10 Remove the lower pin for the lift cylinder.
11 Lift away the lift cylinder.

7 Load handling – Sensor hydraulic pressure lift cylinder 7:25
12 Transfer Valve block lift cylinder to the new lift cylinder.
NOTE
correctly.
13 Lift the new lift cylinder into place.

14 Install the pins for the lift cylinder. Lubricate the shaft with a thin
layer of aluminium paste, exercise caution so that the aluminium
paste does not come into contact with the slide surface of the
bearings in the lift cylinder.
CAUTION
The bearings are lubricant-free and must not be
lubricated.
Product damage.
The slide surface of the bearings is specially treated
and must not be lubricated. When fitting the shafts,
exercise additional caution and ensure that the
lubricant does not come into contact with the slide
surface of the bearings. After assembly, apply
anti-corrosion protection to the bearings externally
with a thin layer of Teflon spray.
15 Connect the hydraulic hoses and the cable harness to Valve block
lift cylinder in accordance with the marking.
hydraulic system.
NOTE
the lock ring.

18 Carefully activate the lift function.
CAUTION
016901

product damage.
19 Check for leaks.

manual.
7:17.

7.2.9 Sensor hydraulic pressure lift cylinder

Sensor hydraulic pressure lift cylinder, general
See Oil pump brake system, general, page 4:49.

7:26 7 Load handling – Lift boom
7.2.10 Lift boom

Lift boom, description
The lift boom lifts the load. The rear section of the boom is secured into
the frame with two bearing-mounted shafts. Fitted in the front edge
is the lift attachment and in the centre on each side of the boom are
lift cylinders which are secured with bearing-mounted shafts. The lift
cylinders angle the boom, and in this way raise the front section of the
boom. The lift boom is available in several versions depending on
reach and load capacity.
The boom consists of an outer boom and an inner boom manufactured
in high-strength steel with a minimum number of welds for maximum
strength.
The inner boom runs in the outer boom and can be extended
longitudinally with the extension cylinder. There are slide plates
between inner boom and outer boom that reduce the friction between
inner boom and outer boom. The slide plates are fitted in the front edge
of the outer boom and the rear edge of the inner boom.
Running along the left 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
1. Outer boom
2. Inner boom
3. Tilt cylinder right side
4. Mounting attachment
5. Tilt cylinder left side
6. Extension cylinder
7. Lift cylinder
8. Mounting lift cylinder
9. Rear boom mounting
7.2.11 Sensor boom angle

Sensor boom angle, general
See Sensor boom angle, description, page 8:18.


7 Load handling – Valve block servo pressure 7:27
7.2.17 Valve block servo pressure

See Valve block servo pressure, description, page 10:25

7:28 7 Load handling – Extension
7.3 Extension
Extension, description
Damping
Extension means sliding the inner boom in and out of the outer boom.
The inner boom is slid in and out of the extension cylinder, which is
pressurised by Control valve lift, lower and extension. Extension is
controlled by Control lever (S8150).
Damping
015598
Length sensors detect when damping should be activated. When

damping is activated the relevant control unit reduces the control
Regeneration
Regeneration
To increase the speed during extension, oil from the rod side (2) is
1 2 re-used for the piston side (1), this is called regeneration. Engagement
of regeneration is controlled by the control system.
000455

7 Load handling – Extension 7:29
Extension, function description

Control breaker Disengaged Control breaker voltage, function description, page 11:19
Overload system Boom out: passive Overload system, description, page 8:5
Bypassed or the attachment Load centre limitation, description, page 8:7
is within the limit for the load
Load centre limitation centre limitation.
Bypassed or boom height Height limitation, description, page 8:7
lower than height limitation.
Height limitation
1
D1
2
D7902 D7950
Pa 21
D7971 D7911
3, 5, 17, 22, 23, 28 27 D21
4 D27
D7940
D23 m 27
D7930 6 D6 6
D17 18 24
D5 16 PSS PSL
PP
A1 VA
13 7 VA 20, 26
P
C-
B1 VB
C+
LS P D
9
15 19, 25
LSP1 A H
LSP2
8, 814
LSPR EF CF 12
LSP3 LSHY C14 P
LSP3X P T T P LSO
LSM
13
C10
C10 C11
10 10 11
016837

7:30 7 Load handling – Extension

1 Control lever (S8150-X) sends voltage Boom in: U = 0.5-2.0 V Control lever, description, page 7:6
signals to Control unit KPU (D7902) Zero position: U = 2.0-3.0 V D1: Diagnostic menu, see 7.1 Controls and
proportional to lever movement. Instr 5/XX DIAGNOSE, page 8:40
Boom out: U = 3.0-4.5 V
0.5 V is the fastest retraction
speed and 4.5 V is the fastest
extension speed. Lower
voltage than 0.5 V and higher
voltage than 4.5 V is used
to detect faults in cable
2 Control unit KPU (D7902) sends Checked by control system, 11.5.3.2 KPU control unit (D7902), page
request for Boom out or Boom in with error shown with error code. 11:27
the speed information on the CAN
bus.
3 If the transmission is in neutral position Checked by control system, 11.5.3.4 KFU control unit (D7971), page
then Control unit KFU (D7971) sends error shown with error code. 11:31
a request for increased engine speed
on CAN bus drive-train.
4 Control unit, engine (D7940) Checked by control system, 11.5.3.6 Control unit, engine (D7940), page
increases the engine speed. error shown with error code. 11:35
5 Boom out I = 360-650 mA 11.5.3.4 KFU control unit (D7971), page
Control unit KFU (D7971) activates 11:31
Solenoid valve boom out (Y6006). D6: Diagnostic menu, see 7.2 Extension
Boom in 11.5.3.4 KFU control unit (D7971), page
Solenoid valve pump unloading D5: Diagnostic menu, see 10.4 Pumps
(Y6093) and Solenoid valve boom in 2/XX DIAGNOSE, page 8:78
(Y6007). D6: Diagnostic menu, see 7.3 Extension
6 Boom out - 7.2.5 Control valve lift, lower and extension,
Solenoid valve boom out (Y6006) page 7:19
pressurises the control valve's D6: Diagnostic menu, see 7.2 Extension
extension slide with servo pressure. 1/XX DIAGNOSE, page 8:43.
Boom in
Solenoid valve boom in (Y6007)
pressurises the control valve's
extension slide with servo pressure.
7 The control valve's extension slide - 7.2.5 Control valve lift, lower and extension,
changes position and pressurises page 7:19
Valve block extension cylinder and
sends load signals to Servo valve
load handling steering.
8 Servo valve load handling steering - Valve block servo pressure, description,
distributes the load signal to hydraulic page 10:25
oil pump 1 - 3. Shuttle valves in servo
valves select the strongest load signal
if other functions are activated at the
same time.
9 Boom in - Solenoid valve pump unloading,
Solenoid valve pump unloading description, page 10:25
(Y6093) opens and drains the load D5: Diagnostic menu, see 10.4 Pumps
signal to hydraulic oil pump 2 to the 2/XX DIAGNOSE, page 8:78
tank so that only hydraulic oil pump 1
and 3 generate pressure.
10 Hydraulic oil pump 2 and 3 pump oil See the pressure plate on the Axial piston pump with variable
from the hydraulic oil tank. left-hand frame beam. displacement, description, page 10:10

7 Load handling – Extension 7:31

11 Hydraulic oil pump 1 pumps oil from See the pressure plate on the Axial piston pump with variable
the hydraulic oil tank to the priority left-hand frame beam. displacement, description, page 10:10
valve.
12 The priority valve leads feed pressure - Priority valve, description, page 5:14
to Control valve, lifting/lowering.
13 High-pressure filter - Hydraulic oil filter, description
(high-pressure filter), page 10:36
On machines with high-pressure filter,
the oil is cleaned after the hydraulic
oil pumps.
14 The pressure reducer in Servo valve See the pressure plate on the Valve block servo pressure, description,
load handling steering reduces the oil left-hand frame beam. page 10:25
pressure from hydraulic oil pump 1 to
servo pressure for the control valve.
15 Servo pressure is stored in the See the pressure plate on the Accumulator servo circuit, description,
accumulator. The non-return valve left-hand frame beam. page 10:29
in the pressure reducer makes it
possible to store the pressure when
the engine is switched off.
16 The servo filter filters the oil before - Servo filter, description, page 7:18
the control valve.
17 Boom in U = 24 V 11.5.3.4 KFU control unit (D7971), page
Solenoid valve blocking extension D17: Diagnostic menu, see 7.3 Extension
(Y6050). 3/XX DIAGNOSE, page 8:43
18 Boom in - Valve block extension cylinder, description,
For boom in Solenoid valve, blocking page 7:34
extension (Y6050) acts on the D16: Diagnostic menu, see 7.3 Extension
blocking slide in Valve block extension 3/XX DIAGNOSE, page 8:43
cylinder.
19 Boom out - Valve block extension cylinder, description,
The blocking slide in Valve block page 7:34
extension cylinder is opened by
hydraulic pressure from the control
valve.
Boom in
The blocking slide in the valve block
opens and releases pressure from the
extension cylinder.
20 Extension cylinder extends or retracts - Extension cylinder, description, page 7:36
the boom.
21 Regeneration U = 0.5-4.5 V Sensor hydraulic pressure lift cylinder,
Sensor, hydraulic pressure lift description, page 8:16
cylinder, piston side left (B7226-1) D201: Diagnostic menu, see 8.2 Monitoring
sends voltage signals to Control unit 17/XX DIAGNOSE, page 8:55
KFU (D7971) proportional to the
cylinder pressure in the lift cylinders.
22 Control unit KFU (D7971) sends Checked by control system, 11.5.3.4 KFU control unit (D7971), page
information about the pressure in the error shown with error code. 11:31
lift cylinders.
23 Control unit KFU (D7971) activates U = 24 V 11.5.3.4 KFU control unit (D7971), page
Solenoid valve regeneration 11:31
(Y6051-1), if the pressure is low 23: Diagnostic menu, see 7.3 Extension
enough for regeneration. 4/XX DIAGNOSE, page 8:44.
24 Solenoid valve regeneration - Valve block extension cylinder, description,
(Y6051-1) pressurises the page 7:34
regeneration valve.

7:32 7 Load handling – Hydraulic oil pump

25 The regeneration valve changes - Valve block extension cylinder, description,
position and leads oil from the rod page 7:34
side of the lift cylinder to the piston
side.
26 Extension speed increases. - Extension cylinder, description, page 7:36
27 Damping - Sensor, boom length, description, page
When the extension is about 0.4 m 8:19
from the end-position damping is D27: Diagnostic menu, see 8.2 Monitoring
activated. 16/XX DIAGNOSE, page 8:54.
Sensor boom length (B7686) sends
voltage signals proportional to the
boom extension to Control unit KFU
(D7971).
28 Control unit KFU (D7971) reduces - 11.5.3.4 KFU control unit (D7971), page
the control current to Solenoid valve 11:31
boom out (Y6006) or Solenoid valve
boom in (Y6007).

machine, page E:6.

10:10.
7.3.2 Servo filter

Servo filter, general
See Servo filter, description, page 7:18.

Accumulator servo circuit, general
See Accumulator servo circuit, description, page 10:29.

7 Load handling – Control valve lift, lower, and extension 7:33
7.3.5 Control valve lift, lower, and extension

Control valve lift, lower, and extension, description
Extension slide
The control valve has two sections: one for the lift function and one
for boom extension. The sections have many similarities, but are
1
described separately under the respective function.
2 For general information on the control valve, refer to 7.2.5 Control valve
9 lift, lower and extension, page 7:19.
3 Extension slide
8
The extension slide controls direction (in or out) and oil flow to valve
7 4 block extension cylinder.
Servo valve, boom out
6 5 Servo valve boom out, controls servo pressure to the extension slide
so that it controls oil pressure for extension.
Servo valve boom out is controlled electrically with Solenoid valve

boom out (Y6006) which is activated by Control unit KFU (D7971).
The signal can be checked with the diagnostic menu, see 7.3 Extension
016839

Servo valve, boom in
1. Connection, rod side, extension cylinder [B1]
2. Solenoid valve, boom out (Y6006) Servo valve boom in, controls servo pressure to the extension slide so
that it controls oil pressure for boom retraction.
3. Solenoid valve, lift (Y6005)
4. Connection, rod side, right lift cylinder [B2] Servo valve boom in is controlled electrically with Solenoid valve boom
5. Connection, piston side, right lift cylinder [A2] in (Y6007) which is activated by Control unit KFU (D7971).
6. Solenoid valve, lower (Y6004) The signal can be checked with the diagnostic menu, see 7.2 Extension
7. Solenoid valve, boom in (Y6007) 1/XX DIAGNOSE, page 8:43.
8. Connection, feed from hydraulic oil pumps [P] Shock valve, extension
9. Connection, piston side, extension cylinder Two shock valves protect the hydraulic system against surges which
[A1]
can occur when operating on uneven ground or when stopping.
The shock valve opens a connection between the extension cylinder

piston side and rod side and tank if the pressure becomes too high.

7:34 7 Load handling – Valve block extension cylinder
7.3.7 Valve block extension cylinder

Valve block extension cylinder, description
Blocking valve
1 Valve block extension cylinder routes pressure to the extension

cylinder. The valve block is fitted at the rear edge of the extension
7 cylinder in the lift boom and contains a blocking valve, regeneration
2 valve and non-return valve.
6 Blocking valve
3
The blocking valve prevents unwanted lowering. The valve holds the
5 load by keeping the connection to the extension cylinder's piston side
4
closed. The pressure passes through a restriction providing a blocking
pressure and holds the valve slide closed.
Solenoid valve blocking (Y6050) acts on the blocking valve. Solenoid

valve blocking extension (Y6050), activated by Control unit KFU
(D7971).
The signal can be checked with the diagnostic menu, see 7.3 Extension
Regeneration valve
The regeneration valve routes oil from the rod side back to the piston
side. This allows the oil to be re-used during extension. For more
information on regeneration, see Extension, description, page 7:28 or
016838
Extension, function description, page 7:29. The regeneration valve is

regulated by servo valve regeneration.
1. Connection, rod side [C-] Solenoid valve regeneration (Y6051-1) pressurises the regeneration
2. Draining [D] valve. Solenoid valve regeneration (Y6051-1) is activated by Control
3. Solenoid valve regeneration (Y6051-1) unit KFU (D7971).
4. Connection, control valve [VB] The signal can be checked with the diagnostic menu, see 7.3 Extension
5. Connection, control valve [VA] 4/XX DIAGNOSE, page 8:44.
6. Connection, control valve [VA]

7. Solenoid valve blocking (Y6050)
Valve block extension cylinder, replacement
NOTE
Safety.
1 Fully retract the boom.

NOTE

7 Load handling – Valve block extension cylinder 7:35
NOTE
from impurities.
5 Remove the valve block from the extension cylinder.
NOTE
017410
from impurities.
6 Move the valve block to a clean area.

7 Transfer over connection adapters, solenoid valves to the new
valve block.
NOTE
correctly.
NOTE
mixed up.
8 Fit the new valve on the extension cylinder.
NOTE
correctly.
9 Connect the hydraulic hoses to the valve block according to the

marking.
NOTE
correctly.
017410
10 Connect the cable harness to the valve block according to the

marking.
Clamp the cable harness as before.
hydraulic system.
NOTE
the lock ring.

manual.

7:36 7 Load handling – Extension cylinder
7.3.8 Extension cylinder

Extension cylinder, description
The extension cylinder forces out and retracts the inner boom. The
extension cylinder is fitted in the lift boom. The rear section is secured
in the outer boom, the front section is secured in the inner boom. A
valve block that controls pressurising of the cylinder and regeneration
for boom out is fitted on the extension cylinder.
The extension cylinder piston rod end is designed as a lug with a flange
which is secured on the piston rod with hex bolts.
016840
Extension cylinder, changing
NOTE
Safety.
Removing
2 Run out the boom until the inspection holes in the side of the inner
boom become accessible.
NOTE
4 Remove the lock rings and press out the pin for the front cylinder
mounting in the inner boom.
5 Remove Sensor boom length from the boom, see Sensor, boom
length, description, page 8:19.
6 Mark up and disconnect the hydraulic hoses from the extension
cylinder.
NOTE
from impurities.
7 Mark and disconnect the cable harness on the extension cylinder.

7 Load handling – Extension cylinder 7:37
8 Remove the valve block from the extension cylinder.
NOTE
from impurities.
9 Remove the lock rings and press out the outer pins for the rear
cylinder mountings in the outer boom.
10 Connect lifting equipment to the rear extension cylinder's mounting.
11 Extend the extension cylinder carefully. When the cylinder has
come out slightly, connect a second lifting device that is moved
forward on the lift cylinder throughout the whole removal in order
to stabilise the lift.
12 Place the cylinder on wooden blocks.
13 Transfer parts to the new extension cylinder.
When moving the brackets for the extension cylinder's rear bearing,
Outer pins extension cylinder
note that the bearings in the extension cylinder are lubricant-free.
Lubricate the centre shaft with a thin layer of aluminium paste,
exercise caution so that the aluminium paste does not come into
contact with the slide surface of the bearings in the lift cylinder.
CAUTION
lubricated.
Product damage.
Installing
14 Measure how long the old extension cylinder is and extend the
new cylinder to the same length.
NOTE
If this is not done, then the front cylinder mounting will not reach
far enough.
15 Lift the extension cylinder into place.
CAUTION
Use the dual lifting devices in order 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.

7:38 7 Load handling – Extension cylinder
16 Install the pin at the front cylinder mounting in the inner boom.
The extension cylinder's bearings are lubricant-free. Lubricate the
shaft with a thin layer of aluminium paste, exercise caution so that
the aluminium paste does not come into contact with the slide
surface of the bearings in the lift cylinder.
CAUTION
lubricated.
Product damage.
17 Install the locks on the pin.
18 Fit the outer shafts at the rear cylinder mountings.

Start with the right-hand shaft. The bushing at the left-hand
mounting is eccentric and must be turned so that the holes align
before the shaft is fitted.
NOTE
Lubricate the pin with grease before installing.
19 Install the locks on the pins.

20 Install the valve block on the extension cylinder.
Outer pins extension cylinder
NOTE
correctly.
21 Connect the hydraulic hoses and the cable harness to the

extension cylinder.
22 Fit sensor boom length, see Sensor, boom length, description,
page 8:19.
hydraulic system.
NOTE
the lock ring.

manual.
26 Calibrate sensor, boom length, see Load sensors, calibration,
page 8:13.


7 Load handling – Lift boom 7:39
7.3.10 Lift boom

Lift boom, general
See Lift boom, description, page 7:26.
Slide plates lift boom, changing
NOTE
When adjusting the side-mounted slide plates, it is important to
check the clearance for the whole travel of the boom.
NOTE
The inner boom must be centred in the outer boom.
Front slide plates

1 Position the boom to the lowest position with the inner boom
extended approx. 50 cm.
2 Remove the cover plate for the side-mounted slide plates and
remove the spacer plates and slide plate.
4 Check the clearance between the boom and slide plate, the
clearance should be 1 mm, adjust with spacer plates as required.
NOTE
The inner boom must be centred in the outer boom.
5 Remove the lock bolts and the slide plates' brackets, and pull out
the upper slide plates and the spacer plates.
1. Side-mounted slide plates
6 Unload the lower slide plates, lift the inner boom at the front edge
2. Lower slide plates and use wooden spacers.
WARNING
Risk of crushing!
Secure the inner boom in relation to the outer boom
with wooden blocks.
7 Remove the lock bolts, slide plates' brackets and pull out the lower
slide plates.
8 Transfer the nuts for the lock bolts for the lower slide plates to
the new slide plates.
9 Install the new lower slide plates, lock bolts, and brackets.
10 Remove the wooden blocks and let down the inner boom so that it
rests on the lower slide plates.
11 Transfer the nuts for the lock bolts for the upper slide plates to
12 Install the new slide plates, spacer plates, lock bolts, 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.

7:40 7 Load handling – Lift boom
Rear slide plates

14 Start the engine and run in the boom completely (fully retracted).
15 Remove the cover plate for the side-mounted slide plates and
remove the spacer plates and slide plate.
17 Check the clearance between the boom and slide plate, the
clearance should be 1 mm, adjust with spacer plates as required.
18 Unload the lower slide plates, use wooden spacers.
WARNING
Risk of crushing!
1. Upper slide plates Secure the inner boom in relation to the outer boom
2. Side-mounted slide plates with wooden blocks.
3. Lower slide plates
19 Remove the cover plates, spacer plates, and the lower slide plates.
20 Install new slide plates, spacer plates and cover plate.
21 Unload the upper slide plates, use wooden spacers.
WARNING
Risk of crushing!
Secure the inner boom in relation to the outer boom
with wooden blocks.
22 Remove the lock bolts, the slide plates' brackets, and pull out the
upper slide plates and the spacer plates.
23 Transfer the nuts for the lock bolts for the upper slide plates to
24 Install the new slide plates, spacer plates, lock bolts, and brackets.
25 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
26 Fully extend the inner boom and lubricate the slide surfaces inside
the outer boom and on the inner boom with lubricating grease
for slide plates.
016265
Slide surfaces, boom

27 Run the boom in and out about 10 times and stop with the boom
fully out.
28 Wipe away excess lubricant at the slide plates and on the slide
surfaces.

7 Load handling – Sensor boom length 7:41
7.3.11 Sensor boom length

Sensor boom length, general
See Sensor, boom length, description, page 8:19.



7:42 7 Load handling – Side shift
7.4 Side shift

Side shift, description
Side shift means repositioning the attachment laterally. The attachment
can be side-shifted ± 800 mm from the centre position.
Control valve attachment pressurises the side shift cylinders that move
001113
the attachment's main beam in relation to the lift boom. Side shift is
controlled by Control lever (S8150).
Side shift, function description

Reference
Condition value Reference
Sensor, operator-in- Not activated Sensor operator in seat, description, page 9:23
seat
1 D1
2
D7902 D7950
D7971 D7911
3 7
D7
D7940
C11 8
D7930 D3
P1
4 9
T1 A B
LSP1 A H
LSP2 LSPR
LSP3
5 8 LSHY
LSP3X P T T P LSO
LSM
C6
10
6
016845

1 Control lever (S8150-ThumbX) sends Left: U = 0.5-2.0 V Control lever, description, page 7:6
voltage signals to Control unit KPU Zero position: U = 2.0-3.0 D1: Diagnostic menu, see 7.1 Controls and
(D7902). V Instr 6/XX DIAGNOSE, page 8:41
Right: U = 3.0-4.5 V
2 Control unit KPU (D7902) sends side Checked by control 11.5.3.2 KPU control unit (D7902), page
shift left or right on the CAN bus. system, error shown with 11:27
error code.
Solenoid valve engagement of 11:31
hydraulics for top lift (Y6003). D3: Diagnostic menu, see 10.4 Pumps 1/XX
DIAGNOSE, page 8:78


4 Solenoid valve engagement of - Solenoid valve, engagement of hydraulics for
hydraulics for top lift (Y6003) opens top lift, description, page 10:25
and sends a load signal to the hydraulic D3: Diagnostic menu, see 10.4 Pumps 1/XX
oil pump 3. DIAGNOSE, page 8:78
sends the load signal to hydraulic oil page 10:25
pump 3. Shuttle valves in servo valves Shuttle valve, description, page 10:26
functions are activated at the same
time.
6 Hydraulic oil pump 3 pumps oil from See the pressure plate on Axial piston pump with variable displacement,
the hydraulic oil tank. the left-hand frame beam. description, page 10:10
7 Control unit KAU (D7911) activates I = 330–570 mA 11.5.3.8 Control unit KAU (D7911), page
Solenoid valve side shift left (Y6020) or 11:38
Solenoid valve side shift right (Y6021). D7: Diagnostic menu, see 7.4 Side Shift
3/XX DIAGNOSE, page 8:44 or 7.4 Side Shift
8 Solenoid valve side shift left (Y6020) or - Attachment control valve, description, page
Solenoid valve side shift right (Y6021) 7:44
pressurises the side shift slide in D7: Diagnostic menu, see 7.4 Side Shift
control valve attachment. 3/XX DIAGNOSE, page 8:44 or 7.4 Side Shift
9 The control valve's side shift slide - Attachment control valve, description, page
changes position and pressurises the 7:44
side shift cylinders.
10 The side shift cylinders push in the - Side shift cylinder, description, page 7:47
main beam sideways in relation to the
side shift frame.
Hydraulic diagram top lift, see Hydraulic diagram top lift, page E:8.
Hydraulic diagram top lift, overheight legs, see Hydraulic diagram top
lift, overheight legs, page E:12.
Hydraulic diagram top lift hydraulic levelling, see Hydraulic diagram top
lift, hydraulic levelling, page E:10.

10:10.

7:44 7 Load handling – Control valve, attachment
7.4.3 Control valve, attachment

Attachment control valve, description
Side shift is controlled by a separate section in control valve attachment.
1
Control valve attachment controls the hydraulic functions on the
attachment. The control valve is fitted in the centre rear of the
2 6
attachment. Electric servo valves control the flow from the valve.
3 The control valve is an electro-hydraulically controlled, proportional and

pressure-compensated directional control valve. Electrically controlled
servo valves convert current to servo pressure. The servo pressure
4 controls the spring-centred valve slides that control pressure and flow
for the function in question. The valve slides have a flow limit so that
5 several functions can be used simultaneously. This enables them to
7
control the main flow.
The control valve has a built-in supply of pilot pressure. This means
that the valve has a built-in pressure reduction that converts feed
pressure to servo pressure for the various functions. The supply of pilot
pressure is common for all functions. This reduces pressure variations
due to long hoses and reduces the number of hoses to the valve.
The control valve has the following sections:

016996
• Side shift
• Spreading (positioning)
1. Solenoid valve, side shift right (Y6021)
• Rotation
2. Solenoid valve, side shift left (Y6020)
• Twistlocks
3. Feed from hydraulic oil pump 2
• Controllable tilt
4. Connection to side shift cylinder
• Hydraulic levelling
5. Connection to side shift cylinder
Side shift slide
6. Drain to tank (unfiltered)
7. Return to tank (through tank filter) The valve slide controls the direction and speed of side shift.
The valve slide is controlled by servo valve for side shift right and servo
valve for side shift left.
Servo valve, side shift left
Servo valve side shift left controls pressure to the side shift slide so that
the side shift slide opens and pressurises the side shift cylinder.
Servo valve, side shift left, is controlled electrically by Solenoid

valve, side shift left (Y6020), which is activated by Control unit KAU
(D7911). The servo valve directs servo pressure to the side shift slide
proportional to the control current to the solenoid valve.
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.8 ATTACH, menu 8.
Servo valve, side shift right
Servo valve side shift right controls pressure to the side shift slide so
that the side shift slide opens and pressurises the side shift cylinder.
Servo valve, side shift, is controlled electrically by Solenoid valve, side

shift right (Y6021), which is activated by Control unit KAU (D7911). The
servo valve directs servo pressure to the side shift slide proportional to
the control current to the solenoid valve.
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.8 ATTACH, menu 8.

7 Load handling – Control valve, attachment 7:45
Control valve attachment, checking hydraulic

pressure
NOTE
Safety.
0:00pm
1 Operate and warm up the machine so that the hydraulic oil is at
a operating temperature, at least 50 °C. As an alternative, operate
until the cooling fan is activated.
75° C 50% transmission and hydraulic system.
b 2 Machine in service position, see section B Safety.
c
50° C 50° C
016372

3 Connect a pressure gauge to pressure check connection PL on

control valve attachment.
4 Start the engine and run it at idle. Check the pressures in the
attachment's different functions by allowing each function go to its
end position and then reading off the pressure gauge.
Function Pressure
Side shift 16.0 MPa
Spreading (positioning) 12.0 MPa
Rotation 15.0 MPa
Pressure check connection, control valve attachment 15.0 MPa
Tilt control
Levelling 15.5 MPa
Twistlocks Same as feed pressure.
Overheight jacks, lowering 10.0 MPa
Lift jacks, knee in/out 13.0 MPa
Lift jacks, jack up/down 10.0 MPa
Lift jacks, clamping 13.0 MPa
measuring outlet.
Control valve attachment, replacement
NOTE
Safety.

NOTE

NOTE
from impurities.
4 Mark and disconnect the cable harness from the control valve.
5 Remove the control valve.
Remove the attaching bolts and lift away the valve. Place the valve
on a clean and protected surface.
6 Transfer the connection adapters to the new control valve.
NOTE
correctly.
NOTE
mixed up.

8 Fit the valve.
Lift the valve into place and install the attaching bolts.
marking.
the marking.
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.

13 Check that the valve\qs hydraulic connections are sealed.
14 Check that the attachment is working.
CAUTION
product damage.
manual.

7 Load handling – Side shift cylinder 7:47
7.4.5 Side shift cylinder

Side shift cylinder, description
The side shift cylinders are two hydraulic cylinders connected crosswise
1 that extend the attachment's main beam laterally in relation to the side
shift frame. The side shift cylinders are fitted along the front and rear of
10 the attachment and are used to centre the load's centre of gravity.
8 2
3
4
7 6 5 001500
1. Side shift frame

2. Side shift cylinder
3. Position sensor, spreading
4. Sensor, contact
5. Twistlock
6. Sensor twistlocks
7. Lock cylinder, twistlocks
8. Spreading boom
9. Spreader motor
10. Main beam, attachment


7:48 7 Load handling – Side shift frame
7.4.6 Side shift frame

Side shift frame, description
The attachment is secured in the boom with the rotation yoke. The side
1 2 3 4 5 6 shift frame is fitted under the rotation yoke. The attachment's main
beam is fitted in the side shift frame. The main beam can be extended
laterally in relation to the side shift frame with two hydraulic cylinders.
Inside the main beam are two spreader beams which can be extended
in and out with a hydraulic motor.
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 plates in the sides and in the bottom. The side shift cylinders
secure 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
levelled 5°. Side shift 800 mm.
000526
• Top lift with hydraulic levelling

1. Main beam The side shift frame is fitted in the rotation yoke with four hydraulic
cylinders that enable levelling to be controlled for adaptation to
2. Ring gear
angled containers. Side shift 800 mm. See Side shift frame,
3. Rotation motor unit description, page 7:101.
4. Rotation yoke
5. Control valve, attachment
6. Side shift frame
Slide plates, side shift frame, changing

1 Loosen 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.
016902
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.

7 Load handling – Side shift frame 7:49
6 Install the new slide plate.

7 Check the slide plate's clearance by measuring the distance
between slide plate and the edge of the cover plate. The clearance
between the attachment's main beam and slide plates must be
1 mm.
8 Install the spacer plates until the distance is correct.
9 Install the cover plate.

10 Repeat steps 7 - 10 on the other slide plates.
Lubrication
11 Lubricate the slide surfaces of the attachment with lubricating
grease for the slide plates.
016902
004875
Slide surfaces, attachment

12 Operate full side shift from right to left approx. 10 times.
surfaces.

7:50 7 Load handling – Side shift frame
Lower slide plates, side shift frame, changing

1 Position axle stands or similar under the attachment's spreader
booms and lower the attachment on the stands so that the side
shift frame's lower slide plates are exposed.
2 Switch off the engine and switch off the main electric power.
3 Place spacers between the cross member and the attachment's
main boom on both cross members
DANGER
Risk of crushing!
Place spacers between the cross member and the
attachment's main boom on both cross members.
4 Remove the attaching bolts and remove the slide plates.

5 Install new slide plates.
6 Remove the spacer.
8 Lift the attachment and remove the stands.
Checking the attachment's levelling

9 Park machine a completely level surface.
The figure shows loose cross member
10 Lower the boom and fully retract the extension and centre the
attachment.
11 Measure the distance between the extension beam and the ground
at all four corners of the attachment.
The difference between the dimensions (A) and (B) side must not
be more than 50 mm at 20' position, or 100 mm for 40' position.
Check the dimensions with the attachment in both 20'and
40'-position.
NOTE
Take into account that the tilt of the attachment affects the
A B position. The dimensions refer to horizontal attachment and
008217
machine.
Measuring points, levelling, attachment
12 If necessary, adjust the lower slide plates so that the attachment
is straight.
Lubrication

7 Load handling – Main beam, attachment 7:51
004875
Slide plates, attachment
14 Operate full side shift from right to left approx. 10 times.
surfaces.
7.4.7 Main beam, attachment

Main beam attachment, description
The main beam attachment is fitted 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). The control valves for the
attachment's hydraulic functions are also fitted on the attachment's
main beam.
000526
1. Main beam
2. Ring gear
3. Rotation motor unit
4. Rotation yoke
6. Side shift frame

7:52 7 Load handling – Relief valve top lift
7.4.8 Relief valve top lift

Relief valve top lift, description
Relief valve top lift opens a connection between the attachment's
pressure feed and tank. This is used to drain the pressure in the hoses
for the attachment before working on the hydraulic system. The relief
valve is fitted at the rear of the lifting beam in front of the transmission.
016255



7 Load handling – Spreading (positioning) 7:53
7.5 Spreading (positioning)

Spreading, description
Damping
Spreading means that the width between twistlocks is changed.

Spreading has 20-foot and 40-foot stops; stops at other distances are
available as options, such as 30-foot stop.
001114
Control valve attachment pressurises Valve block spreader motor that
controls the pressure to the spreader motor. The spreader motor pulls
the spreader chains that pull spreading booms in and out.
Spreading is controlled by Control lever (S8150). Inductive position

sensors indicates the position of the spreader units.
Damping
approaching the end positions. Three to four seconds after the
damping has been activated the function is interrupted. This means
that the mechanics are loaded less when stopping in the end positions.
Position sensors detect when damping should be activated. When


7:54 7 Load handling – Spreading (positioning)
Spreading, function description

Twistlocks Unlocked or bypass Twistlocks, description, page 7:107
activated Bypass, description, page 8:6
Overload system Passive Overload system, description, page 8:5
1 D1
+ 2
D7902 D7950
D7971 D7911
3 7, 13
D7940 D7
D7930 8
14 D12
C9
D3
P1
4 9, 15
T1 A B
LSP1 A H
LSP2 LSPR
LSP3
5 8 LSHY
LSP3X P T T P LSO
LSM 10
C6 12
11, 16
6
016847

1 Switch shift button (S1991) and Control Shift button: U = 24 V Control lever, description, page 7:6
lever (S8150-ThumbX) send voltage In: U = 0.5–2.0 V D1: Diagnostic menu, see 7.1 Controls and
signals to Control unit KPU (D7902). Instr 6/XX DIAGNOSE, page 8:41 and 7.1
Zero position: U = 2.0-3.0
V Controls and Instr 7/XX DIAGNOSE, page
8:41.
Out: U = 3.0–4.5 V
spreading in or out on the CAN bus. system, error shown 11:27
with error code.
Solenoid valve engagement of hydraulics 11:31
for top lift (Y6003). D3: Diagnostic menu, see 10.4 Pumps
4 Solenoid valve engagement of hydraulics - Solenoid valve, engagement of hydraulics
for top lift (Y6003) opens and sends a for top lift, description, page 10:25
load signal to the hydraulic oil pump 3. D3: Diagnostic menu, see 10.4 Pumps


5 Servo valve load handling steering sends - Valve block servo pressure, description,
the load signal to hydraulic oil pump 3. page 10:25
Shuttle valves in servo valves select the Shuttle valve, description, page 10:26
strongest load signal if other functions
are activated at the same time.
6 Hydraulic oil pump 3 pumps oil from the See the pressure plate on Axial piston pump with variable
hydraulic oil tank. the left-hand frame beam. displacement, description, page 10:10
Solenoid valve spreading out (Y6018) or 11:38
Solenoid valve spreading in (Y6019). D7: Diagnostic menu, see 7.5 Spreading
10/XX DIAGNOSE, page 8:45 or 7.5
Spreading 11/XX DIAGNOSE, page 8:46
8 Solenoid valve, spreading out (Y6018) - Attachment control valve, description, page
or Solenoid valve, spreading in (Y6019) 7:44
pressurises the spreader slide in the D7: Diagnostic menu, see 7.5 Spreading
attachment's control valve. 10/XX DIAGNOSE, page 8:45 or 7.5
9 The control valve's spreader slide - Attachment control valve, description, page
changes position and direct pressure to 7:44
the spreader motor.
10 The motor valve block directs the - Valve block spreader motor, description,
pressure to the motor and prevents the page 7:60
motor from pumping (rotating faster than
supplied pressure).
11 The motor drives the chains that extend - Spreader motor, description, page 7:61
or retract the spreader beams.
12 Sensor, end position 20'-40' (B7690) Sensor directly opposite Position sensor spreading, description,
sends voltage signals to Control unit indicator plate: U 24 V page 7:71
KAU (D7911). D12: Diagnostic menu, see 7.5 Spreading
13 Control unit KAU (D7911) reduces - 11.5.3.8 Control unit KAU (D7911), page
the control current to Solenoid valve, 11:38
spreading out (Y6018) or Solenoid valve, D7: Diagnostic menu, see 7.5 Spreading
spreading in (Y6019). 10/XX DIAGNOSE, page 8:45 or 7.5
14 Solenoid valve, spreading out (Y6018) - Attachment control valve, description, page
or Solenoid valve, spreading in (Y6019) 7:60
reduces the pressure to the spreader D7: Diagnostic menu, see 7.5 Spreading
slide in the attachment's control valve. 10/XX DIAGNOSE, page 8:45 or 7.5
15 The control valve's spreader slide - Attachment control valve, description, page
changes position and reduces the 7:60
pressure to the spreader motor.
16 The speed of the spreader motor is - Spreader motor, description, page 7:61
reduced.

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

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

Twistlocks Unlocked or bypass Twistlocks, description, page 7:107
D1
1
2
+
3
D2 D7902 D7950
D7971 D7911
4, 6, 8 D5 D7
D4 5 7
Pos Explanation Signal description Reference 016857
1 Switch, stop at 30'-35' (S1004) sends Switch off: Switch, stop at 30' or 35', description , page
voltage signals to Control unit KPU Conn. 4: U = 0 V 7:11
(D7902). D1: Diagnostic menu, see 7.5 Spreading
Switch on:
Conn. 4: U = 24V
lever (S8150-ThumbX) send voltage In: U = 0.5–2.0 V D2: Diagnostic menu, see 7.1 Controls and
signals to Control unit KPU (D7902). Instr 6/XX DIAGNOSE, page 8:41 and 7.1
Zero position: U = 2.0-3.0
V Controls and Instr 7/XX DIAGNOSE, page
8:41.
Out: U = 3.0–4.5 V
spreading 30' on the CAN bus. system, error shown 11:27
with error code.
4 Spreading is activated in the same way - Spreading, function description, page 7:54
as in normal spreading, steps 9 – 13.
5 When spreading approaches the 30' Sensor directly opposite Position sensor spreading, description,
position, Sensor end position 30' indicator plate: U = 24 V page 7:71
(B7770) sends a voltage signal to D5: Diagnostic menu, see 7.5 Spreading
Control unit KAU (D7911). 8/XX DIAGNOSE, page 8:45


6 Control unit KAU (D7911) dampens the - Spreading, function description, page 7:54
speed in the same way as in normal
spreading, steps 15 – 18.
7 When spreading is at the 30' position, Sensor directly opposite Position sensor spreading, description,
Sensor end position 20'-40' (B7690) indicator plate: U = 24 V page 7:71
sends a voltage signal. D7: Diagnostic menu, see 7.5 Spreading
8 Spreading is interrupted by Control unit U=0V Attachment control valve, description, page
KAU (D7911) disconnecting the current 7:60
to Solenoid valve, spreading out (Y6018) D4: Diagnostic menu, see 7.5 Spreading
or Solenoid valve, spreading in (Y6019). 10/XX DIAGNOSE, page 8:45 or 7.5

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

with Switch, automatic spreading 20'-40'. When the switch is activated,
spreading automatically moves to the next end position when spreading
is activated with Control lever (S8150). During automatic spreading the
buzzer on the attachment sounds.
016349
If the machine is also equipped with 30' or 35'-stop and this is activated,
then spreading stops at this stop. Activate spreading again in order
Event menu automatic spreading 20'-40' to go to the next position.
Automatic spreading functions both during spreading in and spreading

out.
Automatic spreading 20-40 foot, function

description

Control breaker Not activated Control breaker voltage, function description, page 11:19
Twistlocks Unlocked or bypass Twistlocks, function description, page 7:103
Doors Closed Doors, description, page 9:86
Parking brake Released Parking brake system, function description, page 4:35
D2
2
1
+
3 7
D1 D7902 D7950
D7971 D7911
4, 5, 9, 11 D10 D7
D5
D4 10 8
6
016851

1 Switch shift button (S1991) and Shift button: U = 24 V Control lever, description, page 7:6
Control lever (S8150-ThumbX) In: U = 0.5–2.0 V D1: Diagnostic menu, see 7.1 Controls and Instr
send voltage signals to Control unit 6/XX DIAGNOSE, page 8:41 and 7.1 Controls
KPU (D7902). Zero position: U = 2.0-3.0
V and Instr 7/XX DIAGNOSE, page 8:41.
Out: U = 3.0–4.5 V
2 Switch, automatic spreading 20'-40' Switch off: Switch automatic spreading, description, page
(S1012-2) sends voltage signals to Conn. 4: U = 0 V 7:11
Control unit KPU (D7902). D2: Diagnostic menu, see section 7.5 Spreading
Switch on:
Conn. 4: U = 24V


3 Control unit KPU (D7902) sends Checked by control 11.5.3.2 KPU control unit (D7902), page 11:27
"automatic spreading out" or system, error shown
"automatic spreading in" on the with error code.
CAN bus.
4 Control unit KAU (D7911) activates - Spreading, function description, page 7:54
spreading in the same way as in D4: Diagnostic menu, see 7.5 Spreading 10/XX
normal spreading, steps 2 - 11. DIAGNOSE, page 8:45 or 7.5 Spreading 11/XX
DIAGNOSE, page 8:46
5 Control unit KAU (D7911) activates Buzzer active: U = 24 V Buzzer automatic spreading 20'-40', description,
Buzzer, automatic spreading page 7:72
(H9003). D5: Diagnostic menu, see section 8 Control
system, group 8.4.9.15 ATTACH, menu 15
6 Buzzer automatic spreading Buzzer active: U = 24 V Buzzer automatic spreading 20'-40', description,
(H9003) generates acoustic page 7:72
warning signal. D5: Diagnostic menu, see section 8 Control
7 When automatic spreading is - 11.5.3.3 Control unit, KID (D7950), page 11:29
active, the KID control unit (D7950)
activates the Automatic Spreading
event menu.
8 When spreading approaches the Sensor directly opposite Position sensor spreading, description, page
30' position, Sensor end position indicator plate: U = 24 V 7:71
30' (B7770) sends a voltage signal D7: Diagnostic menu, see 7.5 Spreading 8/XX
to Control unit KAU (D7911). DIAGNOSE, page 8:45
9 Control unit KAU (D7911) dampens - Spreading, function description, page 7:54
spreading in the same way as in
normal spreading, position 13-16.
10 When spreading is at the 20', 30' Sensor directly opposite Position sensor spreading, description, page
or 40' position, Sensor end position indicator plate: U = 24 V 7:71
20'-40' (B7690) sends a voltage D10: Diagnostic menu, see 7.5 Spreading 8/XX
signal to Control unit KAU (D7911). DIAGNOSE, page 8:45
11 Control unit KAU (D7911) interrupts I = 0 mA Attachment control valve, description, page 7:60
the control current to Solenoid D4: Diagnostic menu, see 7.5 Spreading 10/XX
valve, spreading out (Y6018) DIAGNOSE, page 8:45 or 7.5 Spreading 11/XX
or Solenoid valve, spreading in DIAGNOSE, page 8:46
(Y6019).

10:10.


Spreading is controlled by a separate section in the attachment's control
1 valve. For a more detailed description of the valve and component
locations, see Attachment control valve, description, page 7:44.
2 6
Spreader slide
3 The valve slide controls the direction and speed of spreading. The
valve slide is controlled by the servo valve for spreading out and the
4 servo valve for spreading in.
Servo valve, spreading out
5
7 Servo valve spreading out controls the pressure to the spreader slide
so that it opens and pressurises the spreader motor.
The servo valve is controlled electrically by Solenoid valve, spreader

out (Y6018), which is activated by Control unit KAU (D7911). The servo
valve directs servo pressure to the spreading slide proportional to the
control current to the solenoid valve.
016997
Servo valve, spreading in

1. Solenoid valve, spreading out (Y6018)
Servo valve spreading in controls the pressure to the spreader slide so
2. Solenoid valve, spreading in (Y6019) that it opens and pressurises the spreader motor.
The servo valve is controlled electrically by Solenoid valve, spreader in
4. Connection to spreader motor (Y6019), which is activated by Control unit KAU (D7911). The servo
5. Connection to spreader motor valve directs servo pressure to the spreading slide proportional to the
control current to the solenoid valve.
6. Drain to tank (unfiltered)
7. Return to tank (through tank filter) The signal can be checked with the diagnostic menu, see 7.5 Spreading

See Control valve attachment, replacement, page 7:45.
7.5.5 Valve block spreader motor

Valve block spreader motor, description
Valve block spreader motor regulates the oil's direction to the spreader
motor. The valve block is fitted on the spreader motor all the way 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. Valve
block spreading contains overcentre valves that block the outlet if the
pressure on the outlet side is higher than the pressure on the inlet side.

7 Load handling – Spreader motor 7:61
7.5.6 Spreader motor

Spreader motor, description
Via two chains, the spreader motor moves the spreader beams in and
out in the attachment's main beam. The spreader motor is fitted all the
1 way out to the left on the front side of the attachment's main beam.
The hydraulic motor is integrated with a planetary gear that reduces

speed and makes the motor more powerful. Fitted on the hydraulic
connections is a valve block with two overcentre valves that prevents
2 the motor from rotating faster than the supplied hydraulic pressure.
3
016953
Spreader motor
1. Filling point
2. Sight glass
3. Drain plug
Spreader motor, replacement
NOTE
Safety.

2 Remove the cover plate on the left-hand side of the attachment's
main beam.

7:62 7 Load handling – Spreader motor
3 Start the engine and run spreading out until the chain tensioners
are visible in the inspection holes.
NOTE
7 Measure and note the chain tensioners' length to attain the correct
chain tension when refitting.
8 Slacken the chain tensioner on the engine side and remove the
chain from the tensioner.
9 Remove the protective plate from over the spreader motor.
10 Mark up and detach the hydraulic hoses from the valve block to
the spreader motor.

7 Load handling – Spreader motor 7:63
11 Remove the protective plate at the spreader motor's gear.

12 Remove the spreader motor unit.
017411
13 Transfer the valve block to the new motor unit.
NOTE
correctly.
14 Clean the contact surfaces between the planetary gear and the
attachment's main beam.
15 Fit the motor unit. Position the chain on the motor's chain wheel
before the motor and protection plate are bolted in.
Tighten the bolts crosswise in steps until 117 Nm is achieved.
16 Attach the hydraulic hoses to the valve block on the motor.
017411

7:64 7 Load handling – Spreader chains
17 Connect the spreader chain to the chain tensioner. Check that the
chain runs straight in the chain wheel on the hydraulic motor.
18 Tension the spreader chain to the same measurement as before.
hydraulic system.
NOTE
the lock ring.

21 Check that the hydraulic connections are sealed tightly.
22 Check that the spreading is working.
23 Check the tension of the spreader chains, see Maintenance
Manual, section 7 Load Handling, group 7.5.7 Spreader chains.
24 Fit the protective plate to the spreader motor's gear.
25 Fit the protective plate over the motor.
26 Brush the spreader chain with lubricating grease.
27 Fit the cover plates on the attachment's main beam.
manual.
7.5.7 Spreader chains

Spreader chains, description
The spreader chains move the extension beams in and out of the
attachment's main beam. The force from the spreader motor is
transferred to the 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 extension
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
Principle diagram, spreader chains
Spreader chain, changing

1 Park the machine with the attachment as far down as possible.
2 Remove the cover plates on the attachment's main beam.

7 Load handling – Spreader chains 7:65
3 Start the engine and run spreading out until the chain tensioners
are visible in the inspection holes.
4 Switch off the engine and switch off the main electric power.
005105
5 Slacken the chain tensioner on the defective chain and remove it

from the tensioner.
NOTE
Measure and note the chain tensioners' length to attain the
correct chain tension when refitting.
005105
6 Remove the chain wheel on the defective chain.
NOTE
Note the location of the spacer ring.
If the chain wheel on the engine side must be removed, first

remove the spreader motor. See Spreader motor, replacement,
page 7:61.
7 Pull the chain out through the hole for the chain wheel 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.
9 Pull out the spreader beam.

Use a machine or similar to pull the spreader beam out of the
attachment's main beam. Stop when the spreader beam is close
to the 40-foot stop.
NOTE
Support the spreader beam to minimise breaks. If necessary,
remove the upper slide plates to reduce resistance.
10 Remove the boom stop from the attachment's main beam.

11 Remove the hydraulic hoses' clamping on the attachment's main
beam.
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.

7 Load handling – Spreader chains 7:67
16 Fasten the chain along the cable rack so that it runs straight along
the spreader beam.
17 Brush grease on the chain.
18 Slide in the spreader beam so that the extension stop can be fitted.
19 Fit the extension stop.
20 Connect the cable rack to the attachment's main beam.
21 Fit the hydraulic hoses' clamping on the attachment's main beam.
22 Slide in the spreader beam until it is inserted the same amount
as the other one. This is important in order to facilitate the fitting
of the chains.
23 Detach the chain from the cable rack and insert it through the
chain wheel's hole.
24 Fit the chain wheel. The spacer ring must be fitted on the
underside of the chain wheel.
If the rotation motor has been removed, refit it. See Spreader
motor, replacement, page 7:61.
NOTE
Check that the chain runs straight in the chain wheels.

25 Connect the chain to the chain tensioner.
NOTE
Use a new split pin.
005105
26 Lubricate the chain wheel's bearings with lubricating grease.

27 Tension the spreader chain to the same measurement as before.
Tighten the lock nut.
28 If the slide plates have been removed, refit them.
30 Check that spreading is working correctly.
32 Check the tension of the spreader chains, see Maintenance
Manual, section 7 Load Handling, group 7.5.7 Spreader chains.
33 Fit the cover plates on the attachment's main beam.

7 Load handling – Spreader beam 7:69
7.5.8 Spreader beam

Spreader beam, description
The spreader beams are the part of the attachment that grips the
1 container. Two spreader beams run along in the main beam. The
spreader beams are slid in and out via the spreader motor and
10 spreader chains.
The spreader beam houses twistlocks. See Twistlocks, description,

9
page 7:107.
8 2
3
4
7 6 5 001500
1. Side shift frame

2. Side shift cylinder
3. Position sensor, spreading
4. Sensor, contact
5. Twistlock
6. Sensor twistlocks
7. Lock cylinder, twistlocks
8. Spreading boom
9. Spreader motor
10. Main beam, attachment
Slide plates extension beam, changing

2 Unload the tension from the slide plate in question.
The pressure can be relieved from the slide plates by raising the
outer edge of the extension beam or inserting wedges to alter the
position of the extension beam in the main beam.
The illustration shows inner slide plates in the


7:70 7 Load handling – Spreader beam
3 Remove the attaching bolts for the slide plate's bracket.

4 Remove the slide plate's guide screw.
5 Pull out the slide plate with spacer plate and bracket.
The illustration shows inner slide plates in the

6 Align the new slide plate in the correct position.

Check the clearance between extension beam and slide plate.
The clearance should be max. 1 mm with all slide plates fitted.
Use a spacer plate to adjust the clearance.
7 Fit the slide plate's bracket and guide screw.
Lubrication
004875
9 Operate spreading in and out fully approximately 10 times and

check the spreading function.
surfaces.
11 Try to lift a container and then check the extension beams'
clearance again on the attachment's main beam.

7 Load handling – Main beam, attachment 7:71
7.5.9 Main beam, attachment

Main beam attachment, description
See Main beam attachment, description, page 7:51.
7.5.10 Position sensor, spreading

Position sensor spreading, description
The spreading position sensors indicate the position of the spreader
1 2 3 4 5
beams. The position sensors are used to control spreading so that
the twistlocks fit the container. The position sensors are fitted under
the protective plate on the top of the attachment's main beam on the
left-hand side.
Sensor, end position 20'-40' (B7690) indicates end position for 20

and 40-foot containers. The sensor detects the spreader beam end
positions via two indicator plates on the top of the spreader beams.
The sensor is used to activate damping.
With the 30-foot stop option, one extra sensor is fitted, Sensor, end
position 30' (B7770), and two indicator plates. The sensor is used to
activate 30-foot stop.
The sensors are supplied with voltage by, and send a 24 V signal to
Control unit KAU (D7911) when the indicator plates pass the sensor.
Indicator plates on the spreader units are fitted 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 with the diagnostic menu, see 7.5
Spreading 8/XX DIAGNOSE, page 8:45.
003165
1. Indicator plate 20'

2. Sensor, end position 20'-40' (B7690)
3. Sensor, end position 30' (B7770)
4. Indicator plate, 30' or 35'
5. Indicator plate 40'

See Position sensor, checking and adjustment, page 7:5.

See Relief valve top lift, description, page 7:52.


7:72 7 Load handling – Buzzer, automatic spread 20'-40'
7.5.13 Buzzer, automatic spread 20'-40'

Buzzer automatic spreading 20'-40', description
The buzzer for automatic spreading 20'-40' (H9003) is fitted on the front
of the attachment on machines equipped with automatic spreading
20'-40'. The buzzer is activated during automatic spreading movement.


7 Load handling – Rotation 7:73
7.6 Rotation
Rotation, description
The attachment can be rotated +195° - 105° in relation to the machine.
Control valve attachment pressurises Valve block rotation motor. Valve

block rotation motor routes pressure to the rotation motors that rotate
the attachment. Rotation is controlled by Control lever (S8150). The
016202
voltage signal controls direction and speed (clockwise or anticlockwise).
Rotation, function description

Reference
Sensor, operator-in-seat Not Sensor operator in seat, description, page 9:23
activated
1 D1
2 16
D7902 D7950
D7971 D7911
3 7, 14, 15
D7940
D7
D7930
C11 8
D3 D13
P1
4 9
T1 A B
LSP1 A H
LSP2 LSPR
LSP3
5 8 LSHY
LSP3X P T T P LSM
LSO 10
C6
11 13
12
6
016848

7:74 7 Load handling – Rotation

1 Control lever (S8150-ThumbY) Anticlockwise: U = 0.5-2.0 V Control lever, description, page 7:6
sends voltage signals to Control unit Zero position: U = 2.0-3.0 V D1: Diagnostic menu, see 7.1 Controls and
KPU (D7902). Instr 6/XX DIAGNOSE, page 8:41.
Clockwise: U = 3.0-4.5 V
0.5 V and 4.5 V represent
the maximum rotation speed.
Lower voltage than 0.5 V and
higher voltage than 4.5 V is
used to detect faults in cable
rotation clockwise or rotation error shown with error code. 11:27
anticlockwise on the CAN bus.
Solenoid valve engagement of 11:31
hydraulics for top lift (Y6003). D3: Diagnostic menu, see 10.4 Pumps 1/XX
DIAGNOSE, page 8:78
hydraulics for top lift (Y6003) opens top lift, description, page 10:25
and sends a load signal to the D3: Diagnostic menu, see 10.4 Pumps 1/XX
hydraulic oil pump 3. DIAGNOSE, page 8:78
sends the load signal to hydraulic page 10:25
oil pump 3. Shuttle valves in servo
valves select the strongest load
signal if other functions are activated
at the same time.
6 Hydraulic oil pump 3 pumps oil from See the pressure plate on the Axial piston pump with variable displacement,
the hydraulic oil tank. left-hand frame beam. description, page 10:10
Solenoid valve rotation clockwise 11:38
(Y6008) or Solenoid valve rotation D7: Diagnostic menu, see 7.6 Rotation 1/XX
anticlockwise (Y6009). DIAGNOSE, page 8:46 and 7.6 Rotation
8 Solenoid valve rotation clockwise - Attachment control valve, description, page
(Y6008), or Solenoid valve rotation 7:76
anticlockwise (Y6009), pressurises D7: Diagnostic menu, see 7.6 Rotation 1/XX
the rotation slide in control valve, DIAGNOSE, page 8:46 and 7.6 Rotation
attachment. 2/XX DIAGNOSE, page 8:47.
9 The rotation slide in Control valve, - Attachment control valve, description, page
attachment changes position and 7:76
controls the pressure to the Valve
block hydraulic motor.
10 Valve block hydraulic motor routes - Valve block rotation motor, description, page
pressure to both the hydraulic 7:76
motors and their disc brakes.
11 The hydraulic motors' disc brakes - Rotation motor unit, description, page 7:77
are disengaged.
12 The hydraulic motors rotate the - Rotation motor unit, description, page 7:77
attachment.
13 Rotation stop Sensor directly opposite Sensor rotation stop, description, page 7:82
Sensor, rotation stop (B7225) sends indicator plate: U = 24 V D3: Diagnostic menu, see 7.6 Rotation 3/XX
voltage signals to Control unit KAU DIAGNOSE, page 8:47
(D7911).


14 Rotation stop - Attachment control valve, description, page
The rotation is stopped by Control 7:76
unit KAU (D7911) disconnecting D7: Diagnostic menu, see 7.6 Rotation 1/XX
the current to Servo valve rotation DIAGNOSE, page 8:46 and 7.6 Rotation
clockwise (Y6008) or Servo valve 2/XX DIAGNOSE, page 8:47.
rotation anticlockwise (Y6009).
15 Rotation stop Checked by control system, 11.5.3.8 Control unit KAU (D7911), page
Control unit KAU (D7911) sends error shown with error code. 11:38
rotation stop on the CAN bus.
16 Rotation stop - 11.5.3.3 Control unit, KID (D7950), page
When the rotation stop has been 11:29
achieved the KID control unit
(D7950) activates the event menu
for rotation stop.
Use bypass to rotate past the
rotation stop

10:10.


Rotation is controlled by a separate section in the attachment's control
1 valve. For a general description of the valve and component locations,
see Attachment control valve, description, page 7:44.
2 6 Rotation slide
The valve slide controls the direction and speed of rotation. The valve
3 slide is controlled by Servo valve rotation clockwise and Servo valve
4 rotation anticlockwise.
Servo valve, rotation clockwise
5 Servo valve, rotation clockwise controls pressure to the rotation slide
7 so that the rotation slide opens and pressurises the rotation motors.
Servo valve rotation clockwise is controlled electrically by Solenoid

valve rotation clockwise (Y6008), which is activated by Control unit
KAU (D7911). The servo valve directs servo pressure to the rotation
slide proportional to the control current to the solenoid valve.
The signal can be checked with the diagnostic menu, see 7.6 Rotation
016995
Servo valve, rotation anticlockwise
1. Solenoid valve rotation clockwise (Y6008) Servo valve, rotation anticlockwise controls pressure to the rotation
slide so that the rotation slide opens and pressurises the rotation
2. Solenoid valve rotation anticlockwise (Y6009)
motors.
Servo valve rotation anticlockwise is controlled electrically by Solenoid
4. Connection to rotation motor
valve rotation anticlockwise (Y6009), which is activated by Control unit
5. Connection to rotation motor KAU (D7911). The servo valve directs servo pressure to the rotation
6. Drain to tank (unfiltered) slide proportional to the control current to the solenoid valve.
7. Return to tank (through tank filter) The signal can be checked with the diagnostic menu, see 7.6 Rotation

7.6.5 Valve block rotation motor

Valve block rotation motor, description
Valve block rotation motor controls pressure to the rotation motors. The
valve block is fitted on one of the rotation motors.
The valve block provides a controlled rotation by preventing the load

1 2 from pulling away and provides faster rotation than that provided by
the hydraulic motor. The valve block contains a shuttle valve and
6 overcentre valves.
3
5
016905
4
1. Hydraulic motor rotation
2. Valve block rotation motor
3. Ring gear
4. Gear wheel
5. Planetary gear
6. Disc brake

7 Load handling – Rotation motor unit 7:77
7.6.6 Rotation motor unit

Rotation motor unit, description
The rotation motors rotate the attachment in relation to the boom. The
motors are fitted along the front of the attachment's rotation yoke. The
motors work against the ring gear between the rotation yoke and the
1 side shift frame. The rotation motor unit consists of hydraulic motor,
2
disc brake and planetary gear which are built together into one unit.
6 The hydraulic motor is fitted on the disc brake's housing. A gear wheel
3 is fitted between the motor and the discs.
5 The disc brake prevents accidental rotation. The disc brake is applied
with springs and is disengaged when the hydraulic pressure is built up
016905
4 to rotate the yoke.
1. Hydraulic motor rotation The planetary gear reinforces the output in the motor and disc brake.
2. Valve block rotation motor The planetary gear changes down the motor's rotation speed so that
motor power is greater.
3. Ring gear
4. Gear wheel
5. Planetary gear
6. Disc brake
Rotation motor unit, changing
NOTE
Safety.

NOTE
3 Mark up and disconnect the hydraulic hoses from motor.
NOTE
from impurities.
4 Remove the hydraulic motor's attaching bolts.

7:78 7 Load handling – Rotation motor unit
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.
9 Connect the hydraulic hoses to the motor and brake according

to the marking.
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.

12 Check that the hydraulic connections are sealed tightly.
13 Check that the rotation works.
manual.

7 Load handling – Rotation yoke 7:79
7.6.7 Rotation yoke

Rotation yoke, description
The rotation yoke is the part of the attachment that connects the
1 2 3 4 5 6 attachment to the boom. The rotation yoke is secured on the inner
boom with two shafts that run in bearing-equipped attaching lugs. The
ring gear is fitted in the bottom of the rotation yoke 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

movement (so-called tilt). The oscillating motion is dampened by two
hydraulic cylinders that are secured between the upper yoke and the
upper edge of the inner boom.
000526
1. Main beam
2. Ring gear
4. Rotation yoke
6. Side shift frame
Rotation yoke, changing

1 Clean the attachment and boom nose.
2 Disconnect the attachment from the boom.
3 Remove the rotation motors from the rotation yoke.
4 Install the lifting equipment on the rotation yoke.
5 Remove the pipes for ring gear lubrication.
The illustration shows removed rotation yoke and ring

gear.

7:80 7 Load handling – Rotation yoke
6 Remove the rotation yoke's attaching bolts.

7 Lift away the rotation yoke.
8 Clean the contact surfaces on the ring gear.
9 Remove the plastic plugs and clean the threads and holes on the
new rotation yoke, clean the contact surface against the ring gear.
10 Transfer parts to the new rotation yoke.
• Grease cups
• Mounting pins
11 Transfer the lifting equipment to the new rotation yoke.

12 Lift the new rotation yoke into place.
NOTE
Align the position against that of the ring gear so that the
lubrication lines can be installed.
13 Brush the rotation yoke's mounting pins with grease and install
them in the rotation yoke.
14 Tighten the rotation yoke's attaching bolts to a torque of 331 Nm.
15 Install the pipes for the ring gear's lubrication lines.

16 Lubricate the ring gear with grease.
Rotate the yoke during lubrication it so that the grease is distributed
evenly.
17 Rotate the yoke so that it is aligned straight.
18 Fit the rotation motors. See Rotation yoke, description, page 7:79.
NOTE
If necessary, rotate the rotation yoke slightly so that the rotation
motor's gear wheel aligns against the ring gear.
19 Connect the attachment to the boom.
NOTE
Make sure you lubricate the shaft and bearing surfaces with
lubricating grease before installation.
20 Start the motor and check that the rotation works.

21 Clean the attachment.
manual.
23 Retighten the rotation yoke's attaching bolts after 50 hours
operating time with a torque of 331 Nm.

7 Load handling – Ring gear 7:81
7.6.8 Ring gear

Ring gear, description
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 2
6
3
5
016905
4
1. Hydraulic motor rotation
3. Ring gear
4. Gear wheel
5. Planetary gear
6. Disc brake
Ring gear, changing

1 Remove the rotation yoke, see Rotation yoke, changing, page
7:79.
2 Remove the lubricating pipes from the ring gear.
NOTE
Note the locations of the lubricating pipes to facilitate reinstalling.
3 Remove the attaching bolts between the ring gear and the side
The illustration shows removed rotation yoke and ring shift frame.
gear.
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

then fit them. Tighten the bolts crosswise in steps until 331 Nm is
achieved.
8 Install the rotation yoke, see Rotation yoke, changing, page 7:79.
9 Install the lubricating pipes for the ring gear.

10 Lubricate the ring gear with grease.
11 Start the motor and check the function of the rotation.
manual.
The illustration shows removed rotation yoke and ring 13 Retighten the rotation yoke's attaching bolts after 50 hours
gear. operating time with a torque of 331 Nm.

See Side shift frame, description, page 7:48.

7:82 7 Load handling – Sensor rotation stop
7.6.10 Sensor rotation stop

Sensor rotation stop, description
Sensor, rotation stop (B7225) indicates when the rotation is 25° from
the centre position and is used to activate the rotation stop. The sensor
is fitted on a bracket on the left-hand side of the rotation yoke and
detects 25° toward the rotation yoke's stop.
The sensor is supplied with voltage and sends voltage signals to

Control unit KAU (D7911) when the stop is directly in front of the sensor.
The signal can be checked with the diagnostic menu, see 7.6 Rotation





7 Load handling – Tilt 7:83
7.7 Tilt
Tilt, description
The mounting for the rotation yoke is jointed and equipped with
two hydraulic cylinders connected crosswise that dampen the
oscillations. The cylinders are pressurised by the hydraulic system and
interconnected with a damping block.
016203
There are four different versions of tilt:
• Damping
• Damping with tilt lock
• Damping with controllable tilt
• Damping with controllable tilt and tilt lock
If the machine is equipped with tilt lock then an electrically controlled

blocking valve is used in the damping block.
If the machine is equipped with controllable tilt then the hydraulic

cylinders are supplied from a separate section in the control valve on
the attachment.

7:84 7 Load handling – Tilt
Tilt damping, description

Tilt means that the attachment can swing forward and back in the
mounting to the boom in order that the load should hang straight
throughout lifting movement. Tilt damping means that the tilt movement
is counteracted.
The attachment's mounting in the boom is jointed and equipped with

two hydraulic cylinders that dampen the oscillations. The hydraulic
cylinders are connected crosswise to Damping block tilt. Damping block
tilt is supplied with servo pressure from Control valve attachment that is
routed to the tilt cylinders and creates overpressure in the tilt cylinders.
Adjustable restrictions between the connections for piston and rod side
in the damping block create resistance that dampens the tilt movement.
Tilt damping, function description

2
C1-
P C2+
C1+ 3
T C2-
016852
1 Hydraulic oil pump 3 pumps oil with standby See the pressure plate Axial piston pump with variable
pressure. on the left-hand frame displacement, description, page 10:10
beam.
2 The tilt damping block distributes oil to the - Damping block tilt, description, page 7:90
tilt cylinders.
3 The tilt cylinders dampen the attachment's - Tilt cylinder, description, page 7:92
movements.

Tilt lock, description
Tilt lock is an option for tilt damping, which means that the tilt movement
can be locked.
Tilt lock uses two solenoid valves in the damping block. One blocks
the connection between the tilt cylinders and the damping block while
the other blocks the supply of servo pressure from Control valve
attachment. Tilt lock is activated by a switch on Control lever (S8150).
016342
When tilt lock is activated, the machine's speed is limited to max. 5
Event menu tilt lock km/h.
Tilt lock, function description
Reference
D1
1 2 7
D7902 D7950
D7971 D7911
9 8 3
D7940
D3
D7930
10 4
C1-
P C2+
5 6
C1+
T C2-
016853

1 Switch, tilt lock (S7251) sends voltage U = 24 V Control lever, description, page 7:6
signals to Control unit KPU (D7902). D1: Diagnostic menu, see 7.1 Controls and
Instr 7/XX DIAGNOSE, page 8:41
2 Control unit KPU (D7902) sends tilt lock Checked by control 11.5.3.2 KPU control unit (D7902), page
on the CAN bus. system, error shown with 11:27
error code.
3 Control unit KAU (D7911) supplies Float position: U = 24 V 11.5.3.8 Control unit KAU (D7911), page
voltage to Solenoid valve tilt lock 1 Lock position: U = 0 V 11:38
(Y6012-1) and Solenoid valve tilt lock 2 D7: Diagnostic menu, see 7.7 Tilt 6/XX
(Y6012-2). DIAGNOSE, page 8:48
4 Solenoid valve tilt lock 1 (Y6012-1) and - Lock valve tilt, description, page 7:91
Solenoid valve tilt lock 2 (Y6012-2) D7: Diagnostic menu, see 7.7 Tilt 6/XX
pressurise the lock valve in the DIAGNOSE, page 8:48
attachment's control valve.


5 The lock valve changes position and - Lock valve tilt, description, page 7:91
blocks the connections to the tilt
cylinders.
6 The tilt cylinders lock the attachment's - Tilt cylinder, description, page 7:92
inclination.
7 When tilt lock is activated, Control unit - 11.5.3.3 Control unit, KID (D7950), page
KID (D7950) shows Event menu tilt lock 11:29
if the speed is approaching the maximum
limit (5 km/h).
When tilt lock is activated, the machine's
speed is limited to max. 5 km/h.
8 Control unit KFU (D7971) sends speed - 11.5.3.4 KFU control unit (D7971), page 11:31
limitation on CAN bus drive-train.
9 Control unit, engine (D7940) limits the - 11.5.3.6 Control unit, engine (D7940), page
engine speed 11:35
10 Control unit transmission (D7930) limits - 11.5.3.7 Control unit, transmission (D7930),
the gear range page 11:37

Tilt control, description
Tilt control is an option for tilt damping and means that tilting the
attachment can be controlled at least ±2° from straight position,
regardless of boom position at max. classified load. Depending on
boom angle and load, the possible tilt angle varies.
Tilt control is controlled by Control lever (S8150). An additional section

in Control valve attachment pressurises the tilt cylinders via Damping
block tilt so that the attachment is angled.
If the machine is equipped with tilt control then tilt lock is also included,
see Tilt lock, description, page 7:85.
Tilt control, function description
Reference
1 D1
+
2 17
D7902 D7950
15 D7971 D7911
3, 14 7, 10
D7940 D10
D7
D7930
16 11 8
C9
D3
P P P1
4 T T 9
12 T1
A A B
C1+ C1-
LSP1 A H C2- C2+ B
LSP2 LSPR
LSP3
5 8 LSHY
LSP3X P T T P LSO
LSM
C6
13
6
016854


Control lever (S8150-ThumbY) In: U = 0.5–2.0 V D1: Diagnostic menu, see 7.1 Controls and
send voltage signals to Control Instr 6/XX DIAGNOSE, page 8:41 and 7.1
unit KPU (D7902). Zero position: U = 2.0-3.0 V
Controls and Instr 7/XX DIAGNOSE, page
Out: U = 3.0–4.5 V 8:41.
2 Control unit KPU (D7902) sends Checked by control system, 11.5.3.2 KPU control unit (D7902), page 11:27
tilt in or tilt out on the CAN bus. error shown with error code.
3 Control unit KFU (D7971) activates U = 24 V 11.5.3.4 KFU control unit (D7971), page 11:31
Solenoid valve engagement of D3: Diagnostic menu, see 10.4 Pumps 1/XX
hydraulics for top lift (Y6003). DIAGNOSE, page 8:78
hydraulics for top lift (Y6003) top lift, description, page 10:25
opens and sends a load signal to D3: Diagnostic menu, see 10.4 Pumps 1/XX
the hydraulic oil pump 3. DIAGNOSE, page 8:78
5 Servo valve load handling steering - Valve block servo pressure, description, page
sends the load signal to hydraulic 10:25
oil pump 3. Shuttle valves in
servo valves select the strongest
load signal if other functions are
activated at the same time.
6 Hydraulic oil pump 3 pumps oil See the pressure plate on the Axial piston pump with variable displacement,
from the hydraulic oil tank. left-hand frame beam. description, page 10:10
7 Control unit KAU (D7911) activates I = 330–570 mA 11.5.3.8 Control unit KAU (D7911), page 11:38
Solenoid valve tilt out (Y6010) or D7: Diagnostic menu, 7.7 Tilt 4/XX
Solenoid valve tilt in (Y6011). DIAGNOSE, page 8:47 or 7.7 Tilt 5/XX
DIAGNOSE, page 8:48
8 Solenoid valve, tilt out (Y6010) - Attachment control valve, description, page
or Solenoid valve, tilt in (Y6011) 7:92
pressurises the tilt slide in the D7: Diagnostic menu, 7.7 Tilt 4/XX
attachment's control valve. DIAGNOSE, page 8:47 or 7.7 Tilt 5/XX
DIAGNOSE, page 8:48
9 The control valve's tilt slide - Attachment control valve, description, page
changes position and pressurises 7:92
the damping valve.
10 Control unit KAU (D7911) Float position: U = 24 V 11.5.3.8 Control unit KAU (D7911), page 11:38
disconnects the voltage feed to Lock position: U = 0 V D10: Diagnostic menu, see 7.7 Tilt 6/XX
Solenoid valve tilt lock 1 (Y6012-1) DIAGNOSE, page 8:48
and Solenoid valve tilt lock 2
(Y6012-2).
11 Solenoid valve tilt lock 1 (Y6012-1) - Lock valve tilt, description, page 7:91
and Solenoid valve tilt lock 2 D10: Diagnostic menu, see 7.7 Tilt 6/XX
(Y6012-2) pressurise the lock DIAGNOSE, page 8:48
valve in the attachment's control
valve.
12 The lock valve changes position - Damping block tilt, description, page 7:90
and directs oil crosswise to the tilt
cylinders.
13 The tilt cylinders change the - Tilt cylinder, description, page 7:92
attachment's inclination.
17 When tilt is controlled and speed Checked by control system, 11.5.3.3 Control unit, KID (D7950), page 11:29
is limited, Control unit KID error shown with error code.
(D7950) shows Event menu speed
limitation.

Tilt damping, adjusting
NOTE
Safety.
NOTE
Tilt damping may need to be adjusted after running-in due to
mechanical tolerances.
1 The engine running at idle.

2 Raise the boom without a load and check that the attachment is
tilting throughout the lifting movement.
The attachment should be tilting slightly backward during the lifting
movement and be set horizontally when lifting has stopped.
The attachment must never tilt forward so that the bottom edge of
1 the intended container swings in against the machine.
3 Adjust tilt damping as required by adjusting the screws on the
damping block. Adjust both screws equally.
Clockwise: increase damping.
Anticlockwise: decrease damping.
4 Lift a loaded container, test run and brake, check that the container
does not swing uncontrollably. If necessary, adjust the damping in
accordance with step 3.
005350
5 Start the machine and check that the function is working

satisfactorily.
1. Adjusting screws

10:10.

7:90 7 Load handling – Damping block tilt
7.7.3 Damping block tilt

Damping block tilt, description
The damping block contains restrictions which create resistance to the
1 2 3 4 movements of the tilt cylinders, which in turn dampen the attachment's
oscillations. The damping block is fitted in the centre of the boom nose.
The damping block receives oil via the return from the attachment's
9 control valve. The supply means that the cylinders are always filled
with oil. Balanced restrictions mean the supply does not affect the
tilting. The constant feed means the tilt cylinders do not need to be
bled after work on the tilt.
8
5 The damping block contains two shock valves which protect the valve
against pressure shocks.
6
7
016850
Damping block tilt, the illustration shows the version

with tilt lock.
1. Return line from attachment to tank [T]
2. Tank drain
3. Solenoid valve tilt lock 1 (Y6043-1)
4. Supply to attachment
5. Connection tilt cylinder piston side [C1+]
6. Connection tilt cylinder rod side [C1-]
7. Solenoid valve tilt lock 2 (Y6043-1)
8. Connection tilt cylinder piston side [C2+]
9. Connection tilt cylinder rod side [C2-]
Damping block tilt, changing
NOTE
Safety.

NOTE
NOTE
from impurities.
4 Remove the valve block from the boom.

5 Transfer the connection adapters to the new valve. Transfer one
adapter at a time so that the marking is not mixed up.
NOTE
correctly.

7 Load handling – Lock valve tilt 7:91
6 Install a new valve block on the boom nose.

7 Connect the hydraulic hoses to the damping block according to
the marking.
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.
9 Start the machine and check sealing integrity and function.

Check both tilt and attachment functions.
10 Adjust the tilt damping, see Tilt damping, adjusting, page 7:89.
manual.
7.7.4 Lock valve tilt

Lock valve tilt, description
On machines with tilt lock there are two solenoid valves on the damping
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 fitted on the damping block.
Solenoid valve tilt lock 1 (Y6012-1) and Solenoid valve tilt lock 2
(Y6012-2) are supplied with voltage by Control unit KAU (D7911) when
tilt lock is not activated.
The signal can be checked with the diagnostic menu, see section 7.7
Tilt 6/XX DIAGNOSE, page 8:48.
016841
Solenoid valve, tilt lock


1
6
Controllable tilt is regulated by a separate section in the attachment's
control valve. For a general description of the valve and component
2
7 locations, see Attachment control valve, description, page 7:44.
3 Tilt slide
4 The valve slide controls the direction and speed of attachment tilt.
The valve slide is controlled by servo valve, tilt in and servo valve,
5 tilt out.
8
Servo valve, tilt out
Servo valve tilt out controls pressure to the tilt slide so that the tilt slide
opens and pressurises the tilt cylinders.
Servo valve tilt out is controlled electrically with Solenoid valve tilt out
(Y6010) which is activated by Control unit KAU (D7911). The servo
valve routes servo pressure to the tilt slide proportional to the control
current to the solenoid valve.
016994
The signal can be checked with the diagnostic menu, see 7.7 Tilt 4/XX
1. Solenoid valve, tilt out (Y6010)
Servo valve, tilt in
2. Solenoid valve, tilt in (Y6011)
3. Feed from hydraulic oil pump 2 Servo valve tilt in controls pressure to the tilt slide so that the tilt slide
opens and pressurises the tilt cylinders.
4. Connection to tilt cylinder
5. Connection to tilt cylinder Servo valve tilt in is controlled electrically with Solenoid valve tilt in
(Y6011) which is activated by Control unit KAU (D7911). The servo
6. Damping pressure to valve block tilt damping valve routes servo pressure to the tilt slide proportional to the control
7. Drain to tank (unfiltered) current to the solenoid valve.
8. Return to tank (through tank filter)
The signal can be checked with the diagnostic menu, see 7.7 Tilt 5/XX

7.7.7 Tilt cylinder

Tilt cylinder, description
The tilt cylinders are located between the front edge of the inner
boom and the top of the rotation yoke. The two cylinders are aligned
diagonally and can therefore effectively dampen or control the tilt
movements.
The piston rod mounting is welded to the piston rod, which is threaded
in the piston head and locked with a lock bolt. The cylinder head is
threaded in the cylinder pipe.
016904
Tilt cylinders

7 Load handling – Lift boom 7:93

7.7.8 Lift boom

Lift boom, general
See Lift boom, description, page 7:26.
7.7.9 Rotation yoke

Rotation yoke, general
See group 7.6.7 Rotation yoke.




7:94 7 Load handling – Levelling
7.8 Levelling
Mechanical levelling, description
Mechanical levelling means that the attachment is angled horizontally.
This means that the machine can handle a load on uneven ground.
The attachment's main beam is located in the side shift frame. The
001117
clearance between the side shift frame and the attachment's main beam
allows a movement of about 5° which makes it possible to lift containers
that are inclined in relation to the machine. It is the attachment's own
weight that adapts the attachment's inclination to the container.
Hydraulic levelling, description
Hydraulic levelling means that the side shift frame is divided and the
parts are connected with four hydraulic cylinders. Hydraulic levelling
increases the mobility of the attachment. The hydraulic levelling has a
passive mode where the attachment floats freely and an active mode
where the inclination can be regulated. Levelling can be locked by
means of the connection to the levelling cylinders being blocked.
Passive levelling means that an unloaded attachment aligns in a float

position and adapts according to the inclination of the container to be
lifted.
Active levelling means that the inclination is controlled by means of

pressurising the hydraulic cylinders. Levelling is controlled by Control
001860
lever (S8150).
Levelling is monitored by sequence valves that close when the feed

pressure is high enough to position all the cylinders in the bottom.

7 Load handling – Levelling 7:95
Hydraulic levelling, function description
Reference
1 D1
+
2
D7902 D7950
D7971 D7911
3 7, 11
D7940
D7 D11
D7930
C11 8
D3
P1
4 9
T1 A B
A H
12
LSP1
LSP2 LSPR
LSP3
5 8 LSHY
10 13
LSP3X P T T P LSM
LSO 14
C6
016855
lever (S8150-X) send voltage signals to Levelling clockwise: U D1: Diagnostic menu, see 7.1 Controls and
Control unit KPU (D7902). = 0.5-2.0 V Instr 5/XX DIAGNOSE, page 8:40 and 7.1
Zero position: U = Controls and Instr 7/XX DIAGNOSE, page
2.0-3.0 V 8:41.
Levelling
anticlockwise: U =
3.0-4.5 V
2 Control unit KPU (D7902) sends levelling Checked by control 11.5.3.2 KPU control unit (D7902), page 11:27
clockwise or levelling anticlockwise on the system, error shown
CAN bus. with error code.
Solenoid valve engagement of hydraulics D3: Diagnostic menu, see 10.4 Pumps 1/XX
for top lift (Y6003). DIAGNOSE, page 8:78
4 Solenoid valve engagement of hydraulics - Solenoid valve, engagement of hydraulics for
for top lift (Y6003) opens and sends a load top lift, description, page 10:25
signal to the hydraulic oil pump 3. D3: Diagnostic menu, see 10.4 Pumps 1/XX
DIAGNOSE, page 8:78

7:96 7 Load handling – Levelling

5 Servo valve load handling steering sends - Valve block servo pressure, description, page
the load signal to hydraulic oil pump 3. 10:25
Shuttle valves in servo valves select the
strongest load signal if other functions are
6 Hydraulic oil pump 3 pumps oil from the See the pressure plate Axial piston pump with variable displacement,
hydraulic oil tank. on the left-hand frame description, page 10:10
beam.
Solenoid valve levelling right (Y6035) or 11:38
Solenoid valve levelling left (Y6036). D7: Diagnostic menu, see 7.8 Levelling 3/XX
DIAGNOSE, page 8:48 or 7.8 Levelling 4/XX
DIAGNOSE, page 8:49
8 Solenoid valve levelling anticlockwise - Attachment control valve, description, page
(Y6035) or Solenoid valve levelling 7:99
clockwise (Y6036) acts on the levelling D7: Diagnostic menu, see 7.8 Levelling 3/XX
slide in the control valve attachment. DIAGNOSE, page 8:48 or 7.8 Levelling 4/XX
DIAGNOSE, page 8:49
9 The control valve's levelling slide changes - Attachment control valve, description, page
position and pressurises the levelling 7:99
overcentre valve.
10 The overcentre valve opens and directs - Overcentre valve, levelling, description, page
pressure to the levelling cylinders' valve 7:100
block.
11 Control unit KAU (D7911) disconnects the Float mode: U = 24 V 11.5.3.8 Control unit KAU (D7911), page
voltage feed to Solenoid valve levelling Lock position: U = 0 V 11:38
lock 1 (Y6034-1) and Solenoid valve D7: Diagnostic menu, see 7.8 Levelling 5/XX
levelling lock 2 (Y6034-2). DIAGNOSE, page 8:49
12 Solenoid valve levelling lock 1 (Y6034-1) - Levelling cylinders' valve block, description,
and Solenoid valve levelling lock 2 page 7:100
(Y6034-2) act on the lock valves in Valve
block, levelling cylinders.
13 The levelling cylinders' valve block directs - Levelling cylinders' valve block, description,
pressure on to the levelling cylinders. page 7:100
14 The levelling cylinders change the - Levelling cylinders, description, page 7:101

7 Load handling – Levelling 7:97
Levelling lock, function description
Reference
Sensor, Not activated Sensor operator in seat, description, page 9:23
operator-in-seat
D1
1
2 7
D7902 D7950
D7971 D7911
8 3
9
D7940 D3
4
D7930
10 5
016856
6

1 Control lever (S815-T3.1) sends voltage US815/T3.1 = 24 V Section 9 Frame, body, cab and accessories,
signals to Control unit KCU (D7901). group 9.1 Controls and instruments
D1: Diagnostic menu, see section 8 Control
2 Control unit KCU (D7901) sends levelling Checked by control 11.5.3.1 KCU control unit (D7901), page
lock on the CAN bus. system, error shown with 11:25
error code.
3 Control unit attachment option (D791-2) Float mode: U = 24 V Levelling cylinders' valve block, description,
interrupts the activation of Solenoid valve Lock position: U = 0 V page 7:100
levelling lock 1 (Y6034-1) and Solenoid D3: Diagnostic menu, see 7.8 Levelling 5/XX
valve levelling lock 2 (Y6034-2). DIAGNOSE, page 8:49
4 Solenoid valve levelling lock 1 (Y6034-1) - Levelling cylinders' valve block, description,
and Solenoid valve levelling lock 2 page 7:100
(Y6034-2) act on the lock slides in Valve D3: Diagnostic menu, see 7.8 Levelling 5/XX
block, levelling cylinders. DIAGNOSE, page 8:49
5 The lock slides in Valve block, levelling - Levelling cylinders' valve block, description,
cylinders change position and block the page 7:100
connections to the levelling cylinders in
Valve block, levelling cylinders.
6 The levelling cylinders lock the - Levelling cylinders, description, page 7:101
7 When levelling lock is activated, Control - 11.5.3.3 Control unit, KID (D7950), page
unit KID (D7950) shows Event menu 11:29
tilt lock if the speed is approaching the
maximum limit (5 km/h).
When levelling lock is activated, the
machine's speed is limited to max. 5
km/h.
8 Control unit KFU (D7971) sends speed - 11.5.3.4 KFU control unit (D7971), page 11:31
limitation on CAN bus drive-train.

7:98 7 Load handling – Hydraulic oil pump

9 Control unit, engine (D7940) limits the - 11.5.3.6 Control unit, engine (D7940), page
engine speed 11:35
10 Control unit transmission (D7930) limits - 11.5.3.7 Control unit, transmission (D7930),
the gear range page 11:37

10:10.

7 Load handling – Control valve, attachment 7:99

Hydraulic levelling is controlled by a separate section in Control valve,
1 attachment. For a general description of the valve and component
locations, see Attachment control valve, description, page 7:44.
2 6
Levelling slide
3 The valve slide controls the direction and speed of attachment levelling.
The valve slide is controlled by Servo valve levelling anticlockwise and

4
Servo valve levelling clockwise.
5 Servo valve levelling anticlockwise

7 Servo valve levelling anticlockwise controls pressure to the levelling
slide so that it opens and pressurises the levelling cylinders.
Servo valve levelling anticlockwise is controlled electrically by Solenoid

valve levelling anticlockwise (Y6035), which is activated by Control unit
KAU (D7911). The servo valve routes servo pressure to the tilt slide
The signal can be checked with the diagnostic menu, see 7.8 Levelling
016993
Servo valve levelling clockwise

1. Solenoid valve levelling anticlockwise (Y6035)
Servo valve levelling clockwise controls pressure to the levelling slide
so that it opens and pressurises the levelling cylinders.
2. Solenoid valve, levelling clockwise (Y6036)
3. Feed from hydraulic oil pump 2 Servo valve levelling clockwise is controlled electrically by Solenoid
valve levelling clockwise (Y6036), which is activated by Control unit
4. Connection to levelling cylinder
KAU (D7911). The servo valve routes servo pressure to the tilt slide
5. Connection to levelling cylinder proportional to the control current to the solenoid valve.
6. Return to tank (through tank filter)
7. Drain to tank (unfiltered) 4/XX DIAGNOSE, page 8:49.
Passive levelling
The servo valves open a connection to the tank, in addition, hydraulic
oil can flow between right and left side levelling cylinders, from piston
sides to rod sides, according to the inclination.
Active levelling
Levelling is monitored by the sequence valves in valve block, levelling
cylinder, which closes when the feed pressure is high enough to
position all the cylinders in the bottom. Following which, hydraulic oil is
supplied to the rod sides on one side's cylinders and the side is lifted.
Consequently, the other side will always be in its lowest position during
levelling. This always results in maximum levelling travel.


7:100 7 Load handling – Overcentre valve levelling
7.8.5 Overcentre valve levelling

Overcentre valve, levelling, description
Passive levelling
The overcentre valve ensures that the levelling cylinders are fully
extended. The valve is fitted to the right of Control valve, attachment
on the rear edge of the side shift frame under Valve block, levelling
cylinders.
Passive levelling
The overcentre valves allow the flow of hydraulic oil between right and
left levelling cylinders, from piston sides to rod sides, according to the
inclination.
Active levelling
The overcentre valves close when the feed pressure is high enough
to position all the levelling cylinders in the bottom. Following which,
hydraulic oil is supplied through Valve block, levelling cylinders, to the
rod sides on one side's (right or left) cylinders and the side is lifted.
Consequently, the other side will always be in its lowest position during
levelling. This always results in maximum levelling travel.
001062
7.8.6 Valve block levelling cylinders

Levelling cylinders' valve block, description
Lock valve
Valve block, levelling cylinders, routes the pressure from Control valve,
attachment, to the levelling cylinders. The valve block includes two
lock valves that block levelling when levelling lock is activated or if
the machine becomes de-energised. The valve is fitted to the right of
Control valve, attachment, on the rear edge of the side shift frame
above Overcentre valve, levelling.
Lock valve
The lock valves are opened by Solenoid valve levelling lock 1 (Y6034-1)
and Solenoid valve levelling lock 2 (Y6034-2). When the lock valves
are closed, the oil to and from the levelling cylinders is blocked and
levelling is blocked. Solenoid valve levelling lock 1 (Y6034-1) and
Solenoid valve levelling lock 2 (Y6034-2) are supplied with voltage by
Control unit KAU (D7911).
001061

7 Load handling – Levelling cylinders 7:101
7.8.7 Levelling cylinders

Levelling cylinders, description
On machines with hydraulic levelling there are four hydraulic cylinders
between the side shift frame's parts, see Side shift frame, description,
page 7:101.
001860


Mechanical levelling
1 2 3 4 The side shift frame is available in two different versions, see Side
shift frame, description, page 7:48.
Mechanical levelling
The side shift frame is larger than the attachment's main beam. The
main beam can move freely between the slide plates, this permits
approx. 5° levelling.
Hydraulic levelling
001932
5 The side shift frame is in two parts. There are four levelling cylinders
between the two parts, see Levelling cylinders, description, page 7:101.
1. Main beam, attachment The outer part is attached into the rotation yoke via the ring gear. The
2. Side shift frame upper section inner part holds the attachment's main beam. The main beam slides
3. Levelling cylinder against the slide plates. The stroke length of the hydraulic cylinders
allows the main beam to be levelled approx. 5°. With hydraulically
4. Side shift frame lower section controllable levelling, the angle of Main beam, attachment, is controlled
5. Side shift cylinder using the control lever.




7:102 7 Load handling – Load carrier
7.9 Load carrier

Load carrier, description
The load carrier is used to secure a load. There are several ways of
securing the load.
• Twistlocks, rotatable lift pins that hold the load in oval holes in the
corners of the load.
• Customised attachments adapted for a particular type of load.
This type of attachment is described if required in a separate
supplement for each attachment.
7.9.1 Twistlocks
Twistlocks, description
The container is held in place on the attachment with four twistlocks.
Twistlocks are controlled by Control lever (S8150) and Switch twistlocks

(S1003). A section in Control valve, attachment, pressurises the two
parallel-connected hydraulic cylinders, one in each spreader boom.
004868
Each hydraulic cylinder actuates a linkage that turns two twistlocks.

Four position sensors, two in each spreader boom, detect the position
of the linkage and indicates whether twistlocks are open or locked.
Indicator lamps on the boom and in the cab show the status for the
twistlocks.
Four position sensors, one at each twistlock, indicate when the

attachment is in contact with the container. This is used to control when
the twistlocks can be activated. An indicator light on the boom and one
in the cab indicate when the attachment has full contact. An event
menu shows which twistlocks have contact (1 - 4). All four twistlocks
must have contact in order for the twistlocks to be activated.

7 Load handling – Twistlocks 7:103
Twistlocks, function description

Contact Full contact or bypass Bypass, description, page 8:6
activated
D2 9, 24
2
D1
1 D8
10 8, 23 5, 25
D7902 D7901 D7950
D7971 D7911
11 6, 15, 20, 22 7, 21
D7940 D15
D6
D7930 D11 C17 16
D19
P1 D3
12 17
T1 A B
LSP1 A H
LSP2 LSPR 19 3
LSP3
138 LSHY
LSP3X P T T P LSO
LSM
C14
18
14
016858
1 Switch, lock twistlocks (S1003) U = 24 V Switch lock twistlocks, description, page 7:10
(automatic mode) sends voltage signals D1: Diagnostic menu, see 7.9 Load Carrier
to Control unit KPU (D7902). 3/XX DIAGNOSE, page 8:49
2 Switch open twistlocks (S1020) in the U = 24 V Control lever, description, page 7:6
control lever sends voltage signals to D2: Diagnostic menu, see 7.1 Controls and
Control unit KPU (D7902) for opening Instr 7/XX DIAGNOSE, page 8:41
the twistlocks.
3 Sensor, contact left front (B7202LE), Sensor directly opposite Sensor, contact, description, page 7:108
Sensor, contact right front (B7202RI), indicator plate: U = 24 V D3: Diagnostic menu, see 7.9 Load Carrier
Sensor, contact left rear (B7203LE) and 4/XX DIAGNOSE, page 8:50
Sensor, contact right rear (B7203RI)
send voltage signals to Control unit,
attachment, Control unit KAU (D7911).
4 Control unit KAU (D7911) sends contact Checked by control 11.5.3.8 Control unit KAU (D7911), page 11:38
on the CAN bus. system, error shown
with error code.
5 Control unit KID (D7950) activates Event - 11.5.3.3 Control unit, KID (D7950), page 11:29
menu, contact.

7:104 7 Load handling – Twistlocks

6 Control unit KAU (D7911) activates U = 24 V D6: Diagnostic menu, see 7.9 Load Carrier
Indicator light, contact (H5640-1) on the 10/XX DIAGNOSE, page 8:51
boom's light panel.
7 Indicator light contact (H5640-1) U = 24 V D6: Diagnostic menu, see 7.9 Load Carrier
illuminates. 10/XX DIAGNOSE, page 8:51
8 Control unit KCU (D7901) activates U = 24 V 11.5.3.1 KCU control unit (D7901), page 11:25
Indicator light contact (H5640-2) in the D8: Diagnostic menu, see 7.9 Load Carrier
cab's light panel. 14/XX DIAGNOSE, page 8:52
9 Indicator light contact (H5640-2) in the D8: Diagnostic menu, see 7.9 Load Carrier
cab's light panel illuminates. 14/XX DIAGNOSE, page 8:52
10 Control unit KPU (D7902) sends "open Checked by control 11.5.3.2 KPU control unit (D7902), page 11:27
twistlocks" or "lock twistlocks" on the system, error shown
Solenoid valve engagement of D11: Diagnostic menu, see 10.4 Pumps 1/XX
hydraulics for top lift (Y6003). DIAGNOSE, page 8:78
hydraulics for top lift (Y6003) opens and top lift, description, page 10:25
sends a load signal to the hydraulic oil D11: Diagnostic menu, see 10.4 Pumps 1/XX
pump 3. DIAGNOSE, page 8:78
13 Servo valve load handling steering - Valve block servo pressure, description, page
sends the load signal to hydraulic oil 10:25
pump 3. Shuttle valves in servo valves
functions are activated at the same time.
beam.
15 Control unit KAU (D7911) activates U = 24 V 11.5.3.8 Control unit KAU (D7911), page 11:38
Solenoid valve "open twistlocks" D17: Diagnostic menu, see 7.9 Load Carrier
(Y6039) or Solenoid valve "lock 6/XX DIAGNOSE, page 8:50 or 7.9 Load
twistlocks" (Y6040). Carrier 7/XX DIAGNOSE, page 8:51
16 The "open twistlocks" solenoid valve - Attachment control valve, description, page
(Y6039) or the "lock twistlocks" solenoid 7:106
valve (Y6040) pressurises the twistlock D17: Diagnostic menu, see 7.9 Load Carrier
slide with servo pressure. 6/XX DIAGNOSE, page 8:50 or 7.9 Load
Carrier 7/XX DIAGNOSE, page 8:51
17 The control valve's twistlock slide valve - Attachment control valve, description, page
changes position and pressurises the 7:106
lock cylinders.
18 The lock cylinders rotate the twistlocks. - Lock cylinder, description, page 7:106
19 Sensor unlocked twistlocks left Sensor directly opposite Sensor, twistlocks, description, page 7:109
(B7204-LE) and Sensor unlocked indicator plate: U = 24 V D21: Diagnostic menu, see 7.9 Load Carrier
twistlocks right (B7204-RI) or Sensor 5/XX DIAGNOSE, page 8:50
locked twistlocks left (B7205-LE)
and Sensor locked twistlocks right
(B7205-RI) send signals to Control unit
KAU (D7911).
20 Control unit KAU (D7911) supplies U = 24 V D6: Diagnostic menu, see 7.9 Load Carrier
voltage to Indicator light "unlocked 8/XX DIAGNOSE, page 8:51 or 7.9 Load
twistlocks" (H5620-1) or Indicator light Carrier 10/XX DIAGNOSE, page 8:51
"locked twistlocks" (H5630-1) on the
boom's light panel.
21 Indicator light unlocked twistlocks U = 24 V D6: Diagnostic menu, see 7.9 Load Carrier
(H5620-1) or Indicator light locked 8/XX DIAGNOSE, page 8:51 or 7.9 Load
twistlocks (H5630-1) on the boom's light Carrier 10/XX DIAGNOSE, page 8:51
panel illuminates


22 Control unit KAU (D7911) sends Checked by control 11.5.3.8 Control unit KAU (D7911), page 11:38
information about "twistlocks unlocked" system, error shown
or "twistlocks locked" on the CAN bus. with error code.
23 Control unit KFU (D7901) supplies U = 24 V 11.5.3.1 KCU control unit (D7901), page 11:25
voltage to Indicator light "unlocked D8: Diagnostic menu, see 7.9 Load Carrier
twistlocks" (H5620-2) or Indicator light 12/XX DIAGNOSE, page 8:52 or 7.9 Load
"locked twistlocks" (H5630-2) on the Carrier 13/XX DIAGNOSE, page 8:52
cab's light panel.
24 Indicator light unlocked twistlocks U = 24 V D8: Diagnostic menu, see 7.9 Load Carrier
(H5620-2) or Indicator light locked 12/XX DIAGNOSE, page 8:52 or 7.9 Load
twistlocks (H5630-2) in the cab's light Carrier 13/XX DIAGNOSE, page 8:52
panel illuminates.
25 Control unit KID (D7950) activates Event Checked by control 11.5.3.3 Control unit, KID (D7950), page 11:29
menu, twistlocks. system, error shown
with error code.
7.9.1.1 Hydraulic oil pump

10:10.

7.9.1.3 Control valve, attachment

The twistlocks function is controlled by a separate section in the
1 attachment's control valve. For a general description of the valve and
component locations, see Attachment control valve, description, page
2 6 7:44.
Twistlocks slide, description
3
The valve slide controls the direction and the lock cylinder.
4
The valve slide is controlled by two servo valves, lock twistlocks and
open twistlocks.
5
7 Servo valve lock twistlocks, description
Servo valve "lock twistlocks" solenoid valve directs pressure to the
twistlock slide so that the slide and pressurises the lock cylinders.
Servo valve lock twistlocks is controlled electrically by Solenoid

valve lock twistlocks (Y6040), which is activated by Control unit KAU
(D7911). The servo valve directs servo pressure to the twistlocks slide
016903
1. Solenoid valve, lock twistlocks (Y6040) Servo valve open twistlocks, description
2. Solenoid valve, open twistlocks (Y6039)
Servo valve "open twistlocks" solenoid valve directs pressure to the
3. Feed from hydraulic oil pump 2 twistlock slide so that the slide and pressurises the lock cylinders.
4. Connection to lock cylinder
Servo valve open twistlocks is controlled electrically by Solenoid
5. Connection to lock cylinder
valve open twistlocks (Y6041), which is activated by Control unit KAU
6. Drain to tank (unfiltered) (D7911). The servo valve directs servo pressure to the twistlocks slide
7. Return to tank (through tank filter) proportional to the control current to the solenoid valve.

7.9.1.5 Lock cylinder

Lock cylinder, description
The lock cylinder activates the lock mechanism so that the twistlocks
are rotated. Two lock cylinders, one in the right and one in the left
spreader beam, activate the lock mechanism. The lock cylinders are
fitted in the centre of the spreader beam's longitudinal section.
016906


7.9.1.6 Lock mechanism
Lock mechanism, description

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 twistlocks.
The lock mechanism consists of a rod with spherical plain bearings

in the end. The rod is fastened in levers that rotate the twistlocks. A
retaining lug for the lock cylinder is fitted in the centre of the rod.
016907
7.9.1.7 Twistlocks
Twistlocks, description
1 WARNING
Dropped load.
2 Extreme danger!
Twistlocks hold the load during load handling and
therefore it is of the utmost importance that twistlocks
are checked according to instructions and are replaced
at the slightest sign of damage or wear.
5
Twistlocks secure the load and are located out in the corners of the
spreader beam's longitudinal section.
4
3 Twistlocks are manufactured from high-strength steel in accordance
with international standards. The lift pins are marked with serial
016945
numbers.
1. Lock mechanism Twistlocks are connected in pairs via a linkage system to a hydraulic
2. Sensor, contact cylinder which in turn is controlled via a section in the attachment's
control valve. Inductive sensors send signals when the twistlocks are
3. Contact pin
locked and unlocked, respectively.
4. Lift pin
5. Lock guide

7.9.1.8 Sensor, contact
Sensor, contact, description

Sensor, contact, detects when the attachment has contact with the
container. Four inductive sensors, one at each twistlock out in the
corners the longitudinal section of the spreader beam, are used to
indicate contact.
The sensor senses the position of a spring pin which is pressed in

when the attachment has contact up against the container. The sensor
is located 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 and send a 24 V signal to Control

unit KAU (D7911) when the indicator pin is pressed in.
016908
Sensor, contact, checking

2 Check that the indicator pins in the corner boxes can move up
and down freely. The indicator pins must spring down when they
are not loaded.
3 Check that the sensor is free of damage and dirt.
4 Start the machine.
5 Lower the attachment to a container and check that all twistlocks

indicate contact, filled circles in the event menu for contact, and
that the indicator light for contact illuminates.
6 Lift the attachment slightly so that contact is just broken (unfilled
circles in the event menu for contact or the indicator light for
contact goes out).
7 Check how much indicator pin movement is required to detect
contact. The movement should be 3–4 mm.
016350
8 Adjust sensor position if necessary. See Position sensor, checking

and adjustment, page 7:5.
Event menu, contact


7.9.1.9 Sensor twistlocks
Sensor, twistlocks, description

Sensor, twistlocks, detects when twistlocks are locked or unlocked.
Four inductive position sensors, two in each spreader beam, detect the
position of the lock mechanism. The sensors are located at the lock
cylinder in the centre of the longitudinal section of the spreader beam.
Both sides function in the same way independently of one another. A

stop is fitted on the lock mechanism by the lock cylinder. When the
lock mechanism is in the position that locks the twistlocks, one of the
sensors sends a signal to Control unit KAU (D7911). When the lock
mechanism is in the position that unlocks the twistlocks, the second
sensor sends a signal to Control unit KAU (D7911). No signals are sent
if the lock mechanism stops midway.
016910
The sensors are supplied with voltage by, and send a 24 V signal to
Control unit KAU (D7911) when the indicator plate is in front of the
sensor.

7.9.1.10 Relief valve top lift

7.9.1.11 Pipes and hoses

7.9.1.14 Valve block servo pressure


7:110 7 Load handling – Other functions
7.10 Other functions

7.10.1 Support jacks
Support jacks description
Support jacks increase stability forward and hence the load capacity
over a longer distance. The support jacks are controlled with Switch
support jacks (S1013). Control valve support jacks pressurises two
parallel-connected cylinders that lower one support jack each. Four
016317
position sensors, two for each support jack, detect whether the support
jacks are fully lowered or fully raised. An indicator light in the cab
indicates when the support jacks are lowered. The support jacks are
fitted on the frame between the drive wheels.
The transmission must be in neutral position and the machine must be

stationary with the parking brake released in order that the support
jacks can be lowered. When the support jacks are not fully raised, the
transmission is locked in neutral position.
Lowering the support jacks can be set to automatic (short press of the
button lowers the jacks) or manual (the button must be held depressed
to end position) with the initiation menus, see 7.10 Other functions
11/XX INITIATE, page 8:125.
Support jacks, function description

Control breaker Disengaged Axial piston pump with variable displacement, description, page 10:10
Sensor, operator-in- Not activated Sensor operator in seat, description, page 9:23
seat
Doors Closed Doors, description, page 9:86.
Parking brake Released Parking brake system, function description, page 4:35
Transmission Neutral position Transmission, function description, page 2:4
Machine stationary Speed = 0 km/h -
17
D1
1
3 16 15
D7902 D7901 D7950
5
D7930 D7971 D7972
4, 6, 14
D7940
2
7 13
A H
C8
LSP1
LSP2 LSPR
915
12
10
8 LS A
LSP3 LSHY
P 8 11
LSP3X P T T P LSO B
LSM T
C10 12
016861
10

7 Load handling – Support jacks 7:111

1 Switch, support jacks (S1013) sends U = 24 V Cab overview, page 9:5
voltage signals to Control unit KPU (D7902).
2 Control unit engine (D7940) sends engine Checked by control 11.5.3.6 Control unit, engine (D7940), page
speed on the CAN bus. system, error shown 11:35
with error code.
3 Control unit KPU (D7902) sends support Checked by control 11.5.3.2 KPU control unit (D7902), page
jacks down or up on the CAN bus. system, error shown 11:27
Before a request for support jacks up is with error code.
sent, there is a check that the load does
not exceed the limit for load curve without
support jacks. If the load exceeds the limit
then Event menu overload is shown when
raising is requested.
4 Control unit KFU (D7971) sends request for Checked by control 11.5.3.4 KFU control unit (D7971), page
neutral position on CAN bus drive-train. system, error shown 11:31
with error code.
5 Control unit transmission (D7930) locks the Checked by control 11.5.3.7 Control unit, transmission (D7930),
transmission in neutral position. system, error shown page 11:37
with error code.
6 Control unit KFU-2 (D7972) activates U = 24 V 11.5.3.5 Control unit KFU-2 (D7972), page
Solenoid valve support jacks down (Y6064) 11:33
or Solenoid valve support jacks up (Y6063).
7 Solenoid valve support jacks down (Y6064) - Control valve, option frame, description,
or Solenoid valve support jacks up (Y6063) page 7:112
pressurises the support jacks slide in
Control valve, option frame.
8 Control valve, option frame, sends load - Control valve, option frame, description,
signals to Servo valve load handling page 7:112
steering and pressurises Valve block,
support jack cylinder.
9 Servo valve load handling steering sends - Valve block servo pressure, description,
the load signal to hydraulic oil pump 1. page 10:25
Shuttle valves in servo valves select the
strongest load signal if other functions are
beam.
11 Valve block support jack cylinder - Valve block, support jacks, description, page
pressurises hydraulic cylinder support 7:117
jacks.
12 The hydraulic cylinder lowers or raises the - Hydraulic cylinder, support jacks, description,
support jack. page 7:114
13 Sensor support jacks up (B7222-RI and Support jacks up or Sensor, support jacks up, description, page
B7222-LE) or Sensor support jacks down down: U = 24 V 7:116
(B7223-RI and B7223-LE) send voltage Support jacks in Sensor, support jacks down, description,
signals to Control unit KFU2 (D7972). intermediate position: page 7:117
U=0V
14 Control unit KFU-2 (D7972) sends Checked by control 11.5.3.5 Control unit KFU-2 (D7972), page
information about the position of the support system, error shown 11:33
jacks on the CAN bus. with error code.
15 Control unit KID (D7950) activates Event - 11.5.3.3 Control unit, KID (D7950), page
menu, support jacks. 11:29

7:112 7 Load handling – Support jacks

16 Control unit KCU (D7901) activates U = 24 V 11.5.3.1 KCU control unit (D7901), page
Indicator light support jacks down (H5740) 11:25
on the light panel in the cab.
When support jacks are lowered, Control
unit KCU (D7901) changes the load curve
(limit for overload system).
When support jacks are raised Control unit
KCU (D7901) allows shifting from neutral
position.
17 Indicator light support jacks down (H5740) U = 24 V
on the light panel in the cab illuminates.
Hydraulic diagram cab movement and support jacks, see Hydraulic

diagram cab movement and support jacks, page E:13.

10:10.
7.10.1.2 Control valve option frame

Control valve, option frame, description
1 2 3
On machines with support jacks, the lowering of the support jacks is
controlled by a separate section in Control valve, frame option. The
control valve is fitted on a screw in the frame at the front of the engine
8 compartment. The control valve is controlled by Control unit KFU-2
(D7972).
7 The control valve is an electro-hydraulically controlled, proportional

and pressure-compensated directional control valve. Electrically
controlled pressure reducing valves convert electric current to servo
6
pressure. The servo pressure controls the spring-centred valve slides
1 4 that control pressure and flow for the function in question. The valve
2 slide has a limitation to the flow so that several functions can be used
5 simultaneously.
Valve slide, support jacks
The valve slide controls the direction and speed of support jack
lowering by controlling the hydraulic pressure to hydraulic cylinder,
support jacks.
The valve slide is controlled by servo valve, support jacks up and servo
016911
valve, support jacks down.

Servo valve, support jacks down
1. Connection hydraulic cylinder (A1 + A2)
2. Connection hydraulic cylinder (B1 + B2) Servo valve, support jacks up controls servo pressure to valve slide
support jacks so that it controls oil pressure for support jacks up.
3. Tank return (T )
4. Pressure feed (P) Servo valve, support jacks down, is controlled electrically with Solenoid
5. Solenoid valve support jacks up (Y6063) valve support jacks down (Y6064), which is activated by Control unit
KFU-2 (D7972).
6. Solenoid valve support jacks down (Y6064)
7. Measuring outlet
Servo valve, support jacks up
8. Load signal (LS) Servo valve, support jacks down controls servo pressure to valve slide
support jacks so that it controls oil pressure for support jacks down.
Servo valve, support jacks up, is controlled electrically with Solenoid
valve support jacks up (Y6063), which is activated by Control unit
KFU-2 (D7972).

Control valve, option frame, changing
NOTE
Safety.

NOTE
1 2 3
NOTE
from impurities.
8
7 5 Remove the control valve.
6 on a clean and protected surface.
1 6 Transfer parts to the new control valve.

4
2
5 NOTE
correctly.
NOTE
016911
mixed up.
1. Connection hydraulic cylinder (A1 + A2)

NOTE
2. Connection hydraulic cylinder (B1 + B2)
Transfer one part at a time so that the marking is not mixed up.
3. Tank return (T )
4. Pressure feed (P) 7 Mark up the servo valves on the new control valve.
5. Solenoid valve support jacks up (Y6063) 8 Fit the valve.
6. Solenoid valve support jacks down (Y6064) 9 Connect the cable harness to the control valve according to the
marking.
7. Measuring outlet
8. Load signal (LS) the marking.
NOTE
correctly.

NOTE

hydraulic system.
NOTE
the lock ring.

CAUTION
product damage.
manual.
7.10.1.3 Hydraulic cylinder support jacks
Hydraulic cylinder, support jacks, description

Hydraulic cylinder support jacks operates the support jack up and
1 down. The hydraulic cylinder is fitted between support jack and frame.
5
001870
7 6
1. Hydraulic cylinder support jacks

2. Sensor support jacks up (B7222-LE or
B7222-RI)
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
7. Sensor support jacks down (B7221-LE or
B7221-RI)

7.10.1.4 Support jacks
Support jacks, description

The support jack consists of a linkage and support. The linkage is
1 designed 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
attaching bolts.
5
001870
7 6

B7222-RI)
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
B7221-RI)

7.10.1.5 Sensor, raised support jacks
Sensor, support jacks up, description

Sensor support jacks up left (B7222-LE) and Sensor support jacks up
1 right (B7222-RI) are fitted under hydraulic cylinder support jacks and
detect when the support jack is raised. There is a sensor fitted by each
support jack. The sensor indicates when the support jack is fully raised.
2 This is used to control Event menu, support jacks.
Sensor support jacks up left (B7222-LE) and Sensor support jacks up

3 right (B7222-RI) send voltage signals to Control unit KFU2 (D7972)
when the support jack is fully raised.
5
001870
7 6

B7222-RI)
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
B7221-RI)


7.10.1.6 Sensor, lowered support jacks
Sensor, support jacks down, description

Sensor support jacks down left (B7221-LE) and Sensor support
1 jacks down right (B7221-RI) are fitted under the support jack's upper
mounting and detect when the support jack is lowered. There is a
sensor fitted by each support jack. This is used to control the support
2 jacks and activation of Indicator light, support jacks down.
Sensor support jacks down left (B7221-LE) and Sensor support jacks
3 down right (B7221-RI) send voltage signals to Control unit KFU2
(D7972) when the support jack is fully lowered.
5
001870
7 6

B7222-RI)
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
B7221-RI)

7.10.1.7 Pipes and hoses

7.10.1.9 Valve block support jacks
Valve block, support jacks, description

Valve block, support jacks is located by the hydraulic cylinders and
contains a blocking valve which protects against accidental raising
and lowering of the support jacks.
7.10.1.10 Valve block servo pressure


7:118 7 Load handling – Weight indicator
7.10.2 Weight indicator

Weight indicator, general
See Weight indicator, description, page 8:22.
7.10.3 Container counter

Container counter, general
See Container counter, description, page 8:23.
7.10.4 Synchronised lift

Synchronised lift, general
Synchronised lift, description, page 8:25

8:1
8 Control system
Contents 8 Control system

8 Control system .................................................................................................. 8:3
8.1.2 Information display ......................................................................................8:4
8.2 Monitoring .......................................................................................................8:5
8.2.1 Overload system .........................................................................................8:5
8.2.2 Bypass ........................................................................................................8:6
8.2.3 Load centre limitation ..................................................................................8:7
8.2.4 Height limitation...........................................................................................8:7
8.2.5 Speed limitation...........................................................................................8:8
8.2.6 Service indicator..........................................................................................8:9
8.2.11 Load sensors.............................................................................................8:12
8.2.12 Statistics ....................................................................................................8:21
8.2.13 Weight indicator.........................................................................................8:22
8.2.14 Container counter......................................................................................8:23
8.2.15 Synchronised lift ........................................................................................8:25
8.4 Diagnostics ....................................................................................................8:26
8.4.1 Engine .......................................................................................................8:28
8.4.2 Transmission .............................................................................................8:33
8.4.4 Brakes .......................................................................................................8:36
8.4.5 Steering .....................................................................................................8:38
8.4.7 Load handling............................................................................................8:40
8.4.8 Control system ..........................................................................................8:53
8.4.9 Frame, body, cab and accessories............................................................8:56
8.4.10 Common hydraulics...................................................................................8:78
8.4.11 Common electrics......................................................................................8:79
8.4.13 Pin diagnostics ..........................................................................................8:95
8.5 Setup..............................................................................................................8:97
8.5.1 Engine .....................................................................................................8:100
8.5.2 Transmission ...........................................................................................8:101
8.5.5 Steering ...................................................................................................8:104
8.5.7 Load handling.......................................................................................... 8:111
8.5.8 Control system ........................................................................................8:125
8.5.9 Frame, body, cab and accessories..........................................................8:131
8.5.11 Common electrics....................................................................................8:138

8:2

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

• Monitoring
• Error codes
• Diagnostics
• Setup
• Software
Monitoring functions describe the machine's monitoring functions that

warn the operator or limit the machine's functions in the event of any
dangerous situations.
Error codes notify operators and mechanics when malfunctions have

been detected.
Diagnostics comprise a tool for performing service and troubleshooting

with menus in the machine's display.
Settings is the tool for setting and adapting the machine's functions.
The software creates the functions in the control system.

8:4 8 Control system – Controls and instruments

8.1.2 Information display
Navigation of menus, description
Information presented on the display (position a). The function keys
a (positions c - e) are used to navigate in the display menus and confirm
selections.
Navigation in and to menus and settings in the menus for Diagnostics,
Initiation and Calibration is performed in the same way for all functions.
10:23
10:23 The Pop-up row for the key function changes in appearance and
function depending on the menu. The different functions are explained
below.
Confirm.
Select the highlighted function.
Activate the output manually.
Save a value.
Change the arrow function from the left/right arrows to
up/down arrows.
The symbol is only shown in menus where settings
are possible.
016040
Exit menu.
b c d e
Cancel setting.
a. Display
Increase/decrease a signal value.
b. Pop-up for button function
Step up/step down in a list.
c. ENTER/YES/ON/SAVE/EDIT/MAN
Go to next menu/back to previous menu.
d. Navigate menus/adjust values , , or
e. EXIT/NO/OFF//LEAVE
Navigation in and to menus and settings can also be done using the
1 2 3
wheel for navigation on the right control panel, rear part, and the keys
to confirm and cancel.
After logging into the service menus, the buttons for adjusting the
right-hand control panel can also be used to navigate in the menus
4
instead of the buttons on the display.
017469
1. Front/rear equivalent to and or and

depending on what is shown on the display
2. Key confirm
3. Key cancel
4. Wheel for navigation
Navigation to a menu, work instruction

To navigate to a menu, do as follows:
10:23 1 Navigate to the service menu using or .

CUSTOMER SETTI NGS
2 Confirm with or cancel with .
0
014981

8 Control system – Monitoring 8:5
8.2 Monitoring
8.2.1 Overload system
Overload system, description
1 0: 2 3 2 The machine's load sensor continuously measures the weight of the

10 20 load, see Load sensors, description, page 8:12. The weight from the
0 30
rpm x 1 00 load sensor and the attachment's position are compared with a load
curve and are used for different warnings for overloading.
21° 18 99999
km / h
Part of the overload system is a warning system, LLMC (Longitudinal
Load Moment Control). The system is used for stationary load handling,
in order not to jeopardise the machine's forward stability. LLMC is not
017470
35. 0t designed to control lateral stability or stability while driving. Nor does it
D U
take inclined ground conditions into account. Current load is shown in
Display of current load in the main menu the main menu with a bar on the right.
The bar's areas have different colours depending on how much of the
capacity is utilised in the current load position:
Blue green = 0-80 % of the max. load in current load position.
Yellow = 80-90 % of the max. load in current load position.
Red = 90-100 % of the max. load in current load position.
In the event of high load on the steering axle, machine speed is limited
dynamically depending on load, see Speed limitation, description, page
8:8.
If the operator exceeds the machine's load handling capacity (load

goes beyond permitted distance in accordance with the load curve)
then all hydraulics are blocked. With Switch bypass, certain parts of
the overload system are bypassed, see Bypass, description, page 8:6.
This makes it possible to lower and retract the boom in order to avoid
danger.
When the overload system blocks the functions, the following occurs:
016335
• the buzzer in the cab sounds (indication to operator)

• the event menu is shown in the display (indication to operator)
Event menu overload forward
• the boom movement is interrupted
Using the bypass, extension can be activated in order to move
away from the overload situation. Retract the extension until the
buzzer stops and the display screen disappears.
NOTE
Retract the boom before lowering it! Applies for all load handling!
8.2.1.5 Sensor boom angle

8.2.1.6 Sensor boom length

8.2.1.7 Sensor hydraulic pressure lift cylinder

See Sensor hydraulic pressure lift cylinder, description, page 8:16.

8:6 8 Control system – Bypass
8.2.2 Bypass
Bypass, description
When the overload system engages and turns off the hydraulic controls,
it may take place in a situation where it is necessary to bypass the
safety system.
012733
0 1 Bypass is activated using the bypass switch by the safety system
Switch, bypass (S1005).
Mode 0, normal function.
Mode 1, bypassing the safety system permits:

• lowering of load in case of overload
• locking and opening of twistlocks without complete contact
• 20'-40' spreading with locked twistlocks
• bottom lift without full contact
• release of parking brake in the event of malfunction of Switch,
parking brake or Sensor, operator-in-seat
• lifting above height limitation
• rotation past rotation stop
• load manoeuvring past limit for load centre limitation.
• lift, lower, and extension with active error in the overload system
• selection of travel direction in case of malfunction of Sensor,
operator-in-seat, speed is limited to 10 km/h
(The machine shifts to neutral position when no one is sitting in
the driver's seat.)
• use load handling functions at reduced speed in the event of faults
in the sensor for operator-in-seat
The Bypass warning lamp illuminates when bypass of safety locks

is activated.
DANGER
Bypassing the safety systems results in a risk of
tipping. Use at your own risk.
Extreme hazard to personal health and risk of property
damage!
Only use the bypass of safety systems in emergency
situations.

8 Control system – Load centre limitation 8:7
8.2.3 Load centre limitation

Load centre limitation, description
Load centre limitation prevents the load being moved too close to the
machine. Load centre limitation is controlled by the control system with
signals from the load sensor (and the cab's position on machines with
hydraulic cab movement ), see 8.2.11 Load sensors, page 8:12
and Hydraulic sliding cab, function description , page 9:92. This is
used, for example, in conjunction with cab lift in order to prevent the
container from damaging the cab.
The load can be operated beyond the set limit by activating bypass,
see Bypass, description, page 8:6.
016228
8.2.4 Height limitation

Height limitation, description
Height limitation prevents the machine lifting higher than a set height
without the operator being informed. Height limitation is controlled by
the control system with signals from the load sensor, see 8.2.11 Load
sensors, page 8:12.
A
When boom angle and boom extension indicate that the permitted
height is reached then lift and extension are blocked, and Event menu,
height limitation, is also activated.
016230

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

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

preset value by regulating the engine speed.
Machine speed is also limited by certain events in order to reduce

the risk of damage, e.g. in the event of: faults in the transmission,
high brake oil temperature, lifting loads near the machine's maximum
016346
capacity, bypass activated, raised cab . In most of these cases the
event menu is shown for the function that limits the speed, such as the
Event menu general speed limitation event menu for high brake temperature.
Machine speed is limited when:

• Control breaker is activated.
• The configuration ID number of the control units is incorrect.
Maximum speed is 10 km/h.
• Hydraulic oil temperature too high.
• The accumulator pressure for the brake function is too low.
Maximum speed is 10 km/h.
• Tilt lock is activated. Maximum speed is 5 km/h.
• Levelling lock is activated. Maximum speed is 5 km/h.
• Dynamic depending on the load on the steering axle, warning for
overload backwards.
Machine speed is limited depending on the load on the steering
axle. Event menu speed limitation steering axle is shown when
the speed is limited. Lower/extend the boom in order to reduce
the load on the steering axle.
NOTE
016336
In the event of overload on the steering axle, it is up to the operator

to exercise caution when manoeuvring, no functions are interrupted.
Event menu speed limitation steering axle load
To reduce the load and regain full operating speed, the boom must
be lowered or extended.
• Dynamic depending on the load on the drive axle, warning for

overload forwards.
Machine speed is limited depending on the load on the steering
axle. Event menu speed limitation drive axle is shown when the
speed is limited. Raise/retract the boom in order to reduce the load
on the drive axle.
• Dynamic depending on critical error codes
017476
The speed limitation is set using the initiation menu, see menu 8.2
Monitoring 1/XX INITIATE, page 8:127.
Event menu speed limitation drive axle load

8 Control system – Service indicator 8:9
8.2.6 Service indicator

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

See Maintenance manual section 8 Control system, group 8.2.6
Service indicator.

8:10 8 Control system – Service indicator
Service indicator, changing the service interval

See also Initiation, work instructions, page 8:98 for a general
explanation of how settings are made.
10:23 2 Navigate to the service menu with or and confirm with .

CUSTOMER SETTI NGS
0 014981
10:23 3 Enter diagnostic code 1111 to set with or and confirm with
0 WRI TE PI N CODE
0 0
015625
4 Select 8. CONTROL SYSTEM by scrolling with or and

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

* 8 . CONTROL SYSTEM *
8.1 Controls & I n s t r u me n t s

8.2 Monitoring
8.3 Error codes
8.4 Diagnostics
8.5 Setup
8.6 Software
015629

8 Control system – Service indicator 8:11
6 Select INITIATE by scrolling with or and confirm with .

8.2 Monitoring
8.3 Error codes
8.4 Diagnostics
8.5 Setup
8.6 Software
015735
7 Select Service time interval by scrolling with or .
See also 8.2 Monitoring 3/XX INITIATE, page 8:128 for setting
the service interval.
8 Press once for EDIT and adjust the interval time with or .
Press once for SAVE in order to save the set value or press
to cancel the entry.
9 Select Service time pop up hours by scrolling with or .

See also 8.2 Monitoring 5/XX INITIATE, page 8:128 for setting
how long the service interval is expired before a warning is shown
to the operator.
10 Press once for EDIT and adjust the time with or .
Press once for SAVE in order to save the set value or press
to cancel the entry.
11 Leave Initiation by scrolling out with .

8:12 8 Control system – Load sensors
8.2.11 Load sensors

Load sensors, description
Load sensors use the pressure sensors for the lift cylinders together
with sensors for boom angle and boom length in order to calculate the
load. The weight of the load is calculated as a function of boom angle,
boom length and the pressure in the lift cylinders. This information is
used for several of the machine's subsystems, e.g.:
• Overload system
• Weight indicator
• Load calculator
• Load centre limitation
• Height limitation
Load sensors, function description
D7950 7
D7971
D5 2, 4, 6
D5
D1
016863
5 5 1 3

1 Sensor boom length (B7686) sends U = 0.5-4.5 V Sensor, boom length, description, page 8:19.
voltage signals proportional to the boom D2: Diagnostic menu, see 8.2 Monitoring
length to Control unit KFU (D7971). 16/XX DIAGNOSE, page 8:54.
2 Control unit KFU (D7971) sends boom Checked by control 11.5.3.4 KFU control unit (D7971), page
length information on the CAN bus. system, error shown with 11:31
error code.
3 Sensor boom angle (B7241) sends U = 0.5-4.5 V Sensor boom angle, description, page 8:18
voltage signals proportional to the boom D4: Diagnostic menu, see 8.2 Monitoring
angle to Control unit KFU (D7971). 16/XX DIAGNOSE, page 8:54.
4 Control unit KFU (D7971) sends boom Checked by control 11.5.3.4 KFU control unit (D7971), page
angle information on the CAN bus. system, error shown with 11:31
error code.
5 Sensor hydraulic pressure lift cylinder U = 0.5-4.5 V Sensor hydraulic pressure lift cylinder,
piston side left (B7226-1), Sensor description, page 8:16
hydraulic pressure lift cylinder rod D6: Diagnostic menu, see 8.2 Monitoring
side left (B7226-3), Sensor hydraulic 17/XX DIAGNOSE, page 8:55 and 8.2
pressure lift cylinder piston side right Monitoring 18/XX DIAGNOSE, page 8:55.
(B7226-2) and Sensor hydraulic pressure
lift cylinder rod side right (B7226-4)
send voltage signals proportional to the
hydraulic pressure in the lift cylinders to
Control unit KFU (D7971).

8 Control system – Load sensors 8:13

6 Control unit KFU (D7971) calculates and Checked by control 11.5.3.4 KFU control unit (D7971), page
sends the weight on the CAN bus. The system, error shown with 11:31
weight is calculated by a machine-unique error code.
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.
7 Control unit KID (D7950) shows weight - 11.5.3.3 Control unit, KID (D7950), page
information in the display. 11:29
Load sensors, calibration
DANGER
Do not leave the machine during calibration. The
machine may start to move.
DANGER
The overload system must be function tested after
calibration.
Extreme danger
Deficient calibration may cause load calculation to be
incorrect. The machine must not be operated without
the overload system having been function tested.
NOTE
It is very important for accuracy that all steps are performed in
the given order.
1 Warm up the hydraulic oil to operating temperature, min. 40 °C.

Use lift and extension during warming up in order to heat the oil in
the cylinders.
2 Park the machine on level ground without load, centre the
attachment and apply the parking brake.
10:23
0
014981

10:23 4 Enter service code with or . Confirm each figure with .

WRI TE PI N CODE
0
NOTE
0 0
015625
0
5 Select 8. CONTROL SYSTEM by scrolling with or and

confirm with .
8 . CONTROL SYSTEM
015624
6 Select 8.2 Monitoring by scrolling with or and confirm with .


8.2 Monitoring
8.3 Error codes
8.4 Diagnostics
8.5 Setup
8.6 Software
015629

8.2 Monitoring
8.3 Error codes
8.4 Diagnostics
8.5 Setup
8.6 Software
015628
8 Lower the boom to the lowest position (0°). Press to save this
value.
9 Select CALIBRATE 6 by scrolling with .

10 Lift the boom to its highest angle. Press to save this value.
12 Retract the boom completely. Press to save this value.

14 Extend the boom completely. Press to save this value.

a. Retract the boom completely.

b. Lower the boom and inch towards the end until 2-4 cm
remains on the lift cylinders.
c. Wait approximately five seconds to stabilise the pressure.
d. Press to save this value.
a. Extend the boom completely.

b. Wait approximately five seconds to stabilise the pressure.
c. Press to save this value.
NOTE
Negative values indicate switched connectors on the pressure
sensors.
Large variations between right and left indicate errors in the
sensors' signals.
Checking the calibration

18 Operate the machine without a load, stop the machine and check
that Actual load = 00000 ± 500 kg.
Check lifting/lowering boom in different operating ranges, as well
as extension long in and extension long out. The boom must not
reach the end positions during checking.
If the weight is not correct, repeat the calibration.
NOTE
Check when stationary. (Operating generates dynamic forces.)
19 Leave Calibration by scrolling out with .

20 Check that the function of the overload system disengages the
boom movement at high load.
a. Take a load and lift it so that it just lifts from the ground.
b. Run out extension and hold the load as close to the ground
as possible.
c. Check that the overload system disengages the boom
movement.
Sensor hydraulic pressure lift cylinder, description

Sensor, hydraulic pressure lift cylinder measures the pressure in the lift
cylinders and is installed on valve block lift cylinder.
The pressure in the cylinders is measured in order to measure the load

as part of the overload system and to determine when regeneration can
be engaged. If the machine is equipped with the option for scale then
the pressure sensors are also used to measure the load.
1 2
The sensors are supplied with voltage by, and send a voltage signal
proportional to the hydraulic oil pressure to Control unit KFU (D7971).
The signals can be checked with the diagnostic menu, see 8.2
Monitoring 17/XX DIAGNOSE, page 8:55 and 8.2 Monitoring 18/XX
016931
Valve block lift cylinder

1. Sensor, hydraulic pressure lift cylinder, rod
side, left (B7226-3)
Sensor, hydraulic pressure lift cylinder, rod side,
right (B7226-4)
2. Sensor, hydraulic pressure lift cylinder, piston
Sensor, hydraulic pressure lift cylinder, piston
side, right (B7226-2)

Sensor, hydraulic pressure lift cylinder, replacement
NOTE
Safety.

NOTE
3 Disconnect the cable harness from the sensor for hydraulic

pressure lift cylinder.
4 Remove the sensor for hydraulic pressure lift cylinder.
NOTE
1 2 from impurities.
5 Fit the new sensor.
NOTE
correctly.
6 Connect the cable harness to the sensor for hydraulic pressure.

7 Clamp the cable harness as before.
hydraulic system.
016931
Valve block lift cylinder NOTE

1. Sensor, hydraulic pressure lift cylinder, rod Check that the accumulator drain valve is fully closed and tighten
side, left (B7226-3) the lock ring.
Sensor, hydraulic pressure lift cylinder, rod side,
right (B7226-4) 9 Turn on the main electric power and start the engine.
2. Sensor, hydraulic pressure lift cylinder, piston 10 Activate the lift carefully.
Sensor, hydraulic pressure lift cylinder, piston
side, right (B7226-2) CAUTION
product damage.
11 Check that the hydraulic connections of the valve block seal tight
and lift/lower works correctly.
manual.

13 Check the function of the sensor from the diagnostic menu. See
8.2 Monitoring 17/XX DIAGNOSE, page 8:55.
Raise the boom and check that the sensor is sending values. The
value should be approximately the same as from the sensor on
the second lift cylinder.
Sensor boom angle, description

The boom's angle is measured by Sensor, boom angle (B7241), that
detects the boom's angle 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.
Sensor boom angle (B7241) is supplied with voltage and sends signals
proportional to the angle to Control unit KFU (D7971)
The signal can be checked with the diagnostic menu, see 8.2
Monitoring 16/XX DIAGNOSE, page 8:54.
016932
Sensor boom angle (B7241)

Sensor, boom angle, replacement

2 Replace the sensor.
3 Turn on the main electric power and turn the start key to position I.
4 Calibrate load sensor, see Load sensors, calibration, page 8:13.
5 Check that the end position damping works in both upper and
lower end positions.
016932
Sensor boom angle (B7241)
Sensor, boom length, description

Sensor, boom length (B7686) detects the lift boom's extension and is
fitted 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 inner
boom. When the boom is extended, the wire acts on the potentiometer
and the signal is changed.
Sensor, boom length (B7686) is supplied with voltage by, and sends a
voltage signal proportional to the length to Control unit KFU (D7971).
Monitoring 16/XX DIAGNOSE, page 8:54.
016932
Sensor, boom length (B7686)

Sensor, boom length, replacement

2 Replace the sensor.
3 Turn on the main electric power and turn the start key to position I.
4 Calibrate the sensor, see Load sensors, calibration, page 8:13.
5 Check that the end-position damping works in both outer and inner
end-positions.
016932
Sensor, boom length (B7686)

8 Control system – Statistics 8:21
8.2.12 Statistics
Trip computer, description
1 2
10:23 2 The trip computer shows fuel consumption, speed and load calculator.
The load calculator option in the trip computer is only available with
1756 r pm
the scales option.
32.8 l/h 9.5 km/h
3
20.2 km/h
21°
26.1 l/h
74.8 km
120:36 h 14432
016518
1. Fuel consumption
2. Speed
3. Load calculator
Statistics menus, description
Data regarding operating time, fuel consumption, mileage and lifting

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

reset
Resettable values
Statistics on operating Operating times engine

times
Operating times
transmission
Operating times
hydraulic pump
Operating times idling
Statistics on fuel Used quantity of fuel l/h

consumption/total
quantity fuel used Used quantity of fuel
l/100 km
Used quantity of fuel
l/each
Statistics on mileage km
Lift statistics Load quantity/h

This option assumes
that the scales functions
and trip computer are
available.

8:22 8 Control system – Weight indicator
8.2.13 Weight indicator

Weight indicator, description
1 0: 2 3 2 The weight indicator shows the weight of the raised load. The weight
10 20 indicator uses the load sensor's sensor signals in order to calculate the
0 30
rpm x 1 00 weight of the lifted load, see Load sensors, description, page 8:12. The
weight is shown in the main menu on the display.
21° 18 99999
km / h
Load weight is shown in the main menu, more detailed weight
information is shown in Operating menu scale and the menus for
statistics and operating time. For information on menus and handling,
017471
16. 7t see Operator's manual.
D U
Display of load weight in the main menu
Scales, weighing and load totalling
1 Grab the load.

1 10:23
4
CUSTOMER SETTI NGS 2 Perform a lift movement and then lower the load slowly about 30
2 cm.
5
0 3 Select Operating menu, scale / . Confirm with .
3 6 4 Select tarring with / .
0 Switch between to tare (current weight displayed) and not to tare
(0 shown).
Confirm with .
0
016095
5 Select load weight with / .

The value of the load weight can be added to the total weight
1. Tare symbol
with .
2. Total symbol
6 Select total weight with /
3. Reset symbol
The value of the total weight can be reset by .
4. Tare weight
7 Exit the menu with .
5. Load weight (net weight)
6. Sum weight (gross weight)

See Sensor hydraulic pressure lift cylinder, description, page 8:16.



8 Control system – Container counter 8:23
8.2.14 Container counter

Container counter, description
10:23
The container counter counts the number of lifted containers. The

counter has two counters that can be reset separately. The container
1 23 1 234 7 6 pcs a counter counts in different ways depending on whether the top
1 23 2 234 7 6 pcs b lift/overheight jacks (twistlocks) or bottom lift (lift jacks) is used.
1 23
1 234 7 6 pcs c Top lift
1 23
2 234 7 6 pcs d The container counter counts lifting when contact is broken with locked
016384
twistlocks and twistlocks are not opened within 8 seconds.
Overheight
Operating menu load counter
a. Counter 1 top lift
b. Counter 2 top lift The container counter counts lifting when contact is broken with locked
c. Counter 1 bottom lift/overheight lift twistlocks and twistlocks are not opened within 8 seconds.
d. Counter 2 bottom lift/overheight lift Bottom lift
The container counter counts lifting when the clamp function is

activated and lifting is started and unloading clamping position is not
activated within 10 seconds.
Container counter, function description (product

alternative top lift)
Reference
1, 4, 7 D2
10 11
D7902 D7901 D7950
D7911
3, 6, 9
D5
D2
2, 8 5
1 23
016864

8:24 8 Control system – Container counter

1 The attachment is positioned over - Lifting/lowering, function description, page 7:14
a container with the functions 7.2 Extension, function description, page 7:29
Lifting/lowering, 7.3 Side shift.
D1: Diagnostic menu, 7.1 Controls and Instr
2 Sensor, contact left front (Y7202L), Sensor directly Sensor, contact, description, page 7:108
Sensor, contact right front (Y7202R), opposite indicator D2: Diagnostic menu, see 7.9 Load Carrier
Sensor, contact left rear (Y7203L), plate: U = 24 V 4/XX DIAGNOSE, page 8:50
Sensor, contact right rear (Y7203R)
send voltage signals to Control unit KAU
(D7911).
3 Control unit KAU (D7911) sends contact Checked by control 11.5.3.8 Control unit KAU (D7911), page 11:38
on the CAN bus. system, error shown
with error code.
4 Twistlocks are rotated to the locked - Twistlocks, function description, page 7:103
position and are closed with the 7.9.1
Twistlocks function.
5 Sensor, locked twistlocks left (B7205L) Sensor directly Sensor, twistlocks, description, page 7:109
and Sensor locked twistlocks right opposite indicator D5: Diagnostic menu, see 7.9 Load Carrier
(B7205R) send voltage signals to plate: U = 24 V 5/XX DIAGNOSE, page 8:50
6 Control unit KAU (D7911) sends locked Checked by control 11.5.3.8 Control unit KAU (D7911), page 11:38
twistlocks on the CAN bus. system, error shown
with error code.
7 The container is lifted with the function - Lifting/lowering, function description, page 7:14
7.2 Lifting/lowering.
8 Sensor, contact left front (Y7202L), U=0V Sensor, contact, description, page 7:108
Sensor, contact right front (Y7202R), D2: Diagnostic menu, see 7.9 Load Carrier
Sensor, contact left rear (Y7203L), 4/XX DIAGNOSE, page 8:50
Sensor, contact right rear (Y7203R)
stop sending voltage signals to Control
unit KAU (D7911).
9 Control unit KAU (D7911) sends no Checked by control 11.5.3.8 Control unit KAU (D7911), page 11:38
contact on the CAN bus. system, error shown
with error code.
10 If the twistlocks remain locked for 8 - 11.5.3.1 KCU control unit (D7901), page 11:25
seconds then Control unit KCU (D7901)
adds one lift to the container counter.
11 Control unit KID (D7950) updates the Checked by control 11.5.3.3 Control unit, KID (D7950), page 11:29
display in Operating menu load counter. system, error shown
with error code.

8 Control system – Synchronised lift 8:25
8.2.15 Synchronised lift

Synchronised lift, description
Synchronised lift is when the load is lifted or lowered straight up or

down by means of the control system activating controlled lift and
extension for a straight movement. Synchronised lift is activated with
the control lever and uses Sensor boom angle and Sensor extension in
order to control the movement. The speed for lift, lower and extension
are controlled synchronously in order to obtain a straight movement.
Synchronised lift, function description

Height limitation Bypassed or boom height Height limitation, description, page 8:7
lower than height limitation.
1 D1
+ 2
D7902
D7971
5
D4
D3
016867
3 4

Control lever (S8150-Y) send Lower: U = 0.5-2.0 V D1: Diagnostic menu, see 7.1 Controls and
voltage signals to Control unit KPU Instr 5/XX DIAGNOSE, page 8:40 and 7.1
(D7902). Zero position: U = 2.0-3.0 V
Controls and Instr 7/XX DIAGNOSE, page
Lift: U = 3.0-4.5 V 8:41.
synchronised lift on the CAN bus. error shown with error code. 11:27
3 Sensor boom angle (B7241) sends U = 0.5-4.5 V Sensor boom angle, description, page 8:18
voltage signals to Control unit KFU D3: Diagnostic menu, see 8.2 Monitoring
(D7971). 16/XX DIAGNOSE, page 8:54
4 Sensor boom length (B7686) sends U = 0.5-4.5 V Sensor, boom length, description, page 8:19
voltage signals to Control unit KFU D4: Diagnostic menu, see 8.2 Monitoring
(D7971). 16/XX DIAGNOSE, page 8:54
5 Control unit KFU (D7971) controls Checked by control system, 11.5.3.4 KFU control unit (D7971), page
the functions 7.2 Lift/lower and 7.3 error shown with error code. 11:31
Extension at the same time so that Lifting/lowering, function description, page
the lifting movement is vertical. 7:14
Extension, function description, page 7:29

8:26 8 Control system – Diagnostics
8.4 Diagnostics
Diagnostics, general
Diagnostics are performed via menus in the display. Diagnostics is a
tool in order to perform service and troubleshooting.
The machine has built-in functions for troubleshooting called diagnostic

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

• Engine 8.4.1 Engine, page 8:28.
• Transmission, 8.4.2 Transmission, page 8:33.
• Brakes, 8.4.4 Brakes, page 8:36.
• Steering, 8.4.5 Steering, page 8:38.
• Load handling, 8.4.7 Load handling, page 8:40.
• Control system, 8.4.8 Control system, page 8:53.
• Frame, body, cab and accessories, 8.4.9 Frame, body, cab and
accessories, page 8:56.
• Common hydraulics, 8.4.10 Common hydraulics, page 8:78.
• Common electrics, 8.4.11 Common electrics, page 8:79.
• Pin diagnostics, 8.4.13 Pin diagnostics, page 8:95.
All diagnostic menus are listed below, except those for pin diagnostics.
The menus for pin diagnosis work in the same way for each
input/output, so only the principle is described. Some menus refer to
options that are only displayed if the machine is equipped with the
selected option.
Navigation diagnostic menus, work instructions

1 Park the machine.

CUSTOMER SETTI NGS
0
014981
10:23 3 Enter diagnostic code 1111 with or and confirm with .
0 WRI TE PI N CODE
0 0
015625

8 Control system – Diagnostics 8:27
4 Select the function with or and confirm with .

2 . TRANSMI SSI ON Symbol Function
1. Engine
2. Transmission
3. Drive axle
4. Brakes
015623
5. Steering
6. Suspension
7. Load handling
8 Control system
9. Frame, body, cab and accessories
10. Common Hydraulics
11. Common electrics
Pin diagnosis
5 Select Diagnose with or and confirm with .

* 2 . TRANSMI SSI ON *
6 Select group by scrolling with or and confirm with .
2.1 Controls & I n s t r u me n t s 7 Each menu group consists of a sequence of a number of menus.
2.2 Torque Conv & Cl u t c h Sy s The first menu for the selected group opens in the display. Use the
2.3 Mechanical T r a n s mi s s i o n
2.4 Hydraulic Tr a ns mi s s i o n arrow keys or to move to the desired menu.
2.5 Electrical T r a n s mi s s i o n
2.6 Lubrication Sys t e m
8 Use the function key to save the desired value. For a description
2.7 Cooling syst em of the menu screen, see Menu example, description, page 8:27.
2.8 Transmission Co n t r ol Sy s
NOTE
016048
Current values can only be adjusted within specific limits.
Menu example, description
1 All diagnostic menu, except for the pin diagnostics, are explained
2 3
separately.
2 . 8 Co n t r o l Sys t e m 2 XX DIAGNOS E
– Menu group, enter the group, 2.8 Control System, whose signals
Cur r e n t ge a r po s i t i o n 0
provides a basis for diagnosis. The menus are subdivided into the
Ope r a t i ng mode 0 same function groups as the manuals.
8
Fa ul t p r e s e nt 0 – Sequence number, 2/XX, enter the page number and total number
Conve r t e r p ump
( i mpe l l e r ) t or q u e
0 Nm 4 of menus in the menu loop. As the number of menus is dependent
Conve r t e r t ur bi n e 0 Nm
on how the machine is equipped, state the number of menus here
t or que with XX.
Ac t i ve c on f i g I D 0
– Diagnose state in the menu example that diagnosis is the selected
015873
MAN LEAVE
setting function. Other setup functions are Initiate for setting and
7 5 Calibrate for calibration.
6
– Variables, such as row 1 Current gear position, describe the
1. Menu group function/component that the signal/measurement comes from.
Each menu can contain 1-6 rows, where each row describes a
2. Sequence number variable with an associated signal value.
3. Selected setting function – Signal value, 0, is the current value for Current gear position.
4. Signal values All signal values in the menus in this manual are examples and
5. Function key LEAVE/Cancel may differ from the values in a real machine.
6. Arrow keys The following icons are used to explain further the signal values:
7. Function key Manual mode/Edit mode denotes a saved value.
8. Variables denotes a value from an output from a control unit.
denotes an input value which is measured by a control unit.

8:28 8 Control system – Engine
Explanation of pin status codes

The variable Pin status can have the following values.
Code Explanation
OK There is no error
O.C Open circuit
S.C Short circuit
O.C/S.C Open or short circuit
Other Other error
CfgErr Configuration error
8.4.1 Engine
8.4.1.1 Diagnostic menus Controls and instruments
engine
1.1 Controls & Instr 1/XX DIAGNOSE
Row 1 shows signal A from the accelerator pedal (B6900).
Row 2 shows the value in row 1 converted into % of the total possible
value.
Row 3 shows signal B from the accelerator pedal (B6900).
Row 4 shows the value in row 3 converted into % of the total possible
value.
Row 5 shows the requested pedal outcome in %.
Row 6 shows the requested speed to the engine via the accelerator
pedal.

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

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

8 Control system – Engine 8:29
1.2 Fuel System 2/XX DIAGNOSE

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

It is possible to reset the average fuel consumption. Change to 0
on row 4, Reset average fuel consumption. See Navigation of
menus, description, page 8:4 for an explanation how settings are
made.
8.4.1.6 Diagnostic menus Air intake and exhaust outlet
1.6 Intake Exhaust 3/XX DIAGNOSE

Row 1 shows the input intake temperature.
Row 2 shows the input pressure.
1.6 Intake Exhaust 4/XX DIAGNOSE

Row 1 describes signals for the emission control system.
Row 2 shows fuel level in AdBlue tank in %.
Row 3 shows temperature in AdBlue tank.
Row 4 shows the status for the exhaust cleaning system.

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

8.4.1.7 Diagnostic menus Cooling system
1.7 Cooling system 2/XX DIAGNOSE

Row 1 shows the engine's coolant temperature.
Row2 shows the transmission's oil temperature.
Row 3 shows the ambient temperature.
Row 4 shows the engine's turbo pressure.
Row 5 shows the intake temperature.
Row 6 shows the cooling fan capacity in %.

It is possible to change the value on row 6, Cooling fan ratio (perc
of engine rpm). See Navigation of menus, description, page 8:4
8.4.1.8 Diagnostic menus Lubrication system
1.8 Lubrication 1/XX DIAGNOSE

Row 1 shows the oil pressure.
Row2 shows the oil temperature.
1.8 Lubrication 2/XX DIAGNOSE

Engine alternative Volvo TAD1360VE
Row 1 shows the oil level.
8.4.1.9 Diagnostic menus, Control system, engine
1.9 Control System 1/XX DIAGNOSE

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

speed (EC1).

8 Control system – Engine 8:31

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

0 = not charging
1 = charging

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

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

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

Engine alternative CUMMINS QSM11
Row 1 shows the input for the start button (S1051).

0 = start button not active.
1 = start button active.
Row 2 shows output signal to starter relay (K3600).

It is possible to set the output signal for the starter relay on row
2, Starter relay output K3600 C1p43 D7971. See Navigation
of menus, description, page 8:4 for an explanation of how the
settings are made.
0 = starter motor not active.
1 = starter motor active.
Row 3 shows the true current to the relay.
Row 4 shows the pin status. See Explanation of pin status codes, page
8:28 for an explanation of pin status.
Row 5 shows the input start immobiliser (K3300).

0 = start immobiliser active, engine will not start.
1 = start immobiliser not active.
1.11 Start & Stop 2/XX DIAGNOSE

Engine alternative Volvo TAD1360VE.
Row 1 shows the input for the start button (S1051).

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

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

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

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

8 Control system – Transmission 8:33
8.4.2 Transmission
transmission

Row 1 describes the input signals from the travel direction selector
(S1310 or S1310-2).
Row 2 shows the input parking brake.
Row 3 shows the input forward.
Row 4 shows the input neutral.
Row 5 shows the input centre.
Row 6 shows the input reverse.
Machine with joystick control or mini-wheel
Row 1 describes the input signals forward/reverse from the mini-wheel

(S1310-3).
Row 2 shows the input forward.
Row 3 shows the input neutral.
Row 3 shows the input reverse.

Row 1 describes the control system's request to the transmission.
Row 2 shows the request forward.
Row 3 shows the request neutral.
Row 4 shows the request reverse.

8:34 8 Control system – Transmission

Row 1 shows the shifting position.
0 = manual.
1 = automatic.
Row 2 shows the input signal from Switch, automatic/manual shifting

(S1790).
0 = not activated.
1 = activated.
Row 3 shows the input signal from Switch, manual shifting down
(S1350-1).
0 = not activated.
1 = activated.
Row 4 shows the input signal from Switch, manual shifting up

(S1350-2).
0 = not activated.
1 = activated.
Row 5 shows the requested gear, +/- 125.
Row 6 shows the current gear +/- 125.
8.4.2.2 Diagnostic menus Torque converter/clutch
2.2 Torq Conv Clutch 1/XX DIAGNOSE

Row 1 describes declutching (CCO clutch cut off).
Row 2 shows the brake pressure.
Row 3 shows the brake pressure when declutching.
Row 4 shows whether declutching is activated.

0 = drive engaged.
1 = transmission disengaged.
Row 5 shows the transmission's current gear.

0 = neutral.
positive value = forward.
negative value = reverse.
8.4.2.6 Diagnostic menus Lubrication system
2.6 Lubrication Sys 1/XX DIAGNOSE

Row 1 shows the oil temperature in the transmission.

8.4.2.8 Diagnostic menus Control system,

transmission

Row 1 shows the current gear position for Transmission ZF. A positive
value means a forward gear is selected, a negative value means that a
reverse gear is selected. The value's range is -125 to +125 where the
number indicates the transmission speed gear.
Row 2 shows operating mode 0-7.

0 = Normal function.
1 = Safe mode "Substitute clutch control".
This operating mode is activated in the event of faults in the engine
speed sensor, check and rectify error codes.
2 = Safe mode "Limp-home".
This operating mode is activated in the event of certain faults in the
transmission, check and rectify error codes.
3 = Safe mode "Shut-down".
This operating mode is activated in the event of certain faults in the
transmission, check and rectify error codes.
4 = Control unit, transmission (D7930) shutdown.
5 = D7930 ignition key off.
The control unit saves settings and shuts down.
6 = D7930 idling.
Row 3 shows whether an error has occurred.

0 = There is no error.
1 = There is an active error, see the error code list and HMI menu
for more detailed information.
Row 4 shows the torque transmitted from the engine to the impeller in
the torque converter.
Row 5 shows the torque transmitted by torque converter to the

transmission.
Row 6 shows the configuration selected in the transmission.

8:36 8 Control system – Brakes

Row 1 shows the transmission's sump temperature.
Row 2 shows the torque converter temperature.
Row 3 shows the status of the transmission's oil filter pressure for
Transmission ZF.
0 = pressure OK.
1 = back pressure too high, change transmission oil filter.
Row 4 shows warning 0-15.
0 = no warning.
1 = warning sump temperature.
2 = warning high temperature in the hydraulic speed retardation
system.
3 = warning engine speed.
4 = warning high temperature torque converter.
5 = warning high output speed in the transmission.
6 = high input speed in the transmission.
7 = warning high input torque in the transmission.
8 = warning low temperature, shifting not permitted.
9 = too high engine speed, no direction change possible.
10 = too high engine speed to shift from neutral.
11 = speed limitation activated.
12 = speed over the limit.
13 = driver not in driver's seat.
14 = slipping wheels.
15 = spare.
8.4.4 Brakes
8.4.4.3 Diagnostic menus Power-assisted brake
system
4.3 Power Assisted 3/XX DIAGNOSE
Row 1 shows the signal from the brake pressure sensor (B7681).
Row 2 shows the brake pressure.
Row 3 shows the signal from the accumulator pressure sensor.
Row 4 shows the accumulator pressure.

Row 1 shows the signal from the accumulator pressure sensor (B7683).
Row 3 shows the requested speed limitation.
Row 4 shows the requested gear limitation.

8 Control system – Brakes 8:37
8.4.4.5 Diagnostic menus Parking brake system

4.5 Park Brake Sys 1/XX DIAGNOSE
Row 1 describes the parking brake system.
Row 2 shows whether the standard travel direction selector (S1310)

is in the parking brake position.
0 = not in position.
1 = in parking brake position.
Row 3 shows whether the travel direction selector (S1310) is in the

centre position.
1 = in centre position.
Row 4 shows whether the brake pressure is OK, when the pressure is
so high that the parking brake may be released.
0 = not OK.
1 = OK.
Row 5 shows whether the parking brake is released.

It is possible to release the parking brake on row 4, Parking brake
released. See Navigation of menus, description, page 8:4 for an
explanation how settings are made.
0 = not released.
1 = released.

Row 1 shows status for the output to Solenoid valve parking brake
(Y6420).
It is possible to set the signal for the output on row 1, Output
Y6420 C1p17 D7971. See Navigation of menus, description, page
8:4 for an explanation of how the settings are made.
0 = no signal.
1 = signal.
Row 2 shows the digital output current.
Row 3 shows the pin status for the output. See Explanation of pin
status codes, page 8:28 for an explanation of pin status.
Row 4 shows the signal from the parking brake sensor (B7682).
Row 4 shows the pressure for parking brake caliper.

0 = not released.
1 = released.

Row 1 describes the parking brake system.

0 = not released.
1 = released.

8:38 8 Control system – Steering
8.4.4.8 Diagnostic menus Temperature control,

cleaning and oil brake system
4.8 Oil Temp/Clean 1/XX DIAGNOSE

Row 1 shows the signal from Sensor, temperature brake system
(B7720).
Row 2 shows temperature of oil for brake system.
Row 3 shows requested speed limitation depending on the temperature

of the oil in the brake system.
Row 4 shows requested gear limitation depending on the temperature

of the oil in the brake system.

Row 1 describes cooling fan brake system (M6740).
Row 2 shows the requested pulse length.

It is possible to set the pulse length on row 2, Requested duty
cycle. See Navigation of menus, description, page 8:4 for an
Row 3 shows the required voltage in relation to the battery voltage
Row 4 shows the true current.
Row 6 shows the calculated impedance.
8.4.5 Steering
8.4.5.2 Diagnostic menus Power assisted system

Row 1 describes joystick control without feedback of the steering wheel
position.
Row 2 shows the on/off button for joystick control.

0 = off.
1 = on.
Row 3 shows whether the left arm rest is in position.

1 = in position.
Row 4 shows the signal from the joystick (R8250-1).

8 Control system – Steering 8:39

Row 1 describes mini-steering wheel.
Row 2 shows the status for the on/off button for mini-wheel steering.
0 = off.
1 = on.
Row 3 shows whether the left arm rest is in position.

1 = in position (lowered).
Row 4 shows the signal from the mini-wheel's sensor channel 1

(R8250-1).
Row 5 shows the signal from the mini-wheel's sensor channel 2

(R8250-2).

Row 1 shows status for voltage feed to the controls in the arm rest.
0 = no voltage feed.
1 = voltage feed.
Row 4 shows status for indicator lamp mini-wheel steering (H5992).

0 = off.
1 = on.
Row 5 shows actual current to indicator lamp mini-wheel steering

(H5992).

Row 1 shows status for voltage feed to Electric steering module
(Y6150).
0 = no voltage feed.
1 = voltage feed (joystick control or mini-wheel active).
Row 4 shows the value of the return signal from the coil for Electric
steering module (Y6150). The return signal shows how much pressure
and in which direction the steering module actuates out to the steering
cylinder, 50% corresponds to no steering angle (neutral position).
Row 5 shows actual voltage from Electric steering module (Y6150).

8:40 8 Control system – Load handling

Row 1 shows error signal for Electric steering module (Y6150).
8.4.7 Load handling

7.1 Controls and Instr 4/XX DIAGNOSE

Row 1 shows whether the hydraulic functions are activated.
0 = not active.
1 = active.
Row 2 shows the signal from the control breaker (S2500).

0 = not activated.
1 = activated.
Row 3 shows the driver in seat sensor (B2300).

0 = driver not in seat.
1 = driver in seat.
Row 4 shows the signal from the bypass switch (S1005).

0 = not bypassed.
1 = bypassed.
Row 5 shows whether the hydraulic functions are reduced.

0 = not reduced.
1 = reduced.
Reduced hydraulic function means that the value of the levers is
restricted to 50% movement speed.
It is possible to use the reduced hydraulic functions when row 3=0
and row 4=1.

Row 1 describes Control lever (S8150).
Row 2 shows the position on the X-axis with the help of signals from
potentiometer (R8070).
Row 3 shows control lever actuation as a percentage.
Row 4 shows the position on the Y-axis with the help of signals from
Row 5 shows control lever actuation as a percentage.

8 Control system – Load handling 8:41

Row 1 describes the thumb control on Control lever (S8150).
Row 2 shows the position on the X-axis with the help of signals from
Row 3 shows thumb lever actuation as a percentage.
Row 4 shows the position on the Y-axis with the help of signals from
Row 5 shows thumb lever actuation as a percentage.

Row 1 describes the buttons on Control lever (S8150).
Row 2 shows the signal from Switch, alternative function (S1991).

0 = not activated.
1 = activated.
Row 3 shows the signal from Switch, horn (S1490).

0 = not activated
1 = activated
Row 4 shows the signal from Switch, open twistlocks (S1020).

0 = not activated.
1 = activated.
Row 5 shows the signal from Switch, levelling lock (S1037).

0 = not activated.
1 = activated.
Row 6 shows the signal from Switch, tilt lock.

0 = not activated.
1 = activated.
8.4.7.2 Diagnostic menus Lifting/lowering
7.2 Lifting Lowering 6/XX DIAGNOSE

Row 1 shows the output to the lift solenoid valve (Y6005). Output
actual current in % of max. current that is set in Initiation, see 7.2
Lifting Lowering 12/XX INITIATE, page 8:113.
Row 2 shows the requested current.

It is possible to set the current on row 2 manually, Requested
current. See Navigation of menus, description, page 8:4 for an
Row 6 shows the pulse length. Pulse length in % of the battery voltage
is another measure of how much the valve is operated.


Row 1 shows the output to the lower solenoid valve (Y6004). Output
Lifting Lowering 14/XX INITIATE, page 8:113.


Row 1 describes controlling blocking valves for the lift cylinders.
Row 2 shows status for activation

0 = blocking valves not activated (lift cylinders blocked).
1 = blocking valves activated (lowering possible).
Row 3 shows actual current to Solenoid valve blocking left (Y6045-LE).
Row 4 shows pin status for the output to Solenoid valve blocking left
(Y6045-LE). See Explanation of pin status codes, page 8:28 for an
explanation of pin status.
Row 5 shows actual current to Solenoid valve blocking left (Y6045-RI).
Row 6 shows pin status for the output to Solenoid valve blocking left
(Y6045-RI). See Explanation of pin status codes, page 8:28 for an

Row 1 describes controlling the regeneration valves for the lift cylinders.

0 = regeneration valves not activated.
1 = regeneration valves activated (regeneration engaged).
Row 3 shows actual current to Solenoid valve regeneration left

(Y6051-LE).
Row 4 shows pin status for the output to Solenoid valve regeneration
left (Y6051-LE). See Explanation of pin status codes, page 8:28 for an
Row 5 shows actual current to Solenoid valve regeneration right

(Y6051-RI).
Row 6 shows pin status for the output to Solenoid valve regeneration
right (Y6051-RI). See Explanation of pin status codes, page 8:28 for an

8.4.7.3 Diagnostic menus Extension
7.2 Extension 1/XX DIAGNOSE

Row 1 shows the output to Solenoid valve boom out (Y6006). Output
Extension 2/XX INITIATE, page 8:116.


Row 1 shows the output to Solenoid valve boom in (Y6007). Output
Extension 4/XX INITIATE, page 8:117.


Row 1 describes controlling Solenoid valve blocking extension (Y6050).

0 = blocking valve not activated (lift cylinders blocked).
1 = blocking valve activated (lowering possible).
Row 4 shows pin status for the output. See Explanation of pin status
codes, page 8:28 for an explanation of pin status.


Row 1 describes controlling Solenoid valve regeneration (Y6051-1).
0 = regeneration valve not activated.
1 = regeneration valve activated (regeneration engaged).

Row 1 describes controlling Solenoid valve pump unloading (Y6093).
0 = regeneration valve not activated.
1 = regeneration valve activated (regeneration engaged).
8.4.7.4 Diagnostic menus Side shift

7.4 Side Shift 3/XX DIAGNOSE
Row 1 shows the output to Solenoid valve, side shift right (Y6021).
Output actual current in % of max. current that is set in Initiation, see
7.4 Side Shift 6/XX INITIATE, page 8:118.
Row 6 shows the pulse length.
7.4 Side Shift 4/XX DIAGNOSE

Row 1 shows the output to Solenoid valve, side shift left (Y6020).
7.4 Side Shift 8/XX INITIATE, page 8:118.

8.4.7.5 Diagnostic menus Spreading
7.5 Spreading 7/XX DIAGNOSE

Row 1 describes switch for the spreading function.
Row 2 shows the signal from Switch stop at 30' (S1004).

0 = not activated.
1 = activated.
Row 3 shows the signal from Switch automatic spreading 20'-40'

(S1012-2).
0 = not activated.
1 = activated.
Row 4 shows the signal from Switch, spreading (S1012).

0 = not activated.
1 = activated (spreading in).
Row 5 shows the signal from Switch, spreading (S1012).

0 = not activated.
1 = activated (spreading out).

Row 1 describes position sensor for the spreading function.
Row 2 shows the signal from Sensor end position 20'-40' (B7690).
0 = not activated.
1 = activated.
Row 3 shows the signal from Sensor end position 30' (B7770).
0 = not activated.
1 = activated.

Row 1 shows the output to Solenoid valve, spreading out (Y6018).
7.5 Spreading 14/XX INITIATE, page 8:119.



Row 1 shows the output to Solenoid valve, spreading in (Y6019).
7.5 Spreading 17/XX INITIATE, page 8:120.


Row 1 describes buzzer for automatic spreading 20 - 40 feet.
Row 2 shows the requested output signal.

It is possible to manually activate the buzzer on row 2, Requested
output. See Navigation of menus, description, page 8:4 for an
0 = not activated.
1 = activated, buzzer active.
Row 3 shows actual current to Buzzer automatic spreading 20 - 40

feet (H9003).
8.4.7.6 Diagnostic menus Rotation
7.6 Rotation 1/XX DIAGNOSE

Row 1 shows output to Solenoid valve rotation clockwise (Y6008).
7.6 Rotation 2/XX INITIATE, page 8:121.



Row 1 shows output to Solenoid valve rotation anticlockwise (Y6009).
7.6 Rotation 4/XX INITIATE, page 8:122.


Row 1 describes position sensors.
Row 2 shows the signal from Sensor, rotation stop (B7225).

0 = not activated.
1 = activated.
8.4.7.7 Diagnostic menus Tilt
7.7 Tilt 4/XX DIAGNOSE

Row 1 shows the output to Solenoid valve, tilt out (Y6010). Output
actual current in % of max. current that is set in Initiation, see 7.7 Tilt
8/XX INITIATE, page 8:123.



Row 1 shows the output to Solenoid valve, tilt in (Y6011). Output actual
current in % of max. current that is set in Initiation, see 7.7 Tilt 10/XX
INITIATE, page 8:123.


Row 1 describes tilt lock.
Row 2 shows the status for tilt lock.

It is possible to manually activate tilt lock on row 2, Requested
0 = lock position
1 = float position (solenoid valves activated)
Row 3 shows actual current to Solenoid valve tilt lock (Y6012-1).
Row 5 shows actual current to Solenoid valve tilt lock (Y6012-2).
8.4.7.8 Diagnostic menus Levelling
7.8 Levelling 3/XX DIAGNOSE

Row 1 shows the output to Solenoid valve clockwise (Y6035). Output
Levelling 6/XX INITIATE, page 8:124.


Row 1 shows the output to Solenoid valve anticlockwise (Y6036).
7.8 Levelling 8/XX INITIATE, page 8:125.

Row 1 describes levelling lock.
Row 2 shows the status for levelling lock.

It is possible to manually activate the levelling lock on row 2,
Requested output. See Navigation of menus, description, page
8:4 for an explanation how settings are made.
0 = lock position
1 = float position (solenoid valves activated)
Row 3 shows actual current to Solenoid valve levelling lock (Y6034-1).
Row 5 shows actual current to Solenoid valve levelling lock (Y6034-2).
8.4.7.9 Diagnostic menus Load carrier
7.9 Load Carrier 3/XX DIAGNOSE

Row 1 describes twistlocks.
Row 2 shows the signal from Switch, lock twistlocks (S1003).

0 = not activated.
1 = activated.
Row 3 shows the signal from Switch, open twistlocks (S1020).

0 = not activated.
1 = activated.


Row 1 describes position sensor for contact twistlocks.
Row 2 shows the signal from Sensor contact left front (B7202-FL).
0 = not activated.
1 = activated.
Row 3 shows the signal from Sensor contact right front (B7202-FR).
0 = not activated.
1 = activated.
Row 4 shows the signal from Sensor contact left rear (B7202-RL).
0 = not activated.
1 = activated.
Row 5 shows the signal from Sensor contact right rear (B7202-RR).
0 = not activated.
1 = activated.

Row 1 describes position sensor for twistlocks.
Row 2 shows the signal from Sensor, locked twistlocks left (B7205-LE).
0 = not activated.
1 = activated.
Row 3 shows the signal from Sensor, unlocked twistlocks left rear
(B7204-LE).
0 = not activated.
1 = activated.
Row 4 shows the signal from Sensor, locked twistlocks right (B7205-RI).
0 = not activated.
1 = activated.
Row 5 shows the signal from Sensor, unlocked twistlocks right

(B7204-RI).
0 = not activated.
1 = activated.

Row 1 describes Solenoid valve lock twistlocks (Y6040).
Row 2 shows status for the output.

Requested output Y6040 C1p14 D7911. See Navigation of
menus, description, page 8:4 for an explanation of how the settings
are made.
0 = not activated.
1 = activated (open twistlocks).


Row 1 describes Solenoid valve open twistlocks (Y6039).

Requested output Y6039 C1p15 D7911. See Navigation of
are made.
0 = not activated.
1 = activated (lock twistlocks).

Row 1 describes Indicator light, locked twistlocks (H6530-1).

Requested output H5630-1 C1p13 D7911. See Navigation of
are made.
0 = not activated.
1 = activated (lamp illuminated).

Row 1 describes Indicator light, open twistlocks (H6520-1).

are made.
0 = not activated.

Row 1 describes Indicator light, contact twistlocks (H6540-1).

are made.
0 = not activated.


Row 1 describes the ground signal to the indicator lights on the boom.
Ground signal pulse length is controlled in order to increase and
decrease the brightness of the indicator lights.
It is possible to manually set the pulse length on row 2, Requested
duty cycle C2p35 D7911. See Navigation of menus, description,
page 8:4 for an explanation of how the settings are made.
Row 3 shows the requested voltage.

Row 1 describes Indicator light, locked twistlocks (H6530-2).
are made.
0 = not activated.

Row 1 describes Indicator light, open twistlocks (H6520-2).
are made.
0 = not activated.

Row 1 describes Indicator light, contact twistlocks (H6540-2).
are made.
0 = not activated.

8.4.7.10 Diagnostic menus Other functions
8.4.8 Control system


Row 1 describes control of the searchlights in the panels.
Row 2 describes Sensor, ambient brightness (B7252).
Row 3 shows the input signal from Sensor, ambient brightness (B7252).
Row 4 describes the drive-train/wiper control panel (A3700-02).

It is possible to manually control the pulse length (brightness)
on row 5, Requested duty C6p18, C7p20 and C9p22. See
Navigation of menus, description, page 8:4 for an explanation of
how the settings are made.

Row 1 describes control of the function lights in the panels.
Row 4 describes the drive-train/wiper control panel (A3700-02).

It is possible to manually control the pulse length (brightness)
on row 5, Requested duty C6p19, C7p21 and C9p23. See

Row 1 describes control of the searchlight on the switch.
Row 4 describes output signal to searchlight in switch.

It is possible to manually control the pulse length (brightness) on
row 5, Requested duty. See Navigation of menus, description,
page 8:4 for an explanation how settings are made.

8:54 8 Control system – Control system
8.4.8.2 Monitoring, diagnostic menu 1-15
8.2 Monitoring 1/XX DIAGNOSE

Row 1 shows the speed limitation request. The value 99.9 kph means
that there is no speed limitation.
Row 2 shows the gear limitation request.
Row 3 shows the speed limitation request.
Row 4 shows whether speed limitation is activated.

0 = not activated.
1 = activated.
Row 4 shows the torque limitation request.
Row 5 shows whether torque limitation is activated.

0 = not activated.
1 = activated.

Row 1 shows the number of hours remaining to the next service
interval.
Row 2 shows the number of hours when restoring a new service

interval.

Row 1 describes the overload system.
Row 2 shows the threshold speed below which the overload system is
active.
Row 4 shows the current vehicle speed.

Row 1 describes hydraulic load sensor.
Row 2 shows the signal from Sensor, boom angle (B7241).
Row 3 shows recalculated boom angle.
Row 4 shows the signal from Sensor, boom length (B7686).
Row 5 shows recalculated boom length.


Row 2 describes pressure sensors.
Row 3 shows the signal from Sensor lift cylinder piston side left
(B7226-1).
Row 4 shows the signal from Sensor lift cylinder rod side left (B7226-3).
Row 5 shows the signal from Sensor lift cylinder piston side right
(B7226-2).
Row 6 shows the signal from Sensor lift cylinder rod side right
(B7226-4).

Row 2 describes pressure sensors.
Row 3 shows the recalculated signal from Sensor lift cylinder piston
side left (B7226-1).
Row 4 shows the recalculated signal from Sensor lift cylinder rod side
left (B7226-3).
Row 5 shows the recalculated signal from Sensor lift cylinder piston
side right (B7226-2).
Row 6 shows the recalculated signal from Sensor lift cylinder rod side
right (B7226-4).

Row 2 shows the permitted load at current load position.
Row 3 shows the measured load at current load positions.
Row 4 shows calculated axle weight on the steering axle at current

load position.
Row 5 shows calculated axle weight on the drive axle at current load
position.
Row 5 shows distance from the drive axle's centre point to the load's
centre point.

Row 2 shows the machine's total height.
Row 3 shows the height from the ground to the attachment's mounting
in the boom.
Row 4 shows the height from the ground to the lower edge of the
attachment.
Row 5 shows distance from the front wheel's front edge to the load's
centre point.
Row 5 shows distance from the drive axle's centre point to the load's
centre point.

8:56 8 Control system – Frame, body, cab and accessories
8.4.9 Frame, body, cab and accessories


Row 1 shows the signal from the bypass switch (S1005).
0 = not activated.
1 = activated.
Row 2 shows bypass active.

It is possible to manually set bypass active on row 2, Override
active. See Navigation of menus, description, page 8:4 for an
0 = not activated.
1 = activated, bypassed.

Row 1 describes the switch to adjust the steering panel.
Row 2 shows the input for the steering panel up adjustment switch
(S1058-1).
Row 3 shows the input for the steering panel down adjustment switch
(S1058-2).

Row 1 describes the adjustment of the steering panel.
Row 2 shows the steering motor output, steering panel up/down

(M6953).
0 = not active.
1 = active.
Row 3 shows the direction H-bridge.

It is possible to manually set the H-bridge direction on row 2,
H-bridge direction. See Navigation of menus, description, page
0 = down.
1 = up.
Row 6 shows the feedback signal for steering panel position.

8 Control system – Frame, body, cab and accessories 8:57

Row 1 describes the adjustment forward/back of the right arm rest.
Row 2 shows the input for right arm rest forward adjustment switch
(S1056-1).
0 = not activated.
1 = activated.
Row 3 shows the input for right arm rest back adjustment switch
(S1056-2).
0 =not activated.
1 = activated.

Row 1 describes the adjustment forward/back of the right arm rest.
Row 2 shows the output for the control motor steering panel
forwards/back (M6941).
0 = not active.
1 = active.

0 = back.
1 = forward.
Row 6 shows the feedback signal for the arm rest length position.

Row 1 describes the height adjustment of the right arm rest.
Row 2 shows the input for right arm rest up adjustment switch
(S1057-1).
Row 3 shows the input for right arm rest down adjustment switch
(S1057-2).


Row 1 describes the height adjustment of the right arm rest.
Row 2 shows the steering motor output, panel up/down (M6942).

0 = not active.
1 = active.

0 = downward.
1 = upward.
Row 6 shows the feedback signal for the arm rest height position.
8.4.9.3 Seat, diagnostic menu 1-2
9.3 Seat 1/XX DIAGNOSE

Row 1 shows the input for seatbelt contact (B2250).
0 = seatbelt not fastened.
1 = seatbelt fastened.
Row 2 shows the input for driver in seat contact (B2300).

0 = no driver in seat.
1 = driver in seat.
Row 3 shows an indication that the seatbelt is not fastened.

0 = seatbelt fastened.
1 = seatbelt not fastened.
8.4.9.4 Diagnostic menus Air conditioning unit
9.4 Climate System 1/XX DIAGNOSE

Row 1 describes the air conditioning control panel.
Row 2 shows the input for the defroster switch (S1390).

0 = not active.
1 = active.
Row 3 shows the input for the recirculation switch (S1910).

0 = not active.
1 = active.
Row 4 shows the input for the residual heat switch (S1019).
0 = not active.
1 = active.
Row 5 shows the input for the auto air conditioning switch (S1054).
0 = not active.
1 = active.


Row 2 shows the input for the increase fan speed switch (S1180-1).
0 = not active.
1 = increases fan speed.
Row 3 shows the input for the decrease fan speed switch (S1180-2).
0 = not active.
1 = reduce fan speed.
Row 4 shows the input for the increase temperature switch (S1052-1).
0 = not active.
1 = increases temperature.
Row 5 shows the input for the decrease temperature switch (S1052-2).
0 = not active.
1 = lower temperature.

Row 2 shows the input for the roof air distribution switch (S1053-1).
0 = not active.
1 = active.
Row 3 shows the input for the central air distribution switch (S1053-2).
0 = not active.
1 = active.
Row 4 shows the input for the floor air distribution switch (S1053-3).
0 = not active.
1 = active.
Row 5 shows the input for the air conditioning switch (S1120).
0 = not active.
1 = active.

Row 1 describes the temperature sensor.
Row 2 shows input Sensor, ambient temperature (B7740).
Row 3 shows input Sensor, deicing temperature (B7753).
Row 4 shows the input for Sensor, fan temperature (B7752).
Row 5 shows input Sensor, inside temperature (B7751).


Row 1 describes the temperature sensor.
Row 2 shows recalculated signal from Sensor, ambient temperature

(B7740).
Row 3 shows recalculated signal from Sensor, deicing temperature

(B7753).
Row 4 shows recalculated signal from Sensor, fan temperature

(B7752).
Row 5 shows recalculated signal from Sensor, inside temperature

(B7751).

Row 1 describes sensors.
Row 2 shows status for signal from Pressure switch refrigerant (B2460)
within normal interval.
0 = not within the interval.
1 = within the interval.
Row 3 shows status for high-pressure signal from Pressure switch

refrigerant (B2460).
0 = low AC pressure, which results in low fan speed.
1 = AC pressure > 16 bar, which results in max fan speed.
Row 4 shows air filter contact input (B2190).

0 = no signal.
1 = signal, which may indicate a clogged filter.

Row 1 describes temperature control.
Row 2 shows the requested temperature.
Row 3 shows the true temperature from the inside temperature sensor
(B7751).
Row 4 shows the feedback signal for position from Water valve (Y6730).
Row 5 shows recalculated value for position of Water valve (Y6730).


Row 1 describes air distribution control.
Row 2 shows the requested air distribution position 0–6

0= Auto position.
1= Windscreen.
2= Windscreen-Panel.
3= Panel.
4= Panel-Floor.
5= Floor.
6= Floor-Windscreen.
Row 3 shows the true air distribution position.

0= Auto position.
1= Windscreen.
2= Windscreen-Panel.
3= Panel.
4= Panel-Floor.
5= Floor.
6= Floor-Windscreen.
Row 4 shows the feedback signal for position on Damper motor, air
distribution (Y6720).

Row 1 describes signals relating to fan motor (M6570) in the cab.

duty cycle. See Navigation of menus, description, page 8:4 for an

Row 1 describes Actuator motor, recirculation (Y6120).

It is possible to manually set the output signal on row 2, Requested
output (0=recirculate). See Navigation of menus, description,
page 8:4 for an explanation how settings are made.
0 = Recirculated air.
1 = Fresh air.


Row 1 describes Actuator motor, recirculation (Y6120).


Row 1 describes Magnetic coupling, AC compressor (Y6450).

It is possible to manually set the signal on row 2, Requested
0 = not activated.
1 = activated.

Row 1 describes opening of Water valve (Y6730).


Row 1 describes closing of Water valve (Y6730).



Row 1 describes opening the Damper motor, air distribution (Y6720).


Row 1 describes closing the Damper motor, air distribution (Y6720).


Row 1 shows the signal from the residual heat switch (S1019).
Row 2 shows whether the function is activated.

It is possible to manually activate the function on row 2, Function
Activated. See Navigation of menus, description, page 8:4 for an
0 = not activated.
1 = activated.
Row 1 shows the signals from the external heater unit for the cab and
engine heater (E6690).
Row 2 shows whether the function is activated

It is possible to manually activate the function on row 2, Function
Activated. See Navigation of menus, description, page 8:4 for an
0 = not activated.
1 = activated.

Row 1 describes the heating system circulation pump (M6670).

0 = not activated.
1 = activated.
8.4.9.5 Diagnostic menus Windscreen wipers
9.5 Wiper & Washer Sys 1/XX DIAGNOSE

Row 1 describes the switch for continuous wiper.
Row 2 shows the input for the continuous front windscreen wiper
switch (S1190-FR).
Row 3 shows the input for the continuous roof windscreen wiper switch
(S1190-UP).
Row 4 describes the switch for the interval wiper.
Row 5 shows the input for the front intermittent wiper switch
(S1520-FR).
Row 6 shows the switch for the roof intermittent wiper switch
(S1520-UP).
For all row it applies:

0 = no signal.
1 = switch activated.

Row 1 describes the combined Wiper motor, front/roof (M6503).
Row 2 shows status for the output to Wiper motor front/roof (M6503).
It is possible to manually activate the output on row 1, Output
M6503 C2p19 D7901. See Navigation of menus, description, page
0 = no signal.
1 = signal active.
Row 5 describes the feedback signal from Wiper motor front/roof

(M6503).
Row 6 shows the feedback signal from Wiper motor front/roof (M6503).
0 = no signal.
1 = signal active.


Row 1 describes the combined windscreen washer front/roof.
Row 2 shows the input for the windscreen washer switch (S1200).
0 = no signal.
1 = signal, switch activated.
Row 3 shows the status for the output washer motor front/roof (M6513).
It is possible to manually activate the signal on row 3, Front roof
washer motor out M6513 C2p15 D7901. See Navigation of
are made.
0 = no signal.
1 = signal active.
Row 6 shows status for signal from Contact level, washer fluid (B2991).
0 = no signal.
1 = fluid level OK.

Row 1 describes the rear windscreen wiper switch.
Row 2 shows the input for the continuous rear windscreen wiper switch
(S1190-RE).
0 = no signal.
Row 3 shows the input for the intermittent rear windscreen wiper switch
(S1520-RE).
0 = no signal.

Row 1 describes Wiper motor rear (M6502).
Row 2 shows output Wiper motor rear (M6502).

It is possible to manually activate the signal on row 2, Output
0 = no signal.
1 = signal.
Row 5 describes rear windscreen wiper motor feedback.
Row 6 shows the feedback signal from Wiper motor rear (M6502).
0 = no signal.
1 = signal.


Row 1 describes signals for rear windscreen wiper.
Row 2 shows the input for the washer switch (S1200).
Row 3 shows output Washer motor rear (M6512).

It is possible to manually activate the signal on row 3, Rear washer
motor Out M6512 C2p16 D7901. See Navigation of menus,
description, page 8:4 for an explanation of how the settings are
made.
0 = no signal.
1 = signal.

Row 6 shows status for signal from Contact level, washer fluid (B2991).
0 = no signal.
1 = fluid level OK.
8.4.9.6 Diagnostic menus Lighting
9.6 Lighting Sys 1/XX DIAGNOSE

Row 1 shows the headlights switch input (S1000).
Row 2 describes high beam
Row 3 shows the input for Switch, high beam (S1600).
Row 4 shows the input for Switch, high beam on the arm rest for
joystick/mini-wheel steering (S1992).

0 = no signal.

Row 1 describes high beam.

It is possible to set the signal on row 2, Requested output. See
Navigation of menus, description, page 8:4 for an explanation how
settings are made.
0 = no signal.
1 = high beam lamp should be lit.
Row 3 shows the true current in the left high beam lamp (E4020-LE).
Row 5 shows the requested current in the right high beam lamp
(E4020-RI).


Row 1 describes low beam.

settings are made.
0 = no signal.
1 = low beam lamp should be lit.
Row 3 shows the true current in the left low beam lamp (E4000-LE).
Row 5 shows the true current in the right low beam lamp (E4000-RI).

Row 1 describes tail lights.

It is possible to set the signal on row 2, Requested output.
See Navigation of menus, description, page 8:4 for an explanation
how settings are made.
0 = no signal.
1 = tail light lamp should be lit.
Row 3 shows the true current in the tail light lamp (H4120-LE/RI).

Row 1 describes the brake light.

settings are made.
0 = no signal.
1 = brake light lamp should be lit.
Row 3 shows the true current in the brake light lamp (H4110-LE/RI).


Row 1 describes the direction indicators.
Row 2 shows the multi-function lever right direction indicator input
(S1600:R).
Row 3 shows the multi-function lever left direction indicator input
(S1600:L).
Row 4 shows the input for the direction indicator switch (S1470) on the
arm rest right mini-wheel/joystick control (S1470:1)
Row 5 shows the input for the direction indicator switch (S1470) on the
arm rest left mini-wheel/joystick control (S1470:3).
0 = no signal.

Row 1 describes the direction indicators.
Row 2 shows the requested left output signal.
It is possible to set the signal on row 2, Requested output left.
0 = no signal.
1 = left direction indicator lamp should be lit.
Row 3 shows the true current for the left direction indicator lamp
(H4220-FL/RL).

Row 1 describes the direction indicators
Row 2 shows requested output right.
It is possible to set the signal on row 2, Requested output right.
0 = no signal.
1 = right direction indicator lamp should be lit.
Row 3 shows the true current for the right direction indicator lamp
(H4220-FR/RR).

Row 1 describes side lights.
Row 2 shows requested output signal for side lights.
It is possible to set the signal on row 2, Requested output C1p16
D7971. See Navigation of menus, description, page 8:4 for an
explanation of how the settings are made.
0 = no signal.
1 = side lights lamp should be lit.
Row 3 shows actual current in the light for side marking.


Row 1 shows signals for rear work light switch (S1032).

settings are made.
0 = no signal.
1 = rear work light lamp should be lit.
Row 3 shows true current for left rear work light lamp (E4050-LE).
Row 5 shows true current for right rear work light lamp (E4050-RI).

Row 1 shows signals for cab work light switch (S1050-1).

settings are made.
0 = no signal.
1 = work light lamp should be lit.
Row 3 shows the true current for left cab work light lamp (E4042-LE).
Row 5 shows the true current for right cab work light lamp (E4042-RI).

Row 1 shows signals for cab work light switch extra S1050-4.

settings are made.
0 = no signal.
1 = cab work light lamp should be lit.
Row 3 shows the true current for cab work light lamp extra (E4042-1).


Row 1 shows signals for cab work light switch extra S1050-4.

settings are made.
0 = no signal.
1 = cab work light lamp should be lit.
Row 3 shows the true current for cab work light lamp (E4042-2).

Row 1 shows signals for mast/boom work light switch (S1050-2).

settings are made.
0 = no signal.
1 = the mast/boom work light lamp should be lit.
Row 3 shows the true current for left mast/boom work light lamp
(E4043-LE).
Row 5 shows the true current for right mast/boom work light lamp
(E4043-RI).

Row 1 shows signals for frame work light switch (S1050-3).

settings are made.
0 = no signal.
1 = frame work light lamp should be lit.
Row 3 shows the true current for frame work light lamp (E4041-1).


Row 1 shows signals for frame work light switch (S1050-4).

settings are made.
0 = no signal
1 = frame work light lamp should be lit

Row 1 describes cab lighting
Row 2 shows the input for the interior lighting switch (S1160).
Row 3 shows the input for the step lighting switch (S1410).
Row 4 shows the input for the right cab door contact switch (B2660-RI).
Row 5 shows the input for the left cab door contact switch (B2660-LE).

0 = no signal.

Row 1 describes signals for interior lighting lamp (E4340)

It is possible to set the pulse length on row 2, Requested duty
cycle. See Navigation of menus, description, page 8:4 for an


Row 1 shows the signals from Switch, work light attachment (S1050-3).

settings are made.
0 = no signal.
1 = working lights attachment illuminated.
Row 3 shows actual current to Working lights on attachment left

(E4044-LE).
Row 5 shows actual current to Working lights on attachment right

(E4044-RI).

Row 1 shows the signals from Switch, work light attachment (S1050-3).

settings are made.
0 = no signal.
1 = working lights attachment illuminated.
Row 3 shows actual current to Working lights on attachment left

(E4044-LF).
Row 5 shows actual current to Working lights on attachment right

(E4044-RF).

8.4.9.7 Diagnostic menus Signal system

9.7 Signalling Sys 1/XX DIAGNOSE
Row 1 describes the horn.
Row 2 shows the multi-function lever horn (S1600:31b).
0 = no signal.
Row 3 shows the input for the right panel horn switch (S1490).
0 = no signal.
Row 4 shows the horn output (H8500).
It is possible to manually set the signal on row 4, Output M8500
C2p12 D7901. See Navigation of menus, description, page 8:4 for
an explanation of how the settings are made.
0 = no signal.
1 = horn sounds.

Row 1 describes revolving beacon cab.
Row 2 shows the input for Switch, revolving beacon (S1100).
0 = no signal.
Row 3 shows the output for Revolving beacon (H4282).
It is possible to manually set the signal on row 3, Output H4282
C2p13. See Navigation of menus, description, page 8:4 for an
0 = no signal.
1 = revolving beacon switched on.
Row 1 describes the revolving beacon on the frame.

Row 2 shows the input for the revolving beacon switch (S1100).
0 = no signal.
It is possible to set the signal on row 3, Output H4281 C1p45
0 = no signal.
1 = revolving beacon frame switched on.

Row 1 describes the revolving beacon on the attachment.
Row 2 shows the input for the revolving beacon switch.

0 = no signal.

0 = no signal.
1 = warning beacon attachment illuminates.

Row 1 describes the reversing alarm.
Row 2 shows the request for reversing (H9650).

0 = no signal.
1 = reversing.
Row 3 shows the reversing alarm output (H9650).

0 = no signal.
1 = reversing alarm.

Row 1 describes the hazard warning lights.
Row 2 shows the input for the hazard warning lights switch (S1090).
0 = no signal.
Row 3 shows requested output.

It is possible to set the signal on row 3, Output request. See
settings are made.
0 = no signal.
1 = hazard flashers flash.

8.4.9.9 Diagnostic menus, Glass/windows/mirrors
9.9 Glass Wind Mirr 1/XX DIAGNOSE
Row 1 describes the heating of mirrors.
Row 1 shows the input from electrically heated rear view mirror/screen
switch (S1046).
0 = no signal.
Rows 2 shows the electrically heated rear view mirror/screen output

(E8020).
It is possible to set the signal on row 2, Output E8020 C2p22
0 = no signal.
1 = heating of the rear view mirror/screen.
9.9 Glass Wind Mirr 2/XX DIAGNOSE
Row 1 describes the heating of rear screen.
Row 2 shows the input from electrically heated rear screen switch
(S1046).
0 = no signal.
Row 3 show the output for the electrically heated screen relay (K8881).
It is possible to set the signal on row 3, Output K8881 C2p06
0 = no signal.
1 = electrically heated screen.

8.4.9.10 Diagnostic menus Structure and suspension

of cab
9.10 Cab suspension 1/XX DIAGNOSE

Row 1 describes the switch.
Row 2 shows the signal from Switch cab (S1751) forward.

0 = not activated.
1 = activated.
Row 3 shows the signal from Switch cab (S1751) backward.

0 = not activated.
1 = activated.
Row 4 shows the signal from Sensor damping end position (B7248).
0 = not activated.
1 = activated.
Row 5 shows voltage signal from Sensor cab position (B7254).
Row 6 shows cab position measured from rearmost position.

Row 1 shows output to Solenoid valve cab forward/up (Y6016). Output
actual current in % of max. current that is set in Initiation, see 9.10 Cab


Row 1 shows output to Solenoid valve backward/down (Y6017). Output
actual current in % of max. current that is set in Initiation, see 9.10 Cab


8.4.9.14 Diagnostic menus Central lubrication
9.14 Central Lubr 1/XX DIAGNOSE
Row 1 describes central lubrication frame.
Row 2 shows remaining pause time (time until next lubrication cycle).
Row 3 shows the feedback signal from Sensor, central lubrication

(B7242).
0 = not active.
1 = active (lubrication system pressurised).
Row 4 shows the number of performed lubrication cycles.
Row 5 shows the timeout status.

0 = OK.
1 = timeout, central lubrication interrupted.

Row 1 describes central lubrication frame.
Row 2 shows the status for Lubrication motor (M6930).

It is possible to manually start the motor on row 2, Motor on/off
0 = off.
1 = on.
Row 1 describes central lubrication attachment.
Row 2 shows remaining pause time (time until next lubrication cycle).
Row 3 shows the feedback signal from Sensor, central lubrication

(B7242).
0 = not active.
1 = active (lubrication system pressurised).
Row 4 shows the number of performed lubrication cycles.
Row 5 shows the timeout status.

0 = OK.
1 = timeout, central lubrication interrupted.

8:78 8 Control system – Common hydraulics

Row 1 describes central lubrication attachment.
Row 2 shows the status for Lubrication motor (M6930).

It is possible to manually start the motor on row 2, Motor on/off
0 = off.
1 = on.
8.4.10 Common hydraulics

8.4.10.4 Diagnostic menus Pumps
10.4 Pumps 1/XX DIAGNOSE

Row 1 describes activation of hydraulic pressure to attachment.
Row 2 shows status for Solenoid valve engagement of hydraulic

pressure to top lift (Y6003).
It is possible to manually activate the solenoid valve on row 2,
Requested output Y6003 C1p15 D7971 KFU. See Navigation
of menus, description, page 8:4 for an explanation of how the
settings are made.
0 = off.
1 = on (attachment pressurised).
10.4 Pumps 2/XX DIAGNOSE

Row 1 describes disengagement of hydraulic pump 2 at boom in.
Row 2 shows status for Solenoid valve pump unloading (Y6003).

It is possible to manually activate the solenoid valve on row 2,
Requested output. See Navigation of menus, description, page
0 = off.
1 = on (hydraulic oil pump 2 disengaged).

8 Control system – Common electrics 8:79
8.4.10.6 Oil temperature/Cleaning, diagnostic menu

1-2

Row 1 shows the input for hydraulic oil temperature sensor (B7760).
Row 2 shows the hydraulic oil temperature.
Row 4 shows the requested gear limitation.

Menu shows signals relating to hydraulic oil cooling fan (M6680).

0 = no signal.
1 = signal.
8.4.11 Common electrics


Row 1 describes signals relating to driving forward.
Row 2 shows the output for Control unit KCU (D7901).

It is possible to manually set the signal on row 2, Output C2p31
D7901 KCU. See Navigation of menus, description, page 8:4 for
0 = no signal.
1 = driving forward.

8:80 8 Control system – Common electrics

Row 1 describes signals relating to driving backward.
Row 2 shows the output for Control unit KCU (D7901).

D7901 KCU. See Navigation of menus, description, page 8:4 for
0 = no signal.
1 = driving backward.

Row 1 describes signals relating to driving forward.
Row 2 shows the output for Control unit KFU (D7971).

D7971 KFU. See Navigation of menus, description, page 8:4 for
0 = no signal.
1 = driving forward.

Row 1 describes signals relating to driving backward.
Row 2 shows the signal from Control unit KFU (D7971).

D7971 KFU. See Navigation of menus, description, page 8:4 for
0 = no signal.
1 = driving backward.
8.4.11.4 Diagnostic menus Alternator
11.4 Alternator 1/XX DIAGNOSE

Row 1 shows status for alternator charging voltage (D+).
0 = not charging.
1 = charging.
Row 2 shows the battery voltage.

8.4.11.5 Diagnostic menus Distribution of electricity

11.5 Distr of Electr 1/XX DIAGNOSE
Row 1 describes the voltage feed to and from Control unit KCU
(D7901).
Row 2 shows the battery voltage input (F9968-RD:2).
Row 3 shows the ignition current input.
Row 4 shows the input for the ignition key lock switch (S1500).
0 = no signal.
Row 5 shows the output for voltage feed to sensors and transducers.

Row 1 describes redundant voltage feed (CPU Power) from Control
unit KCU (D7901).
Row 2 shows output redundant voltage feed (CPU Power).

It is possible to manually set the signal for redundant voltage
feed (CPU Power) on row 2, CPU power supply system output
C2p35. See Navigation of menus, description, page 8:4 for an
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed from Control unit KCU (D7901).
Row 2 shows output for 24 V sensor voltage feed to controls for

mini-wheel/joystick control, pressure switch cab filter, pressure switch
refrigerant, level switch washer fluid, feedback wiper motors.
It is possible to manually set the signal on row 2, 24V sensor
power supply cabin, output C2p05. See Navigation of menus,
made.
0 = no signal.
1 = voltage feed.


Row 1 describes the voltage feed to and from Control unit KFU (D7971).
Row 2 shows input redundant voltage feed (CPU Power).
Row 3 shows input voltage feed ignition voltage (voltage bolt).
Row 4 shows output for 5 V voltage feed to sensors.


Row 1 describes the voltage feed from Control unit KFU (D7971).
Row 2 shows output for 24 V sensor voltage feed to sensors for central
lubrication and electric heater.
It is possible to manually set the 24V sensor power supply,
output C2p32. See Navigation of menus, description, page 8:4 for
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed from Control unit KFU (D7971).
Row 2 shows output for 24 V voltage feed to sensors and switches

mast/boom.
It is possible to manually set on row 2, 24V sensor power supply
mast/boom, output C2p33. See Navigation of menus, description,
page 8:4 for an explanation of how the settings are made.
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed to Control unit KFU-2 (D7972).

Row 1 describes the voltage feed from Control unit KFU-2 (D7972).
Row 2 shows output for 24 V voltage feed to sensors and switches.

It is possible to manually set the 24V sensor power supply TDS
etc. output C2p32. See Navigation of menus, description, page
0 = no signal.
1 = voltage feed.



power supply Output C2p33. See Navigation of menus,
made.
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed to Control unit KAU-2 (D7912).

Row 1 describes the voltage feed from Control unit KAU-2 (D7912).

It is possible to manually set the 24V sensor power supply
Output C2p32. See Navigation of menus, description, page 8:4
for an explanation of how the settings are made.
0 = no signal.
1 = voltage feed.


power supply output C2p33. See Navigation of menus,
made.
0 = no signal.
1 = voltage feed.


Row 1 describes the voltage feed to Control unit KAU (D7911).


It is possible to manually set the 24V sensor power supply
output C2p32. See Navigation of menus, description, page 8:4 for
0 = no signal.
1 = voltage feed.


power supply Output C2p32. See Navigation of menus,
made.
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed to Control unit KPU (D7902).
Row 3 shows input voltage feed ignition voltage.


Row 1 describes the voltage feed from Control unit KPU (D7902).
Row 2 shows output for 5 V voltage feed to analogue controls and

feedback signals (internally connected to C3p01 and C8p04).
It is possible to manually set the voltage feed to sensors on row 2,
5V ref. power supply output C2p01 (internally connected to
C3p01 and C8p04). See Navigation of menus, description, page
0 = no signal.
1 = voltage feed.
Row 3 shows the output voltage.

Row 2 shows output for 5 V voltage feed to the steering panel, silicone
panel, right-hand dashboard panel front section (climate controls)
and silicone panel, right-hand dashboard panel rear section (lighting
controls), (internally connected to C7p01 and C9p01).
It is possible to manually set the voltage feed to sensors on row 2,
5V ref. power supply Output C6p01 (internally connected to
C7p01 and C9p01). See Navigation of menus, description, page
0 = no signal.
1 = voltage feed.
Row 3 shows the output voltage.

Row 2 shows output for 24 V sensor voltage feed to Switch, control

lever (off/on buttons), output C3p09.
It is possible to manually set the voltage feed on row 2, 24 sensor
power supply (switches, joystick, etc.) Output C3p09. See
0 = no signal.
1 = voltage feed.

Row 2 shows output for 24 V sensor voltage feed to Switch, output

C4p01.
It is possible to manually set the voltage feed on row 2, 24
sensor power supply Output C4p01. See Navigation of menus,
made.
0 = no signal.
1 = voltage feed.


Row 2 shows output for 24 V voltage feed to travel direction selector

and parking brake, sensor steering wheel angle and multi-function
lever, output C5p01.
It is possible to manually set the voltage feed on row 1, 24 sensor
power supply (steering column, etc.) Output C5p01. See
0 = no signal.
1 = voltage feed.

Row 2 shows output for 24 V voltage feed to Switch control breaker

(S2500), output C8p01.
It is possible to manually set the voltage feed on row 1, 24
sensor power supply Output C8p01. See Navigation of menus,
made.
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed to Control unit KID (D7950).
Row 3 shows input voltage feed ignition voltage.
Row 4 shows the output for voltage feed to sensors.

Row 1 shows input from Switch control breaker (S2500)
0 = no signal (control breaker depressed).
1 = breaker activated.


Row 1 describes safe voltage feed (Control breaker voltage) group 1 in

0 = no signal.
1 = voltage feed.
Row 3 shows voltage to Solenoid valve boom up (Y6004), Solenoid

valve boom down (Y6005), Solenoid valve boom in (Y6007) and
Solenoid valve boom out (Y6006), output C1p27-C1p29, C1p33.
Row 4 shows voltage to Solenoid valve blocking left (Y6045-LE),

Solenoid valve blocking left (Y6045-RI) Solenoid valve blocking (Y6050)
and Solenoid valve regeneration (Y6051-1), output C1p34-C1p37.
Row 5 shows voltage to Solenoid valve cab front/up (Y6016) and

Solenoid valve cab rear/down (Y6017), output C1p38-C1p41.

Control unit KFU (D7971)

0 = no signal.
1 = voltage feed.
Row 3 shows voltage to Electronic steering module (Y6150), output

C1p47-C1p48, C1p50.

Row 2 shows status for requested output signal to Cooling fan hydraulic
system (M6680) and Cooling fan brake system (M6740), output C2p37,
C2p35.
0 = no signal.
1 = voltage feed.

Row 1 describes safe voltage feed (Control breaker voltage) ground 1
in Control unit KFU (D7971), output C1p10.

0 = no signal.
1 = voltage feed.


in Control unit KFU (D7971), output C1p30.

0 = no signal.
1 = voltage feed.

Row 1 shows the signal from safe voltage feed (Control breaker
voltage) group 1 in Control unit KFU-2 (D7972).
0 = no signal.
1 = voltage feed.
Row 3 shows voltage on, output C1p27-C1p29, C1p33.
Row 4 shows voltage on, output C1p34–C1p37.

Row 1 describes safe voltage feed (Control breaker voltage) group
2 in Control unit KFU-2 (D7972).

0 = no signal.
1 = voltage feed.

Control unit KFU-2 (D7972), output C2p35, C2p37.

0 = no signal.
1 = voltage feed.


in Control unit KFU-2 (D7972) output C1p10.

0 = no signal.
1 = voltage feed.

in Control unit KFU-2 (D7972), output C1p30.

0 = no signal.
1 = voltage feed.

voltage) group 1 in Control unit KAU-2 (D7912).
0 = no signal.
1 = voltage feed.

Row 1 describes safe voltage feed (Control breaker voltage) group
2 in Control unit KAU-2 (D7912).

0 = no signal.
1 = voltage feed.


Control unit KAU-2 (D7912), output C2p35, C2p37.
0 = no signal.
1 = voltage feed.

in Control unit KAU-2 (D7912) output C1p10.
0 = no signal.
1 = voltage feed.

in Control unit KAU-2 (D7912), output C1p30.
0 = no signal.
1 = voltage feed.

voltage) group 1 in Control unit KAU (D7911).
0 = no signal.
1 = voltage feed.
Row 3 shows voltage to Solenoid valve rotation clockwise (Y6008),
Solenoid valve rotation anticlockwise (Y6009), Solenoid valve
spreading out (Y6018) and Solenoid valve spreading in (Y6019), output
C1p27-C1p29, C1p33.
Row 4 shows voltage to Solenoid valve tilt in (Y6011) and Solenoid
valve tilt out (Y6010), output C1p34-C1p37.
Row 5 shows voltage to Solenoid valve side shift left (Y6020), Solenoid
valve side shift right (Y6021), Solenoid valve levelling clockwise
(Y6035) and Solenoid valve levelling anticlockwise (Y6036), output
C1p38-C1p41.



0 = no signal.
1 = voltage feed.

Row 1 describes safe voltage feed (Control breaker voltage) group 3
in Control unit KAU (D7911) to indicator lights on the boom, output
C2p35, C2p37.

0 = no signal.
1 = voltage feed.

in Control unit KAU (D7911), output C1p10.

0 = no signal.
1 = voltage feed.

in Control unit KAU (D7911), output C1p30.

0 = no signal.
1 = voltage feed.



power supply Output C2p22 Attachment, support jacks, etc..
of how the settings are made.
0 = no signal.
1 = voltage feed.
8.4.11.6 Diagnostic menus Communication
11.6 Communication 1/XX

Row 1 describes the RedCAN system.
Row 2 shows the expected number of nodes.
Row 3 shows the true number of nodes.
Row 4 shows discovered cable errors on the CAN bus.
Row 5 shows the communication mode.

0 = normal.
1 = scanning.
2 = RedCAN locked.
3 = Program downloading.
Row 6 shows scanning of the RedCAN system.

It is possible to manually activate scanning on row 5, Scan
RedCAN system. See Navigation of menus, description, page 8:4
0 = no scanning.
1 = scanning.

Row 1 describes the expected RedCAN system.
Row 2 shows the 1st node number.
Row 3 shows the 2nd node number.
Row 4 shows the 3rd node number.
Row 5 shows the 4th node number.
The 1st node number is the first node in the loop, the 2nd node
number is the second node in the loop, etc. For a description of node
numbering, see 11.6.2 Redundant CAN bus, page 11:48.


Row 1 describes the expected RedCAN system.
The 6th node number is the sixth node in the loop, the 7th node
number is the seventh node in the loop, etc. For a description of node
numbering, see 11.6.2 Redundant CAN bus, page 11:48.

Row 1 describes which nodes actually communicate in the RedCAN
system.
Row 2 shows the 1st node number.
Row 3 shows the 2nd node number.
Row 4 shows the 3rd node number.
For a description of node numbering, see 11.6.2 Redundant CAN bus,

page 11:48.

Row 1 describes which nodes actually communicate in the RedCAN
system.

page 11:48.

Row 1 describes the RedCAN system.
Row 2 shows the node number for the node that has detected a cable
error on its normal side.
Row 3 shows the node number for the node that has detected a cable
error on its redundant side.

page 11:48.


Row 1 describes RedCAN nodes, which are not found during start-up
of the CAN bus. For a more detailed explanation, see Redundant CAN
bus, start-up, page 11:49.
Row 2 shows 1st node not found.
Row 3 shows 2nd node not found.
Row 4 shows 3rd node not found.
Row 5 shows 4th node not found.
Row 6 shows 5th node not found.

0 = OK
1= node not found

page 11:48.

Row 1 describes RedCAN, which nodes disappear (unresponsive)
after start-up of the CAN bus. For a more detailed explanation, see
Redundant CAN bus, start-up, page 11:49.
Row 2 shows 1st node disappeared.
Row 3 shows 2nd node disappeared.
Row 4 shows 3rd node disappeared.
Row 5 shows 4th node disappeared.
Row 6 shows 5th node disappeared.

0 = OK.
1 = node disappeared.

page 11:48.

Row 1 describes the RedCAN statistics.
Row 2 shows the number of system scans since start-up. Scanning

is performed in the event of problems delivering messages, a high
number of scans may be due to intermittent faults in the cable harness.
Row 3 shows the last scan time. A short scanning time means that the
CAN bus is working well.
Row 4 shows scanning of the RedCAN system.

It is possible to manually activate scanning on row 4, Scan
RedCAN system. See Navigation of menus, description, page 8:4
0 = no scanning.
1 = scanning in progress.

8 Control system – Pin diagnostics 8:95
8.4.13 Pin diagnostics

Pin diagnostics, description
The menus for pin diagnostics have the same structure as other
diagnostic menus. See Navigation of menus, description, page 8:4 for
an explanation of how to navigate to and through the menus.
The pin diagnostics are used to quickly diagnose all functions in

the control system. Input signal values from e.g. a lever are shown
in the diagnostic menus. A control unit's output signal current to a
corresponding valve can be shown and with that it is possible to check
whether the software sends a correct signal to control the valve. It can
be quickly determined whether the problem is on the input or output
side and if the control unit is working properly without connecting to
other instruments.
Outputs and inputs are described with respect to the contact and pin,
for example C2p01, which denotes contact 2, pin 1.
Outputs can also be controlled with the right permissions in the

diagnostic system. The variable Request can be activated manually.
Example 1:
It is discovered that there is no input signal from the lift lever, but to
be able to move the machine to the workshop the attachment must
be lifted from the ground. In this situation the lifting can be "force
operated" from the display using service code and wiring diagram.
Example 2:
It is established that everything seems to be OK for lifting, and input

and output signals are as they should be. Despite this lifting does not
work. If the "forced operation" function does not work despite stronger
current than normal to the solenoid valve, then the fault probably lies in
the valve or cables.
1 The following terms are used in pin diagnostic menus.

Actual current indicates the true current.
1 1 . 7 I / O D7 9 0 1 KCU 1 0 XX DIAGNOS E
Digital input indicates digital input.
C2 p 0 1 d i g i t a l i n p u t 0
2 Digital output indicates digital output.
C2 p 0 1 d i g i t a l o u t p u t
4 Direction indicates the direction.
Re q u e s t 1
3 5 Duty cycle indicates the pulse length of an analogue PWM output.
Ac t u a l c u r r e n t 8 00 . 0 mA
6
Pi n s t a t u s OK Frequency input indicates the frequency input.
016092
H bridge indicates H-bridge for engine control.

MAN LEAVE
Impedance indicates impedance.
1. Example Menu group PWM output indicates pulse width modulated output
2. Signal from digital input, contact 2 pin 1 PVE output indicates PVE output of the Sauer Danfoss type.
3. Signals from digital output, contact 2 pin 1 Request indicates the ability to manually set the signal value.
4. Request for signal to the digital output Requested current indicates the requested current.
5. True current Requested duty cycle indicates the requested pulse length.
6. Pin status Requested voltage indicates the requested voltage.
Resistance input indicates the resistance measurement input.
Voltage input indicates the voltage input.
11.7 I/O D7901 KCU 1-48/XX DIAGNOSE

Contains diagnostic menu 1-48 for Control unit KCU (D7901).
11.8 I/O D7902 KPU 1–41/XX DIAGNOSE

Contains diagnostic menu 1-41 for Control unit KPU (D7902).

8:96 8 Control system – Pin diagnostics
11.9 I/O D7971 KFU 1–75/XX DIAGNOSE

Contains diagnostic menu 1-75 for Control unit KFU (D7971).
11.10 I/O D7950 KID 1–4/XX DIAGNOSE

Contains diagnostic menu 1-4 for Control unit KID (D7950).
11.11 I/O D7911 KAU 1–75/XX DIAGNOSE

Contains diagnostic menu 1-75 for Control unit KAU (D7911).

8 Control system – Setup 8:97
8.5 Setup
Initiation, general
Initiation is performed before using the machine for work and means to
set e.g., start and stop currents, deadband, sensitivity, minimum and
maximum values for the control of different functions.
DANGER
The settings influence the functions. Adjustments
may impair the function.
If uncertain, contact Cargotec Service.
NOTE
The machine must be stationary with parking brake applied in order
to enable access to the menus.
After changes have been made, the ignition must be switched off
and then on for the changes to be saved and start to apply.
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
Initiation is available for the following groups:

• Engine, 8.5.1 Engine, page 8:100
8.5.1.1 Initiation menus Controls and instruments engine, page
8:100
8.5.1.9 Initiation menus Control system, engine, page 8:100
• Transmission, 8.5.2 Transmission, page 8:101
8.5.2.1 Initiation menus Controls and instruments transmission,
page 8:102
8.5.2.2 Initiation menus, Torque converter and clutch, page 8:103
• Steering, 8.5.5 Steering, page 8:104
8.5.5.2 Initiation menus, Power assisted system, page 8:104
• Load handling, 8.5.7 Load handling, page 8:111
8.5.7.1 Initiation menus Controls and instruments load handling,
page 8:111
8.5.7.2 Initiation menus Lifting/lowering, page 8:112
8.5.7.3 Initiation menus, Extension, page 8:116
8.5.7.4 Initiation menus, Side shift, page 8:117
8.5.7.5 Initiation menus, Spreading, page 8:119
8.5.7.6 Initiation menus, Rotation, page 8:121
8.5.7.7 Initiation menus, Tilt, page 8:122
8.5.7.8 Initiation menus, Levelling, page 8:124
• Control system, 8.5.8 Control system, page 8:125
8.5.8.1 Initiation menus Controls and instruments, page 8:125
8.5.8.2 Initiation menus, Monitoring, page 8:127
• Frame, body, cab and accessories, 8.5.9 Frame, body, cab and
accessories, page 8:131
8.5.9.4 Initiation menus, Climate system, page 8:131
8.5.9.5 Initiation menus, Windscreen wipers, page 8:131
8.5.9.6 Initiation menus, Lighting, page 8:132

8:98 8 Control system – Setup
8.5.9.7 Initiation menus, Signal system, page 8:133

8.5.9.9 Initiation menus, Glass/windows/mirrors,, page 8:134
8.5.9.10 Cab frame and suspension , page 8:134
8.5.9.14 Initiation menus, Central lubrication, page 8:137
• Common electrics, 8.5.11 Common electrics, page 8:138
8.5.11.5 Initiation menus, Voltage feed, page 8:138
Initiation, work instructions

Navigation to a menu, work instruction
To navigate to a menu for setup or calibration, do as follows:
NOTE
The machine must be stationary with parking brake applied in
order to enable access to the menus.

CUSTOMER SETTI NGS
0
014981
10:23 2 Enter service code with or and confirm with .

WRI TE PI N CODE
0
NOTE
0 0
015625
3 Select the function with or and confirm with .

2 . TRANSMI SSI ON
015623

8 Control system – Setup 8:99
4 Select INITIATE with or and confirm with

* 2 . TRANSMI SSI ON *
5 Select group by scrolling with or and confirm with .
2.1 Controls & I n s t r u me n t s 6 Each menu group consists of a sequence of a number of menus.
2.2 Torque Conv & Cl u t c h Sy s The first menu for the selected group opens in the display. Use the
2.3 Mechanical T r a n s mi s s i o n
2.4 Hydraulic Tr a ns mi s s i o n arrow keys or to move to the desired menu.
2.5 Electrical T r a n s mi s s i o n
2.6 Lubrication Sys t e m
7 Use the function key to save the desired value.
2.7 Cooling syst em
2.8 Transmission Co n t r ol Sy s
NOTE
015626
Current values can only be adjusted within specific limits.
Menu example, description
1 All menus for initiation and calibration are explained separately.

2 3
– The menu group, indicates the group, 1.7 Cooling System, whose
signals need to be initiated.
8 – Sequence number, 1/XX, enter the page number and total number
4 of menus in the menu loop. As the number of menus is dependent
on how the machine is equipped, state the number of menus here
with XX.
– Initiate indicates in the menu example to initiate the selected setup
function. The other setup function is Calibrate for calibration.
015883
– Variables, such as row 1 Cooling fan start current, describe the

function/component that the signal/measurement comes from.
7 5 Each menu can contain 1-6 rows, where each row describes a
6
variable with an associated signal value.
1. Menu group – Signal value, 450.0 mA, is the saved value for Cooling fan start
2. Sequence number current.
3. Selected setting function All signal values in the menus in this manual are examples.
4. Signal values The following icons are used to explain further the signal values:
5. Function key LEAVE/Cancel denotes a saved value.
6. Arrow keys denotes a value from an output from a control unit.
7. Function key Manual mode/Edit mode denotes an input value which is measured by a control unit.
8. Variables

8.5.1 Engine
8.5.1.1 Initiation menus Controls and instruments
engine
1.1 Controls & Instr 1/XX INITIATE
1. Read the explanation of initiation menus before making any
changes, see Initiation, general, page 8:97.
For a description of navigation to this menu, see Navigation to a
menu, work instruction, page 8:98
2. Row 1 shows the setting value of the accelerator pedal's deadband
when the pedal is released.
Row 2 shows the saved value of the accelerator pedal's deadband
when the pedal is released.
Row 3 shows the true position of the accelerator pedal.
3. Set the deadband for the accelerator pedal's zero position on row
1, Throttle pedal start deadband. Change the value with /
and store the value with Save .

2. Row 1 shows the setting value of the accelerator pedal's deadband
at full throttle in the setup position.
Row 2 shows the saved value of the accelerator pedal's deadband
when the pedal is at full throttle.
Row 3 shows the true position of the accelerator pedal.
3. Set the deadband for the accelerator pedal's full throttle position on
row 1, Throttle pedal end deadband. Change the value with /
8.5.1.9 Initiation menus Control system, engine

1.9 Control System 1/XX INITIATE
2. Row 1 shows the setting value for the lowest engine speed (idling
speed).
Row 2 shows the saved value for the lowest engine speed.
3. Set the lowest engine speed on row 1, Engine min rpm. Change
the value with / and save the value with Save .

2. Row 1 shows the setting value for the highest permitted engine
speed (speed inhibitor).
Row 2 shows the saved value for the highest permitted engine
speed.
3. Set the highest permitted engine speed on row 1, Engine max
rpm. Change the value with / and save the value with Save
.


2. Row 1 shows the setting value for the engine's ramp time down
(how fast the engine speed is allowed to idle). Too short a time
may result in engine stop.
Row 2 shows the saved value for the engine's ramp down time.
3. Set the engine's ramp down time on row 1, Engine request speed
decrease time. Change the value with / and save the value
with Save .

2. Row 1 shows the setting value for the engine's ramp up time
(throttle response).
Row 2 shows the saved value for the engine's ramp up time.
3. Set the engine's ramp up time on row 1, Engine request speed
increase time. Change the value with / and save the value
with Save .

2. Row 1 shows the setting value for the engine's max. speed in
neutral position for the transmission.
Row 2 shows the stored value for the engine's max. speed in
neutral position for the transmission.
3. Set the engine's max. speed on row 1, Engine max rpm at
neutral. Change the value with / and save the value with
Save .
8.5.2 Transmission
Initiation transmission, general
NOTE
The machine must be stationary with parking brake applied in order
to enable access to the menus.

8:102 8 Control system – Transmission

transmission
2. Row 1 shows the setting value for shifting points.
Row 2 shows the saved value for shifting points.
3. Set the shifting points on row 1 Auto shifting points. Change the
value with / and save the value with Save .
0 = Normal shifting points selected with early upshifting at low load.
1 = Normal shifting points selected with earlier upshifting between
gear 1 and gear 2.
2 = Later upshifting on all gears.

2. Row 1 shows the setting value for tyre radius correction.
Row 2 shows the saved value for tyre radius correction.
Row 3 shows tyre radius plus correction.
3. Set tyre radius correction on row 1, Tyre rolling radius offset, to
adjust the speedometer with tyre wear. Change the value with /

2. Row 1 shows the setting value for start gear.
Row 2 shows the saved value for start gear.
3. Set the start gear on row 1 Transmission start gear. Change the
value with / and save the value with Save .

2. Row 1 shows the setting value for automatic engine speed
reduction when changing travel direction.
Row 2 shows the stored value for automatic engine speed
reduction when changing travel direction.
3. Set automatic engine speed reduction on row 1, Automatic engine
rpm limit at the forward/reverse request (1 = on). Change the
value with / and store the value with Save .
0 = No engine speed reduction when changing travel direction.
1 = Automatic reduction of engine speed when changing travel
direction.


2. Row 1 shows the setting value for engine speed for the function
automatic engine speed reduction when changing travel direction.
Row 2 shows the saved value for the engine speed.
3. Set engine speed on row 1, Automatic engine rpm limit at the
forward/reverse request. Change the value with / and store
the value with Save .

2. Row 1 shows the setting value for max. rotation speed of output
shaft on the transmission during reversing.
Row 2 shows the saved value for rotation speed.
3. Set the engine speed on row 1, Max reversing speed
transmission output. Change the value with / and store
1 = 50 rpm.
2 = 150 rpm.
3 = 500 rpm.
8.5.2.2 Initiation menus, Torque converter and clutch
2.2 Torq Conv Clutch 1/XX INITIATE

2. Row 1 shows the setting value for brake pressure when declutching
the transmission.
Row 2 shows the saved value for brake pressure when declutching
the transmission.
Row 3 shows the true brake pressure.
3. Set the brake pressure on row 1, Declutch brake pressure.
Change the value with / and save the value with Save .
2.2 Torq Conv Clutch 2/XX INITIATE

2. Row 1 show the accelerator's minimum value for declutching.
Row 2 shows the saved value for the accelerator pedal's minimum
value for declutching.
Row 3 shows the true accelerator pedal in %.
3. Set the accelerator pedal's minimum value for declutching on row
1, Declutch throttle min percent. Change the value with /

8.5.5 Steering
8.5.5.2 Initiation menus, Power assisted system
5.2 Power Assisted 1/XX INITIATE

2. Row 1 shows the sensitivity of the joystick or the mini-wheel.
Row 2 shows the stored value for joystick or mini-wheel sensitivity.
3. Set joystick or mini-wheel sensitivity on row 1, Comfort steering
sensitivity. 0 = no deflection and 10 = max valve deflection.
Change the value with / and store the value with Save .

2. Row 1 shows the max. value for the output signal to Electric
steering module (Y6150) for steering right.
Row 2 shows the stored value for output signal to Electric steering
module (Y6150).
3. Set the value on row 1, Comfort steering duty max right valve
output. The values for steering right are from 50.00 to 0 where
50.00 is the neutral position. Change the value with / and
store the value with Save .

2. Row 1 shows the start value for the output signal to Electric
steering module (Y6150) for steering right.
module (Y6150).
3. Set the value on row 1, Comfort steering duty start right valve
output. The value for steering right is from 50.00 to 0, where 50.00
is the neutral position. Change the value with / and store

2. Row 1 shows the start value for the output signal to Electric
steering module (Y6150) for steering left.
module (Y6150).
3. Set the value on row 1, Comfort steering duty start left valve
output. The value for steering left is from 50.00 to 100.00, where
50.00 is the neutral position. Change the value with / and


2. Row 1 shows the max. value for the output signal to Electric
steering module (Y6150) for steering left.
module (Y6150).
3. Set the value on row 1, Comfort steering duty max left valve
output. The value for steering left is 50.00-100.00, where 50.00
is the neutral position. Change the value with / and store

2. Row 1 shows the setting of % control current at break point profile
for steering angle at 0 km/h (BP0).
Row 2 shows the stored break point profile for steering deflection
at 0 km/h (BP0).
Y 3. Set break point profile for steering deflection at 0 km/h (BP0) on

row 1, Comfort steering stpt profile at 0 kph. Change the value
BP 0 with / and store the value with Save .
BP 5
BP 10
BP 15
BP 20
BP 25
V
016935
0 5 10 15 20 25
Y = Output signal to Electric steering module (Y6150).

V = machine speed in km/h.
BP0-PB25 = Break point profile for 0-25 km/h.


at 5 km/h (BP5).

BP 5
BP 10
BP 15
BP 20
BP 25
V
016935
0 5 10 15 20 25



at 10 km/h (BP10).

BP 5
BP 10
BP 15
BP 20
BP 25
V
016935
0 5 10 15 20 25



at 15 km/h (BP15).

BP 5
BP 10
BP 15
BP 20
BP 25
V
016935
0 5 10 15 20 25



at 20 km/h (BP20).

BP 5
BP 10
BP 15
BP 20
BP 25
V
016935
0 5 10 15 20 25



at 25 km/h (BP25).

BP 5
BP 10
BP 15
BP 20
BP 25
V
016935
0 5 10 15 20 25


2. Row 1 shows the setup of the joystick profile for steering deflection.
Row 2 shows the saved profile.
Y 3. Set the profile on row 1, Comfort steering lever stpt linear

0 profile. 0 = linear profile, 10 = max exponential profile. Change
the value with / and store the value with Save .
10
016934
X = Lever movement.
0-10 = Profile.


2. Row 1 shows the joystick's deadband at the end positions.
Row 2 shows the saved value for deadband.
3. Set the deadband on row 1, Comfort steering lever high/low
deadband. Change the value with / and store the value
with Save .

2. Row 1 shows the joystick's deadband at the centre position.
Row 2 shows the saved value for deadband.
3. Set the deadband on row 1, Comfort steering lever mid
deadband. Change the value with / and store the value
with Save .
8.5.7 Load handling

8.5.7.1 Initiation menus Controls and instruments load
handling

2. Row 1 shows the setting value for Control lever (S8150) deadband
in centre position.
Row 2 shows the stored value for Control lever (S8150) deadband
in centre position.
3. Set the Control lever (S8150) deadband on row 1, Joystick
middle deadband. Change the value with / and store the
value with Save .

2. Row 1 shows the setting value for Control lever (S8150) deadband
in end position.
Row 2 shows the stored value for Control lever (S8150) deadband
in end position.
3. Set the Control lever (S8150) deadband on row 1, Joystick
high/low deadband. Change the value with / and store the
value with Save .


2. Row 1 shows the setting value for the thumb control on Control
lever (S8150) deadband in centre position.
Row 2 shows the stored value for the thumb control on Control
lever (S8150) deadband in centre position.
3. Set the thumb control on Control lever (S8150) deadband on row
1, Thumb joystick middle deadband. Change the value with /

2. Row 1 shows the setting value for the thumb control on Control
lever (S8150) deadband in end position.
Row 2 shows the stored value for the thumb control on Control
lever (S8150) deadband in end position.
3. Set the thumb control on Control lever (S8150) deadband on row
1, Thumb joystick high/low deadband. Change the value with
/ and store the value with Save .
8.5.7.2 Initiation menus Lifting/lowering
7.2 Lifting Lowering 11/XX INITIATE

2. Row 1 shows the setting value for start current for Solenoid valve
lift (Y6005).
Row 2 shows the saved value for start current.
3. Set the start current for Solenoid valve, lift (Y6005) on row 1, Start
current lift boom. Change the value with / and store the
value with Save .
The start current is the lowest current that can be actuated. In
practice, it controls how slowly a function can be operated. On
functions with analogue control/activation (controllable), e.g. lift,
this is the current which is triggered when the lever leaves the zero
position (deadband).


2. Row 1 shows the setting value for end current for Solenoid valve
lift (Y6005).
Row 2 shows the saved value for end current.
3. Set the end current for Solenoid valve, lift (Y6005) on row 1, End
current lift boom. Change the value with / and store the
value with Save .
The end current is the highest current that can be actuated. In
practice, it controls how quickly a function can be operated. On
this is the current which is triggered when the lever is in the end

lower (Y6004).
3. Set the start current for Solenoid valve, lower (Y6004) on row 1,
Start current lower boom. Change the value with / and

lower (Y6004).
3. Set the end current for Solenoid valve, lower (Y6004) on row 1,
End current lower boom. Change the value with / and store


2. Row 1 shows the setting value for limitation of lifting speed when
the gear is selected. Lifting speed is limited when the machine can
be operated in order to reduce centre of gravity changes.
Row 2 shows the stored value for limitation of lifting speed.
3. Set the end current for Solenoid valve lower (Y6004) on row 1, Lift
boom max output When drivetrain is engaged. Change the
value with / and store the value with Save .

2. Row 1 shows the setting value for engine speed at minimum
deflection of the control lever for lifting without load. The rotation
speed is the lower level for rotation speed increase for the lifting
function for lifting without load. Engine speed affects lifting speed.
3. Set the engine speed on row 1, Boom engine speed request
unloaded, min. Change the value with / and store the value
with Save .


2. Row 1 shows the setting value for engine speed at maximum
deflection of the control lever for lifting without load. The rotation
speed is the upper level for rotation speed increase for the lifting
function for lifting without load. Engine speed affects lifting speed.
unloaded, max. Change the value with / and store the value
with Save .

2. Row 1 shows the setting value for engine speed at minimum
deflection of the control lever for lifting with load. The rotation
speed is the lower level for rotation speed increase for the lifting
function for lifting with load. Engine speed affects lifting speed
loaded, min. Change the value with / and store the value
with Save .


2. Row 1 shows the setting value for engine speed at maximum
deflection of the control lever for lifting with load. The rotation
speed is the upper level for rotation speed increase for the lifting
function for lifting with load. Engine speed affects lifting speed.
loaded, max. Change the value with / and store the value
with Save .
8.5.7.3 Initiation menus, Extension

7.3 Extension 1/XX INITIATE
boom out (Y6006).
3. Set the start current for Solenoid valve, boom out (Y6006) on row
1, Start current extend boom. Change the value with /

boom out (Y6006).
3. Set the end current for Solenoid valve, boom out (Y6006) on row
1, End current extend boom. Change the value with / and


boom down (Y6007).
3. Set the start current for Solenoid valve, boom down (Y6007) on
row 1, Start current retract boom. Change the value with /

boom down (Y6007).
3. Set the end current for Solenoid valve, boom down (Y6007) on row
1, End current lift boom. Change the value with / and store
8.5.7.4 Initiation menus, Side shift

7.4 Side Shift 5/XX INITIATE
2. Row 1 shows the setting value for start current to Solenoid valve
side shift right (Y6021).
3. Set the start current for Solenoid valve, side shift right (Y6021) on
row 1, Start current side shift right. Change the value with /
this is the current which is triggered when the lever leaves the
zero position.


2. Row 1 shows the setting value for end current to Solenoid valve
side shift right (Y6021).
3. Set the end current for Solenoid valve, side shift right (Y6021) on
row 1, End current side shift right. Change the value with /
functions with analogue control activation (controllable), e.g. lift,
position.

side shift left (Y6020).
3. Set the start current for Solenoid valve, side shift left (Y6020) on
row 1, Start current side shift left. Change the value with /
zero position.

side shift left (Y6020).
3. Set the end current for Solenoid valve, side shift left (Y6020) on
row 1, End current side shift left. Change the value with /
position.

8.5.7.5 Initiation menus, Spreading
7.5 Spreading 13/XX INITIATE

spreading out (Y6018).
3. Set the start current for Solenoid valve, spreading out (Y6018) on
row 1, Start current spreading out. Change the value with /
zero position.

spreading out (Y6018).
3. Set the end current for Solenoid valve, spreading out (Y6018) on
row 1, End current spreading out. Change the value with /
position.

2. Row 1 shows the setting value for damping of spreading out.
Row 2 shows the saved value for damping.
3. Set the value for damping of spreading out on row 1, Damp value
spreading out. Change the value with / and store the value
with Save .
Damping is the percentage by which the control current to the
solenoid valve is reduced approaching the end position. Damping
is used to increase accuracy and reduce mechanical stress on
the machine.


spreading in (Y6019).
3. Set the start current for Solenoid valve, spreading in (Y6019) on
row 1, Start current side shift left. Change the value with /
zero position.

spreading in (Y6019).
3. Set the end current for Solenoid valve, spreading in (Y6019) on
row 1, End current side shift left. Change the value with /
position.

2. Row 1 shows the setting value for damping spreading in.
3. Set the value for damping of spreading in on row 1, Damp value
spreading out. Change the value with / and store the value
with Save .
the machine.

8.5.7.6 Initiation menus, Rotation

7.6 Rotation 1/XX INITIATE
rotation clockwise (Y6008).
3. Set the start current for Solenoid valve, rotation clockwise (Y6008)
on row 1, Start current rotation clockwise. Change the value
with / and store the value with Save .
zero position.

rotation clockwise (Y6008).
3. Set the end current for Solenoid valve, rotation clockwise (Y6008)
on row 1, End current rotation clockwise. Change the value with
position.

3. Set the start current for Solenoid valve, rotation anticlockwise
(Y6009) on row 1, Start current rotation anticlockwise. Change
zero position.


3. Set the end current for Solenoid valve, rotation anticlockwise
(Y6009) on row 1, End current rotation anticlockwise. Change
position.

2. Row 1 shows the setting value for the direction of rotation.
Row 2 shows the saved value for the direction of rotation.
3. Set the desired direction of rotation on row 1, End current rotation
anticlockwise. Change the value with / and store the value
with Save .
The setting turns round the control lever's deflection for rotation.
0 = Normal rotation.
1 = Reverse rotation.
8.5.7.7 Initiation menus, Tilt
7.7 Tilt 7/XX INITIATE

tilt in (Y6011).
3. Set the start current for Solenoid valve, tilt in (Y6011) on row 1,
Start current tilt in. Change the value with / and store the
value with Save .
zero position.


tilt in (Y6011).
3. Set the end current for Solenoid valve, tilt in (Y6011) on row 1,
End current tilt in. Change the value with / and store the
value with Save .
position.

tilt out (Y6010).
3. Set the start current for Solenoid valve, tilt out (Y6010) on row 1,
Start current tilt out. Change the value with / and store
zero position.

tilt out (Y6010).
3. Set the end current for Solenoid valve, tilt out (Y6010) on row 1,
End current tilt out. Change the value with / and store the
value with Save .
position.

8.5.7.8 Initiation menus, Levelling

7.8 Levelling 5/XX INITIATE
levelling clockwise (Y6036).
3. Set the start current for Solenoid valve, levelling clockwise (Y6036)
on row 1, Start current levelling clockwise. Change the value
zero position.

levelling clockwise (Y6036).
3. Set the end current for Solenoid valve, levelling clockwise (Y6036)
on row 1, End current levelling clockwise. Change the value
position.

levelling anticlockwise (Y6035).
3. Set the start current for Solenoid valve, levelling anticlockwise
(Y6035) on row 1, Start current levelling anticlockwise. Change
zero position.


levelling anticlockwise (Y6035).
3. Set the end current for Solenoid valve, levelling anticlockwise
(Y6035) on row 1, End current levelling anticlockwise. Change
position.
8.5.7.10 Initiation menus, Hydraulics
7.10 Other functions 11/XX INITIATE

2. Row 1 shows the setting value for automatic lowering of support
jacks.
Row 2 shows the stored value for automatic lowering of support
jacks.
3. Set the speed factor on row 1, Support jacks auto move. 1
indicates that automatic lowering is set. Change the value with /
and store the value with .
8.5.8 Control system


2. Row 1 shows the brightness for the panel's searchlight in the dark.
Row 2 shows the stored value for the panel's searchlight in the
dark.
3. Set the value for the panel's searchlight in the dark on row 1, Panel
searchlight brightness at darkness. Change the value with /


2. Row 1 shows the brightness for the panel's searchlight in daylight.
Row 2 shows the stored value for the panel's searchlight in daylight.
3. Set the value for the panel's searchlight in daylight on row 1, Panel
searchlight brightness at daylight. Change the value with /

2. Row 1 shows the brightness for the panel's function light in the
dark.
Row 2 shows the stored value for the panel's function light in the
dark.
3. Set the value for the panel's function light in the dark on row 1,
Panel function light brightness at darkness. Change the value
with / and store the value with .

2. Row 1 shows the brightness for the panel's function light in daylight.
Row 2 shows the stored value for the panel's function light in
daylight.
3. Set the value for the panel's function light in daylight on row 1,
Panel function light brightness at daylight. Change the value

2. Row 1 shows the brightness for the button searchlight in the dark.
Row 2 shows the stored value for the button's searchlight in the
dark.
3. Set the value for the button's searchlight in the dark on row 1,
Button searchlight brightness at darkness. Change the value


2. Row 1 shows the brightness for the searchlight buttons in daylight.
Row 2 shows the stored value for the searchlight buttons in
daylight.
3. Set the value for the searchlight buttons in daylight on row 1,
Button searchlight brightness at daylight. Change the value

2. Row 1 shows the brightness for indicator lights, attachment in the
dark.
Row 2 shows the stored value for brightness in the dark.
3. Set the value for the brightness for indicator lights, attachment in
the dark on row 1, Attach indicator light brightness at darkness.
Change the value with / and store the value with .

2. Row 1 shows the brightness for indicator lights, attachment in
daylight.
Row 2 shows the stored value for brightness in daylight.
3. Set the value for the brightness for indicator lights, attachment
in the daylight on row 1, Attach indicator light brightness at
daylight. Change the value with / and store the value with .
8.5.8.2 Initiation menus, Monitoring
8.2 Monitoring 1/XX INITIATE

2. Row 1 shows max. speed forwards in km/h.
Row 2 shows the stored value for max. speed forwards.
3. Set the max. speed forwards in km/h. on row 1, Speed limit
forward. Change the value with / and store the value with .


2. Row 1 shows max. speed reverse in km/h.
Row 2 shows the stored value for max. speed reverse.
3. Set the max. speed reverse in km/h. on row 1, Speed limit
reverse. Change the value with / and store the value with .

2. Row 1 shows the service interval.
Row 2 shows the saved value for the service interval.
3. Set the service interval on row 1, Service time interval . Change
the value with / and save the value with .
The service interval can be changed between 0 and maximum
service interval for the machine. If the interval is set to 0 then the
service indication is switched off completely.

2. Row 1 shows resetting of the service interval.
Row 2 shows the saved value for resetting.
3. Activate resetting on row 1, Service time interval reset. Change
the value with / and save the value with .

2. Row 1 shows the number of hours left to service when Event
menu, service, shall be shown.
Row 2 shows the saved value for resetting.
3. Set the number of hours left to service when Event menu, service,
shall be shown on row 1, Service time pop up hours. Change the
value with / and store the value with .


2. Row 1 shows the setting value for load centre limitation.
Row 2 shows the saved load centre limitation.
Row 3 shows the value for load centre.
3. Set load centre limitation on row 1, Load centre (L) min limit.
If the limit is set to -2000 then the load centre limitation is
disengaged.

2. Row 1 shows the setting value for height limitation.
Row 2 shows the saved height limitation.
Row 3 shows the value for total height.
Row 4 shows the value for height under the attachment.
3. Set the load centre limitation on row 1, Height limit (total).
Change the value with / and save the value with .
If the limit is set to 4000 then the load centre limitation is
disengaged.

2. Row 1 shows the setting value for the cab position at which the
machine's speed should be limited on machines with hydraulic
cab movement.
Row 2 shows the saved position of the cab for speed limitation.
Row 3 shows the value for speed limitation. The speed limitation is
set in menu 12, see 8.2 Monitoring 12/XX INITIATE, page 8:130
Row 4 shows the value for the cab's actual position on the machine.
3. Set the position for the cab on row 1, Cab position speed limit.
Distance from rear position. Change the value with / and
store the value with .
If the limit is set to 0 then the speed limitation is disengaged.


2. Row 1 shows the setting value for speed limitation when the cab is
slid forward on machines with hydraulic cab movement.
Row 2 shows the saved value for speed limitation.
Row 3 shows the value for requested speed limitation.
Row 4 shows the value for the cab's measured position on the
machine.
3. Set the position for the cab on row 1, Cab position speed limit.
Max allowed speed. Change the value with / and store the
value with .

2. Row 1 shows the setting value for load centre limitation depending
on the cab's position on machines with hydraulic cab movement,
setting based on the cab's position from the rearmost position.
Row 2 shows the saved value for cab position for load centre
limitation.
Row 3 shows the value for the cab's measured position from the
centre of the drive axle. (A negative value means that the cab is
behind the centre of the drive axle.)
Row 4 shows the value for the load centre's measured position
from the centre of the drive axle. (A negative value means that the
load centre is behind the centre of the drive axle.)
3. Set the position for the cab on row 1, Load centre limit dependent
on cab position. Distance to cab rear position. Change the
value with / and store the value with .

2. Row 1 shows the setting value for load centre limitation depending
on the cab's position on machines with hydraulic cab movement,
distance limit between the front edge of the cab and load centre.
Row 2 shows the saved value for the distance limit.
Row 3 shows the value for the cab's measured position from the
centre of the drive axle. (A negative value means that the cab is
behind the centre of the drive axle.)
Row 4 shows the value for the load centre's measured position
from the centre of the drive axle. (A negative value means that the
load centre is behind the centre of the drive axle.)
3. Set the position for the cab on row 1, Load centre limit dependent
on cab position. Clearance distance. Change the value with /

8.5.9 Frame, body, cab and accessories

8.5.9.4 Initiation menus, Climate system
9.4 Climate System 1/XX INITIATE

2. Row 1 shows the max. time for pause heating.
Row 2 shows the stored value for max. time for pause heating.
3. Set the max. time for pause heating on row 1, Pause heating
time. Change the value with / and store the value with .

2. Row 1 shows the setting value for the lowest temperature that the
pause heating is permitted to be active.
Row 2 shows the saved value for the pause heating temperature.
3. Set the pause heating temperature when the climate system shuts
down on row Pause heating temp. Change the value with /

2. Row 1 shows the sleep mode functionality. Sleep mode means
that cab cooling/heating is switched off when the cab door is open.
Row 2 shows the saved value for the status of sleep mode
functionality.
3. Activate sleep mode functionality on row 1, Sleep mode
functionality enable, with a 1. Charge the value with / and
8.5.9.5 Initiation menus, Windscreen wipers
9.5 Wiper & Washer Sys 1/XX INITIATE

2. Row 1 shows the time interval for fast wiper interval.
Row 2 shows the saved value for the time interval.
3. Set the time for fast wiping interval on row 1, Intermittent wiper
fast. Change the value with / and save the value with .

9.5 Wiper & Washer Sys 2/XX INITIATE

2. Row 1 shows the time interval for slow wiper interval.
Row 2 shows the saved value for the time interval.
3. Set the time for slow wiping interval on row 1, Intermittent wiper
slow. Change the value with / and save the value with .
8.5.9.6 Initiation menus, Lighting
9.6 Lighting Sys 1/xx INITIATE

2. Row 1 shows the setting for working lights when starting the
engine.
Row 2 shows the stored value for working lights when starting
the engine.
3. Set use of working lights when starting the engine on row 1,
Working lights on during start engine. Change the value with
/ and store the value with .
0 = switched off when the starter motor is running.
1 = switched on.
9.6 Lighting Sys 2/xx INITIATE

2. Row 1 shows the setting for error code display for open circuit for
lighting and revolving beacon.
Row 2 shows the stored value for error code display for open
circuit for lighting and revolving beacon.
3. Set the error code display for open circuit on row 1, Disable O.C.
error code light/rotating beacon. Change the value with /
On machines with LED lighting, an error code will be generated
because the power consumption of LED lights is low. By setting
this value, incorrect error codes for lighting can be avoided.
0 = error code display for open circuit active.
1 = error code display for open circuit deactivated.

8.5.9.7 Initiation menus, Signal system
9.7 Signalling Sys 1/XX INITIATE

2. Row 1 shows the use of the revolving beacon, boom.
Row 2 shows the saved value for use.
3. Set the use of the revolving beacon on row 1, Revolving beacon
cab and boom. Change the value with / and store the value
with .
0 = off.
1 = activated only with the switch.
2 = activated with the switch or during reversing.
3 = activated with the switch or when the engine is running.
4 = activated with the switch or during ignition on.

2. Row 1 shows the use of the revolving beacon, frame.
frame. Change the value with / and store the value with .
0 = off
3 = activated with the switch or during driving forward.
5 = activated with the switch or during automatic functions.

2. Row 1 shows the use of the revolving beacon attachment.
attachment. Change the value with / and store the value
with .
0 = off
3 = activated with the switch or during driving forward.
5 = activated with the switch or during automatic functions.

8.5.9.9 Initiation menus, Glass/windows/mirrors,
9.9 Glass Wind Mirr 1/XX INITIATE

2. Row 1 shows the heating time for mirrors.
Row 2 shows the saved value for the heating time.
3. Set the heating time for mirrors on row 1, Mirror heating time.
0 = no time limit.
9.9 Glass Wind Mirr 2/XX INITIATE

2. Row 1 shows the heating time for rear window.
Row 2 shows the saved value for the heating time.
3. Set the heating time for rear window on row 1, Window heating
time. Change the value with / and store the value with .
0 = no time limit.
8.5.9.10 Cab frame and suspension
9.10 Cab Suspension 1/XX INITIATE

cab forward/up (Y6016).
3. Set the start current for Solenoid valve, cab forward/up (Y6016) on
row 1, Start current sliding cab forward. Change the value with
zero position.


cab forward/up (Y6016).
3. Set the end current for Solenoid valve, cab forward/up (Y6016) on
row 1, End current sliding cab forward. Change the value with
position.

2. Row 1 shows the setting value for damping of cab forward or up.
3. Set the value for damping, damping of cab forward or up on row 1,
Damp value sliding cab forward. Change the value with /
the machine.

cab back/down (Y6017).
3. Set the start current for Solenoid valve, cab back/down (Y6017)
on row 1, Start current sliding cab reverse. Change the value
zero position.


cab back/down (Y6017).
3. Set the end current for Solenoid valve, cab back/down (Y6017) on
row 1, End current sliding cab reverse. Change the value with
position.

2. Row 1 shows the setting value for damping cab back/down.
3. Set the value for damping, damping of cab back/down on row 1,
Damp value sliding cab reverse. Change the value with /
the machine.

2. Row 1 shows the setting value for distance from end position for
damping cab movement.
Row 2 shows the saved value for the distance.
3. Set the value for distance on row 1, Damp distance sliding cab.
Change the value with / and store the value with Save .
the machine.


2. Row 1 shows the setting value for using the thumb control for
shifting on the control lever with the shift button on the control lever
for cab movement.
Row 2 shows the stored value for the switch's function.
3. Set the value of the switch's function on row 1, Enable Fwr/Rev
switch for sliding cab. Change the value with / and store
the machine.
0 = Cab movement via the control lever's thumb control for shifting
disengaged.
1 = Cab movement via the control lever's thumb control for shifting
with the shift-button activated.
8.5.9.14 Initiation menus, Central lubrication
9.14 Central Lubr 1/XX INITIATE

2. Row 1 shows the setting value for the capacity of central
lubrication, frame.
Row 2 shows the saved value for the capacity.
3. Set the capacity for central lubrication, frame on row 1, Grease
capacity frame adjust 0-150%. Change the value with / and
0% means lubrication is turned off and at 150% the central
lubrication system lubricates about 50% more than in normal mode.
9.14 Central Lubr 2/XX INITIATE

2. Row 1 shows the setting value for the capacity of central
lubrication, attachment.
Row 2 shows the saved value for the capacity.
3. Set the capacity for central lubrication, attachment on row 1,
Grease capacity attach. adjust 0-150%. Change the value with
/ and store the value with .
0% means lubrication is turned off and at 150% the central
lubrication system lubricates about 50% more than in normal mode.

8.5.11 Common electrics

8.5.11.5 Initiation menus, Voltage feed
11.5 Distr Of Electr 1/XX INITIATE

2. Row 1 shows the time for automatic system and engine shut down.
Row 2 shows the saved value for time.
3. Set the time for automatic system and engine shut down on row 1,
Automatic system shut down time. Change the value with /

9:1
9 Frame, body, cab and accessories
Contents 9 Frame, body, cab and accessories

9 Frame, body, cab and accessories ................................................................. 9:3
9.1.1 Multi-function lever ....................................................................................9:14
9.2 Safety and emergency equipment .................................................................9:16
9.2.1 Control breaker .........................................................................................9:16
9.2.2 Seat belt ....................................................................................................9:17
9.2.3 Fire extinguisher........................................................................................9:17
9.3 Seat................................................................................................................9:18
9.3.1 Seat cushion .............................................................................................9:19
9.3.2 Back rest cushion ......................................................................................9:21
9.3.3 Heating coil ...............................................................................................9:22
9.3.4 Bumper......................................................................................................9:22
9.3.5 Air suspension...........................................................................................9:22
9.3.6 Compressor air-suspension seat...............................................................9:22
9.3.8 Passenger seat .........................................................................................9:23
9.3.11 Arm rest.....................................................................................................9:23
9.3.17 Head rest...................................................................................................9:23
9.3.19 Sensor, operator-in-seat............................................................................9:23
9.4 Heating, ventilation and air conditioning ........................................................9:24
9.4.1 Fresh air filter ............................................................................................9:29
9.4.2 Fresh air/recirculation damper...................................................................9:30
9.4.3 Cab fan......................................................................................................9:31
9.4.4 Heat exchanger heat .................................................................................9:34
9.4.5 Water valve ...............................................................................................9:36
9.4.6 Sensor coolant temperature ......................................................................9:37
9.4.7 Compressor...............................................................................................9:38
9.4.8 Condenser unit ..........................................................................................9:40
9.4.9 Particle and moisture filter.........................................................................9:40
9.4.10 Pressure switch .........................................................................................9:42
9.4.11 Expansion valve ........................................................................................9:43
9.4.12 Temperature deicing sensor ......................................................................9:44
9.4.13 Heat exchanger, cooling............................................................................9:44
9.4.14 Air distributor .............................................................................................9:46
9.4.15 Defroster nozzles ......................................................................................9:47
9.4.16 Fan temperature sensor ...........................................................................9:48
9.4.17 Interior temperature sensor ......................................................................9:49
9.4.18 Ambient temperature sensor .....................................................................9:49
9.4.19 Pause heater .............................................................................................9:50
9.5 Wiper/washer system.....................................................................................9:51
9.5.4 Washer motor and reservoir......................................................................9:54
9.5.7 Wiper motor rear .......................................................................................9:55
9.5.8 Wiper motor, front and roof .......................................................................9:57
9.6 Lighting system ..............................................................................................9:58
9.6.1 Headlights .................................................................................................9:61
9.6.2 Running lights ...........................................................................................9:61
9.6.3 Tail lights ...................................................................................................9:61
9.6.4 Brake light .................................................................................................9:62
9.6.5 Back-up lights............................................................................................9:62
9.6.6 Direction indicators....................................................................................9:62
9.6.7 Warning lamp, Hazard...............................................................................9:62
9.6.8 Revolving beacon......................................................................................9:63
9.6.9 Working lights, cab ....................................................................................9:63
9.6.10 Work light boom ........................................................................................9:64
9.6.11 Working lights, attachment ........................................................................9:64
9.6.12 Interior lighting...........................................................................................9:64

9.6.13 Extra working lights frame .........................................................................9:64

9.7 Signalling system ...........................................................................................9:65
9.7.1 Horn ..........................................................................................................9:67
9.7.2 Warning lamp, Hazard...............................................................................9:67
9.7.3 Revolving beacon......................................................................................9:67
9.7.4 Warning parking brake ..............................................................................9:67
9.7.5 Back-up alarm ...........................................................................................9:68
9.7.7 Buzzer .......................................................................................................9:68
9.8 Entertainment and communication ................................................................9:69
9.8.1 Radio with CD ...........................................................................................9:69
9.8.7 Voltage converter ......................................................................................9:69
9.9 Glass/windows/mirrors...................................................................................9:72
9.9.1 Windscreen ...............................................................................................9:73
9.9.2 Side window ..............................................................................................9:78
9.9.3 Roof window..............................................................................................9:78
9.9.4 Rear window .............................................................................................9:83
9.9.5 Rear view mirror ........................................................................................9:83
9.9.8 Rear view camera and load camera..........................................................9:83
9.10 Cab structure and suspension .......................................................................9:85
9.10.1 Cab frame .................................................................................................9:85
9.10.2 Doors.........................................................................................................9:86
9.10.3 Cab substructure .......................................................................................9:89
9.10.4 Sliding cab.................................................................................................9:90
9.11 Cab interior ..................................................................................................9:102
9.11.1 Instrument and control panels .................................................................9:102
9.11.2 Interior fittings, plastic .............................................................................9:104
9.11.3 Interior fittings, textile ..............................................................................9:109
9.11.4 Floor covering ......................................................................................... 9:110
9.11.5 Insulation ................................................................................................. 9:110
9.11.6 Sun visors ............................................................................................... 9:111
9.12 Frame........................................................................................................... 9:112
9.13 Body structure.............................................................................................. 9:113
9.13.1 Wings ...................................................................................................... 9:113
9.13.2 Hood engine compartment ...................................................................... 9:113
9.13.3 Footsteps and hand rail........................................................................... 9:113
9.13.4 Counterweight ......................................................................................... 9:114
9.13.5 Battery compartment ............................................................................... 9:114
9.13.8 Tool kit ..................................................................................................... 9:114
9.13.9 Lifting lugs ............................................................................................... 9:115
9.14 Central lubrication ........................................................................................ 9:116
9.14.1 Pump unit ................................................................................................ 9:117
9.14.2 Distribution block ..................................................................................... 9:117
9.14.3 Lines........................................................................................................ 9:118
9.14.4 Lubricant nipples ..................................................................................... 9:118
9.14.5 Sensor, central lubrication ....................................................................... 9:119
9.15 Paint/coatings ..............................................................................................9:120

9 Frame, body, cab and accessories – Frame, body, cab and accessories 9:3
9 Frame, body, cab and

accessories
Frame, body, cab and accessories, general
and instructions for components and systems belonging to the
frame, body, cab and accessories, refer to the relevant supplier
documentation.


9:4 9 Frame, body, cab and accessories – Frame, body, cab and accessories
Frame, body, cab and accessories,

description
The machine consists of frame, body and cab.
The frame is the machine's structural part and is made of high-strength

steel.
The body consists of fenders, engine hood and other parts mounted
on the frame.
The cab is built separately and insulated from the frame using
heavy-duty rubber dampers. Driver's seat, steering wheel and control
lever for hydraulics can be adjusted for optimal individual operating
position. Effective insulation results in a minimum of vibration and a low
sound level. The machine is equipped with a heating and ventilation
unit with air conditioning.
WARNING
Each case of mechanical damage to the cab
may involve risks since the strength is changed.
Consequently, making holes in load bearing parts is
forbidden.
Contact Cargotec for recommendations.
WARNING
The strength of the roof window may be significantly
reduced in case of exposure to substances containing
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the surface layer of the roof window and
clean only with washer fluid or mild detergent. Rinse
thoroughly with lukewarm water afterwards. Replace a
damaged roof window that shows cracks or scratches
immediately!
CAUTION
All reworking of the roof window is forbidden (e.g.
making holes, cutting or widening existing holes).
Risk of material damage.
Small cracks in the material around outer edges for
example indicate that the strength of the roof window
is affected and it must be replaced immediately.

9 Frame, body, cab and accessories – Controls and instruments 9:5

Cab overview
1 2 3 4 5
015581
13 12 11 10 9 8
2. Multi-function lever
3. Steering wheel
4. Steering panel
5. Display with function keys
6. Right dashboard panel, front section
7. Right dashboard panel, middle section
8. Right dashboard panel, rear section
9. Arm rest and storage box
10. Driver's seat
11. Accelerator
12. Brake pedals
13. Joystick or mini-wheel
Cab rear section, see Cab rear section, page 9:8.

9:6 9 Frame, body, cab and accessories – Controls and instruments
Steering panel
Steering panel
14. Ignition
14
21 22 23 30 16 17 15. Engine start and stop button
16. Indicator light, parking brake
17. Indicator light, high beams
18
18. Indicator light for active error code
24 19
19. Indicator light for direction indicators
25 20 20. Warning lamp, by-pass of safety system
21. Switch for combined windscreen wipers front windscreen/roof
26 windows, continuous
22. Switch for combined windscreen wipers front windscreen/roof
012692 windows, intermittent
27 28 29 32 31 33 15
23. Windscreen washer switch
Steering panel
24. No function
25. No function
26. Switch, windscreen wiper rear, continuous
27. Switch, windscreen wiper rear window, intermittent
28. Light sensor
29. No function
30. Manual shifting up switch
31. Manual shifting down switch
32. Switch for automatic shifting
33. Travel direction indicator, Forward Neutral Reverse
Right dashboard panel, front section
34 35 36 37 38 39 40 34. Control breaker for hydraulics

43
35. Switch for pause heater
36. Switch for recirculation
37. Switch for defroster
38. Switch for reduced fan speed
41 42 44 45 46 39. Switch for automatic control of the climate system

40. Switch for increased fan speed
41. Switch for increased temperature
42. Switch for reduced temperature
012693
43. Switch for cooling

47 48 49 50 51 52
44. Switch for air distribution, to the floor
45. Switch for air distribution, to the driver
46. Switch for air distribution, to the roof
47. Switch for bypass of safety system
48. Switch for electrically heated rear view mirror
Switch for electrically heated rear window
49. Control lever for electrically operated mirrors
Switch for support jacks
50. Spare
51. Spare
52. Switch for radio mute

Right control panel, middle section
Right control panel, middle section

53 53. Control lever
d
c a Travel direction selector, Forward - Neutral - Reverse
b b Control for side shift/spreading/rotation/tilt
a 54 55 56 57
c Switch for opening the twistlocks
d Switch for alternative function
e Switch for tilt lock
f f Switch for levelling lock
54. Switch for bottom lift-attachment, front legs
e
55. Switch for bottom lift-attachment, rear legs
56. Switch for automatic spreading 20'-40'
015582
62 58 59 60 61 57. Switch for 30'-stop
Right dashboard panel, middle section 58. Switch for twistlocks, automatic/manual
59. Switch for bottom lift-attachment, clamping position
Switch for lowering overheight legs
60. Switch for cab movement
61. Spare
62. Switch for horn
Right control panel, rear section
Right control panel, rear section

63. Switch for working lamps on cab
63 64 65 66 67 68 69 70 71
64. Switch for working lights on boom
65. Switch for working lights on attachment
66. Switch for extra working lights on frame
67. Switch for reversing light
68. Switch for length adjustment of right control panel
69. Switch for height adjustment of the steering wheel
72 73 74 75
When the service menus are active, the buttons can be used to
select up/down in the menus.
70. Switch for height adjustment of right control panel
10:23
10 20
When the service menus are active, the buttons can be used to
0
rpm x 100
30
select right/left in the menus.
71. Switch and navigation wheel for control system
21°
13 85 km/h
km/h
9999
72. Switch for headlights
73. Switch, interior lighting
74. Switch for revolving beacon
75. Switch for warning lamp
016430
71
Right dashboard panel, rear section and display

Cab rear section
Cab rear section

76. Compartment for operator's manual
77
77. Electrical distribution box with fuses and relays
76
016431
Cab rear section

Roof panel
Roof panel
78 79 80 81 82 78. Light sensor

79. Indicator light for lowered support jacks
016432
80. Indicator light for locked twistlocks

81. Indicator light for contact
Roof panel 82. Indicator light for unlocked twistlocks
Control for load handling

For further information about controls for load handling and associated
functions, see section Operator's manual section 4.6 Load handling.

Operating menus, overview

1
10:23 2
10 20
0 30
7 rpm x 100
2
10: 23 1 0: 2 3 2
0
21° 18 99 999
km / h 32.8 l/h 1756
9.5
r pm
k m/ h
20.2 k m/ h
26.1 l/h
16.7 t 74.8 km
0 D U
120:36 h 1 23 14432
0
6 3
0:0 0pm 12: 5 9pm
- 1. 9 t 80 ° C 5. 0 b a r
7 4. 9 t
5 2 2. 9 t 10 0 %
10: 23 0: 00pm
7 5° C 5 0%
2 8. 0 V
5 0° C 5 0° C
016373
5 4
Examples of operating menus 5. Operating menu electrical system

1. Operating menu 6. Operating menu, scale (after this are operating menus
for optional functions)
2. Operating menu, trip computer work shift
7. Operating menu, customer settings
3. Engine operating menu
4. Operating menu, transmission and hydraulics

Silicone panel right-hand dashboard panel front

section, replacement
4 Turnover the panel and remove the nuts and washers that secure
the silicone panel.
5 Replace the silicone panel.
CAUTION
015760
The panel's plastic parts may be damaged if the screws

are tightened too hard.
Product damage.
Exercise caution when tightening, do not tighten the
screws too hard.

Switch right-hand dashboard panel front section,

replacement
4 Detach the connector from the switch.

5 Replace the switch.
CAUTION
015879

are tightened too hard.
Product damage.
screws too hard.

Silicone panel right-hand dashboard panel rear

section, replacement
2 Open the cover on the storage box.
015771
1 2
1. Navigation wheel
2. Lid, storage box

015762
4 Loosen the spring and carefully turnover the storage box.

Avoid stretching the cables.
015781

1 2 5 Carefully separate the navigation wheel and silicon panel's

connectors.
CAUTION
The navigation wheel's contact is only soldered onto
the circuit board.
Product damage.
Exercise caution when the connector is separated in
order to avoid damage to the circuit board.
6 Remove the nuts and washers that secure the silicone panel.
015761
4 3
1. Contact, silicone panel
2. Nut, silicone panel
3. Nut, navigation wheel
4. Contact, navigation wheel
7 Carefully remove the navigation wheel's circuit board with sensor

1 from the silicone panel.
Pull the navigation wheel straight up and undo the plastic nut
under the wheel.
2 8 Replace the silicone panel.
CAUTION
3 are tightened too hard.
Product damage.
screws too hard.
4
017459
Navigation wheel parts

1. Navigation wheel
2. Plastic nut
3. Washer
4. Circuit board
Navigation wheel, replacement

See Silicone panel right-hand dashboard panel rear section,
replacement, page 9:12.

9:14 9 Frame, body, cab and accessories – Multi-function lever
Silicone panel steering panel, replacement

2 Remove the five screws.
015769
1 2 3 3 Turnover the panel and disconnect the contact.

4 Remove the nuts and washers that secure the silicone panel.
5 Replace the silicone panel.
015770
1. Silicone panel
2. Contact
3. Nut
9.1.1 Multi-function lever

General
Light control, horn and direction indicators are handled by a
2 multi-function lever (position 2).
015221

9 Frame, body, cab and accessories – Multi-function lever 9:15
Multi-function lever, replacement

2 Remove the gaiter from the multi-function lever.
015778

015776
4 Remove the screws and fold out the multi-function lever.

Mark the pins and then remove them.
5 Replace the multi-function lever.
6 Fit in the reverse order. Replace pins as marked.
015777

9:16 9 Frame, body, cab and accessories – Safety and emergency equipment
9.2 Safety and emergency equipment

Safety and emergency equipment, description
Safety components for protecting the driver.
A good work environment has safety and emergency equipment in

order to facilitate the operator's work and make it safer.
The operator's cab contains equipment designed to fulfil the safety

requirements imposed by authorities, customers, operators and
Cargotec.
The machine may be equipped with the following:
11
7
1, 8
10 13
016938
5 6, 12 9 3, 4
1. Back-up alarm 8. Back-up lights
2. Revolving beacon 9. External rear view mirrors
3. Horn Used to provide increased visibility during manoeuvring
and load handling. One rear view mirror on each side.
4. Electrically-driven loud horn
10. Control breaker for hydraulics
5. Fire extinguisher
Disengages all power transmission and control signals
Fire extinguishers may also be located externally. to the hydraulics.
If the machine is equipped with a fire extinguisher then 11. Emergency exit cab, right-hand door and rear window
it must be approved in accordance with European
( )
standard EN3. The fire extinguisher must be specified
so that it is designed for use against fire in: fibrous fuels 12. Switch in driver's seat. (Not positioned in figure.)
(Class A), liquid fuels (Class B), gaseous fuels (Class
Disengages the drive and load handling functions if
C) and electrical appliances. Adapted fire extinguishing
the operator leaves the operator's station. In addition,
equipment can be ordered from Cargotec.
a warning is activated when the operator leaves the
6. Seat belt operator's station without applying the parking brake.
For the hydraulic vertically adjustable cab there is always 13. Buzzer, automatic spread 20'-40'.
a seat belt and safety chains by the doors.
7. Buzzer in cab to indicate alarm, overload or forgotten
action, e.g. if the operator leaves the cab without applying
the parking brake.
9.2.1 Control breaker

Control breaker, description
See section 11 Common electrics, group 11.5.1.4 Control breaker
voltage.

9 Frame, body, cab and accessories – Seat belt 9:17
9.2.2 Seat belt

Seat belt, description
Two-point seatbelt fitted in the seat. See Driver's seat, page 9:18.
There are also 3-point seatbelt .
For diagnostic menu, see 9.3 Seat 1/XX DIAGNOSE, page 8:58.
A pop-up appears on the display indicating that the speed of the

machine is above 3 km/h and the seat belt sensor's output signal is 0
V (seat belt not fastened).
9.2.3 Fire extinguisher

Fire extinguisher, description
Usage instructions are on the fire extinguisher.

9:18 9 Frame, body, cab and accessories – Seat
9.3 Seat
Seat, general
The seat's function is to provide the operator with a good sitting position
and contribute to a good work environment. The cab's seat has several
adjustment options and fulfils high comfort standards.
Driver's seat
The driver's seat is equipped with a number of adjustment controls and
11 are as follows (adjustment is easier when the seat is unloaded):
1. Seat belt, 2-point.
Seat belt, 3-point .
2. Seat tilt.
3. Horizontal suspension .
4. Seat length.
10 5. Seat height position.
For mechanical raising:
1 Turn the knob clockwise or anticlockwise until the desired height
9
is reached.
For air suspension raising: .
2 Lift the lever up to raise the seat height or press the lever down to
lower the seat height. The suspension corresponds automatically
8 to the driver's body weight.
3 An indicator shows a green marking when the correct setting is
7 reached. The indicator shows red when the seat's suspension is
set outside the comfort zone.
6. Distance to pedals.
4
Release the seat using the lever and move the seat forwards or
5 6 backwards.
7. Backrest rake.
Release the lock with the lever, set the desired angle and release
the lever to lock in position.
8. Adjusting arm rest, left .
9. Lumbar support.
Turn the knob until the desired hardness in the lumbar support is
set.
017255
10. Seat heating .

11. Adjusting the headrest .
Driver's seat with adjustment options
Driver's seat, replacement

2 Slide the seat fully backwards, remove the two front screws that
hold the seat in place.
015800

9 Frame, body, cab and accessories – Seat cushion 9:19
1 3 Slide the seat fully forwards, remove the two rear screws that hold
the seat in place.
5 Secure the right-hand console so it does not fall down when the
seat is lifted out.
Secure it with a cord from the roof, or get the help of a colleague.
6 Remove the seat.
015801
2
1. Screw
2. Contact
9.3.1 Seat cushion

Seat cushion, description
Seat cushion fabrics are interchangeable. These should be replaced
with new ones when they show signs of wear.
Seat cushion, replacement
NOTE
Note how the seat cushion's guides and locking catches hold and
lock the seat cushion when it is removed in order to facilitate fitting.
1 Fully tilt up the seat cushion and then slide the seat cushion fully
forward (only the cushion, not the seat).
2 Press up the plastic arm under the seat cushion so that the plastic
arm snaps out of its locking catch.
Note how the plastic arm should align in relation to the mechanism
for the controls at the front of the seat cushion.
015802
Plastic arm, seat cushion
3 Fully slide back the seat cushion and carefully lift at the rear edge
1 2
so that the mechanism for the control (position 1) is clear of the
guide grooves in the seat undercarriage.
4 Pull the seat cushion forward enough that the guide grooves in the
seat (position 2) are clear of the seat undercarriage.
5 Lift the seat cushion and turn it over.
017477
Attaching points seat cushion

1. Mechanism for controls
2. Guide grooves seat cushion

9:20 9 Frame, body, cab and accessories – Seat cushion
6 Remove the pins from the connector behind the seat.

7 Connect the seat cushion's cable harness behind the seat.
015803
8 Position the seat cushion so that the guide grooves in the seat
1 2 cushion engage in the mountings on the seat undercarriage.
9 Fully slide back the seat cushion and align the mechanism
for the control (position 2) into the guide grooves on the seat
undercarriage.
Check that the plastic arm is aligned on the correct side of the
control arm.
017477
Attaching points seat cushion

1. Mechanism for controls
2. Guide grooves seat cushion
10 Slide the seat cushion forward so that the plastic arm locks the
seat cushion in the recess on the mechanism for the controls on
the front of the seat cushion.
11 Check that the longitudinal adjustment of the seat and the seat
cushion is working correctly.
015802
Plastic arm, seat cushion

9 Frame, body, cab and accessories – Back rest cushion 9:21
Seat cushion fabrics, replacement

1 Remove the seat cushion, see Seat cushion, replacement, page
9:19.
2 Place the seat cushion upside down and unscrew the controls.
3 Squeeze together the foam rubber.
015804
1
1. Screw, control
4 Pull the fabric from the seat cushion's groove.

Align the plastic part in the seat cushion's groove.
015805
The fabric's plastic part in the seat cushion groove
9.3.2 Back rest cushion

Back rest cushion, description
Backrest cushion fabrics are interchangeable. These should be
replaced with new ones when they show signs of wear.
Backrest cushion fabrics, replacement

1 Remove the rotary control on the side of the seat and possibly
the headrest.
2 Pull the fabric down and out from the rear of the backrest.
Remove the fabric.
015807

9:22 9 Frame, body, cab and accessories – Heating coil
9.3.3 Heating coil

Heating coil, description
Used for seat and backrest heating.
9.3.4 Bumper
Bumper, description
The shock absorbers are integrated in the suspension unit and are
self-adjusting, that is, adjust automatically to the operator\qs weight.
9.3.5 Air suspension

Air suspension, description
A seat with air suspension has rubber bellows and a compressor. The
air suspension is self-adjusting, that is, it adjusts automatically to the
operator's weight. The compressor supplies the suspension unit with
compressed air.
9.3.6 Compressor air-suspension seat

Compressor air-suspension seat, description
The compressor can be part of the air-suspended seat. In this case it

is located inside the seat's suspension unit.
Compressor air-suspension seat, replacement

2 Remove the seat, see Driver's seat, replacement, page 9:18.
3 Turnover the seat.
4 Cut the cable ties.
5 Disconnect the cable terminals and unscrew the air connection.
6 Change the compressor.
015861
1 2 3 4
1. Cable terminal
2. Air connection
3. Cable ties
4. Compressor

9 Frame, body, cab and accessories – Passenger seat 9:23
9.3.8 Passenger seat

Passenger seat, description
Passenger seat are available in several different designs.

The seat folds (vertically) in order not to obstruct the entrance when not
in use. Located to the left of the driver's seat.
017439
9.3.11 Arm rest

Armrests, description
Right side armrest is integrated into the right console and is attached to
the seat's seat frame. The height can be adjusted separately.
Arm rest for left side is an option .
The options for the left arm rest are:
A. Mini-wheel
See Joystick control/mini-wheel, function description, page 5:11.
On machines with mini-wheel there is also a switch fitted that
detects when the arm rest is lowered, see Arm rest in position
sensor, description, page 5:28.
B. Joystick control
See Joystick control/mini-wheel, function description, page 5:11.
On machines with joystick control there is also a switch fitted that
detects when the arm rest is lowered, see Arm rest in position
sensor, description, page 5:28.
9.3.17 Head rest

Head restraint, description
Some models of seat can be adjusted with a head restraint for

increased comfort.
9.3.19 Sensor, operator-in-seat

Sensor operator in seat, description
Sensor, operator-in-seat (B2300) detects whether the driver's seat
cushion is depressed, which indicates to the control system that
the driver's seat is occupied. This is used when the control system
indicates, with a buzzer located in the KPU control unit (D7902) (right
console), if the operator leaves the driver's seat without applying the
parking brake. The operator-in-seat sensor (B2300) also cuts operation
and hydraulic functions.
For diagnostic menu, see 9.3 Seat 1/XX DIAGNOSE, page 8:58.

9:24 9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
9.4 Heating, ventilation and air

conditioning
Heating, ventilation and air conditioning,
description
The machine is equipped with an air conditioning unit, ECC (Electronic
Climate Control, electronic control of fan, air distribution, cooling and
F
heating).
The air conditioning unit consists of different modules: fan module, heat
2 exchange module, air distribution module and silicone panel. The fan
module takes in air from the outside (or inside the cab) and directs the
4
air to the heat exchange module. In the heat exchange module the air
C temperature is moderated and directed on towards the air distributor.
D The air distributor directs the air towards channels in the cab's interior
for floor, defroster and air vents.
3
The heat exchange module consists of heat exchangers, one for
heating and one for cooling. The heat exchanger for heating is
E connected to the engine's cooling system and provides heat when the
engine is hot. The heat exchanger for cooling (evaporator) is connected
to the AC compressor, which is activated when cooling is required.
The compressor is activated during cooling which compresses the

refrigerant. The refrigerant is evaporated in the evaporator inside
the cab. When the refrigerant is evaporated, cooling is created in
6 the evaporator. When outside air is forced through the evaporator
A B
by the cab fan, the air is cooled down. The cooling is automatically
deactivated when a door is open. When the door is closed the cooling
is reactivated. The air conditioning unit has a delay of 45 seconds
between deactivation and activation.
Air conditioning includes the parts presented in the illustration and

ensures the operator's cab climate is as comfortable as possible. The
1 function of the air conditioning is to:
5 G • heat the air when it is cold
015310
• dehumidify the air when it is damp

1. Fluid reservoir/receiver dryer • clean the air of impurities
2. Evaporator • cool the air when it is hot
3. Fan • defrost (defroster function)
4. Expansion valve The unit is controlled with switches and controls on the dashboard
5. Condenser panel.
6. Compressor The system's fan is operated variably 0-100 %.
A. High-pressure gas
B. High-pressure fluid
C. Low-pressure fluid
D. Low-pressure gas
E. Heating, cab air
F. Cooled air to cab
G. Outdoor air for removal of heat

9 Frame, body, cab and accessories – Heating, ventilation and air conditioning 9:25
Heating, ventilation and air conditioning, function

description
1,2,3,4,5,29,30,32
D1
35
D7902 D7950
6 D7901 D7971
D6 9,11,18 20 D7940
15 D13
8 D8
22 D25 D27
34 26
19 D19
D20
D34
M 25 27
D18 23 24 C 28
D7
17 21
M
7 D17
16,31
M 12
D16 D11 D12
M
D33 33 13
10 14
016091
1 The Increase temperature switch U=5V Cab overview, page 9:5
(S1051-1) or Decrease temperature D1: 9.4 Climate System 2/XX DIAGNOSE,
switch (S1051-2) sends a voltage signal page 8:59
to the KPU control unit (D7902).
2 The Increase fan speed switch (S1180-1) U=5V Cab overview, page 9:5
or Decrease fan speed switch (S1180-2) D1: 9.4 Climate System 2/XX DIAGNOSE,
sends a voltage signal to the KPU page 8:59
3 Air distribution to roof (S1053-1), to U=5V Cab overview, page 9:5
operator (S1053-2) or to floor (S1053-3) D1: 9.4 Climate System 3/XX DIAGNOSE,
switches send a voltage signal to KPU page 8:59
4 Automatic regulation of the climate U=5V Cab overview, page 9:5
system switch (S1054) sends a voltage D1: 9.4 Climate System 1/XX DIAGNOSE,
signal to the KPU control unit (D7902). page 8:58
5 Cooling switch (S1120) sends a voltage U=5V Cab overview, page 9:5
signal to the KPU control unit (D7902). D1: 9.4 Climate System 1/XX DIAGNOSE,
page 8:58
6 Interior temperature sensor (B7751) R = 10 kΩ at 25 °C Interior temperature sensor, description,
sends a voltage signal proportional to page 9:49
the temperature to KCU control unit D6: 9.4 Climate System 4/XX DIAGNOSE,
(D7901). page 8:59 and 9.4 Climate System 5/XX
DIAGNOSE, page 8:60


7 Fan temperature sensor (B7752) R = 10 kΩ at 25 °C Fan temperature sensor, description, page
sends a voltage signal proportional to 9:48
DIAGNOSE, page 8:60
8 Ambient temperature sensor (B7740) R = 10 kΩ at 25 °C Ambient temperature sensor, description,
sends a voltage signal proportional to page 9:49
DIAGNOSE, page 8:60
9 KCU control unit (D7901) regulates Checked by control 11.5.3.1 KCU control unit (D7901), page
temperature and air distribution with system, error shown with 11:25
signals from sensors and controls. error code.
10 The engine produces heat while running. -
It is cooled with the cooling system. The
heat from the cooling system is used to
heat the cab air.
11 KCU control unit (D7901) controls Water U = ±10 V 11.5.3.1 KCU control unit (D7901), page
valve (Y6730), which routes hot water 11:25
for heating heat exchanger. D11: 9.4 Climate System 14/XX DIAGNOSE,
page 8:62 and 9.4 Climate System 15/XX
DIAGNOSE, page 8:62
12 The water valve's opening (%) is fed U = 0.5-4.5 V Water valve, description, page 9:36
back to the KCU control unit (D7901). D12: 9.4 Climate System 7/XX DIAGNOSE,
This gives information for controlling the page 8:60
water valve's position.
13 Sensor, engine temperature, sends a Checked by control D13: 1.7 Cooling system 2/XX DIAGNOSE,
voltage signal proportional to the engine system, error shown with page 8:30
temperature to Control unit, engine error code.
(D7940).
14 Heat exchanger heat supplies heat to - Heat exchanger heat, description, page
the cab air. The heat is transferred from 9:34.
the engine's cooling system to the cab
air.
15 Control unit, engine (D7940) transmits Checked by control 11.5.3.6 Control unit, engine (D7940), page
engine temperature in the cooling system, error shown with 11:35
system on the CAN bus. error code.
16 KCU control unit (D7901) controls Checked by control Fresh air/recirculation damper, description,
Actuator motor, recirculation (Y6120) system, error shown with page 9:30
which sets the fresh air or recirculation error code. D16: 9.4 Climate System 11/XX DIAGNOSE,
damper in the required position. page 8:61 and 9.4 Climate System 12/XX
DIAGNOSE, page 8:62
17 KCU control unit (D7901) controls Fan Checked by control Cab fan, description, page 9:31
motor (M6570), which increases the system, error shown with D17: 9.4 Climate System 16/XX DIAGNOSE
airflow in the cab. error code. , page 8:63
18 KCU control unit (D7901) controls U = ±12 V Air distributor, description, page 9:46
Damper motor (Y6720), which sets the D18: 9.4 Climate System 16/XX DIAGNOSE
air distributor to the required position. , page 8:63 and 9.4 Climate System 17/XX
DIAGNOSE, page 8:63
19 The air distributor's position is fed back U = 0.5-4.5 V Air distributor, description, page 9:46
to KCU control unit (D7901). This D19: 9.4 Climate System 8/XX DIAGNOSE,
gives information for controlling the air page 8:61
distributor's position.
20 KFU control unit (D7971) voltage feeds U = 24 V 11.5.3.4 KFU control unit (D7971), page
the Magnetic coupling (M6450) on the 11:31
compressor. D20: 9.4 Climate System 13/XX
DIAGNOSE, page 8:62

9 Frame, body, cab and accessories – Heating, ventilation and air conditioning 9:27

21 The compressor draws gaseous - Compressor air conditioning, description,
refrigerant from the evaporator, page 9:38
compresses it, and forces it on to the
condenser.
22 The engine's cooling fan draws air - -
through the condenser and cooling unit.
23 The condenser cools the refrigerant. - Condenser unit, description, page 9:40
The gaseous refrigerant condenses to
liquid form and is pumped on in the
circuit.
24 The moisture filter absorbs any moisture - Particle and moisture filter, description, page
from the cooling circuit. The fluid 9:40.
reservoir stores the refrigerant.
25 The pressure switch (B2460) sends a U = 24 V Pressure switch, description, page 9:42.
signal to the KCU control unit (D7901) D25: 9.4 Climate System 6/XX DIAGNOSE,
if the pressure in the system becomes page 8:60.
abnormally high or low.
26 The expansion valve adjusts the - Expansion valve, description, page 9:43.
amount of refrigerant that is let in to the
evaporator. If the temperature in the
evaporator's outlet pipe increases, the
expansion valve increases the flow of
refrigerant so that heat dissipation in the
evaporator increases.
27 Temperature deicing sensor (B7753) R = 10 kΩ at 25 °C Temperature deicing sensor, description,
sends a voltage signal proportional to page 9:44.
28 Heat exchanger, cooling, dissipates heat - Heat exchanger, cooling, description, page
from the cab air. The heat is transferred 9:44.
from the air to the refrigerant and
transforms the refrigerant to a gaseous
state.
29 Defroster switch (S1390) sends a Checked by control Cab overview, page 9:5.
voltage signal to the KPU control unit system, error shown with D1: 9.4 Climate System 1/XX DIAGNOSE,
(D7902) that activates the defroster error code. page 8:58.
program for the climate system for nine
minutes.
30 Recirculation switch (S1910) sends a Checked by control Cab overview, page 9:5.
(D7902) that activates recirculation. error code. page 8:58.
31 KCU control unit (D7901) controls Checked by control Fresh air/recirculation damper, description,
Actuator motor, recirculation (Y6120) system, error shown with page 9:30.
which sets the fresh air or recirculation error code. D16: 9.4 Climate System 11/XX DIAGNOSE,
damper in the recirculation mode. page 8:61 and 9.4 Climate System 12/XX
32 Pause heater switch (S1019) sends a Checked by control Cab overview, page 9:5.
(D7902). error code. page 8:63
33 KCU control unit (D7901) controls U = 24 V Pause heater, description, page 9:50.
the Circulation pump heating system D33: 9.4 Climate System 20/XX
(M6670) which pumps the coolant DIAGNOSE, page 8:64.
through the heating system when the
engine is turned off.
The pause heater is automatically
switched off by means of a thermostat
in the coolant circuit when the coolant
temperature is below a set value


34 Air filter contact (B2190) sends a signal U = 24 V D34: 9.4 Climate System 6/XX DIAGNOSE,
to the KCU control unit (D7901) if the page 8:60.
pressure in the fresh air filter becomes
abnormally high.
35 Control unit KID (D7950) shows the Checked by control 11.5.3.3 Control unit, KID (D7950), page
heating and ventilation settings in the system, error shown with 11:29.
display. error code.
General instructions for working on the air

conditioning unit
CAUTION
Authorisation is required for repair of the air
conditioning unit.
WARNING
In the event of a rupture of a cooling hose or leakage
on the attachment - switch off the unit immediately.
It is dangerous to get refrigerant on the skin or in the
eyes.
Never release refrigerant in an enclosed space, the gas
may cause suffocation e.g. in assembly pits.
Never weld on or in the vicinity of a closed cooling
system.
Drain the refrigerant during repairs on the air
conditioning.
Work on the refrigerant circuit must only be performed
by an accredited company.
Air conditioning unit, troubleshooting the cooling

circuit
NOTE
The air conditioning unit does not work at temperatures below
approx. 0 °C since the pressure in the refrigerant circuit is too low. If
the pressure in the refrigerant circuit becomes too low then the low
pressure switch disconnects the power supply to the compressor's
magnetic coupling, which means that the air conditioning unit stops
working.
1 Read the safety information for the refrigerant before starting work,
see Refrigerant, page B:20.
2 Read the general instructions before working on the climate
system, see General instructions for working on the air conditioning
unit, page 9:28.
4 Carry out performance tests on the air conditioning unit in
accordance with the maintenance manual, section 9 Frame,
body, cab and accessories, group 9.4 Heating, ventilation and
air conditioning.

9 Frame, body, cab and accessories – Fresh air filter 9:29
5 Check that the hoses and components on the pressure side

maintain a roughly even temperature by feeling them with your
hand.
NOTE
In the event of a stop in one of cooling circuit's components, and
during long-term operation, certain parts (possibly hoses before
the condenser) may be very hot. Risk of burn injuries!
6 All hoses and components on the pressure side (from the

compressor to the expansion valve) should be hot.
7 All hoses and components on the suction side (from the evaporator
to the compressor) should be cold.
8 Check that the expansion valve is not frosty or cold.
Frost or cold temperatures on the inlet side of the expansion valve
indicate that it is defective or clogged and that circulation is limited
or stopped on the pressure side.
9 Check that the compressor engages and disengages normally.
Run the cab fan at low speed and allow the compressor to work
at high rotation speed. When the temperature of the air vents
approaches 0 °C, the compressor is disengaged via ECC and is
016878
re-engaged when the temperature has risen approx. 3-7 °C. (If the
compressor is not disengaged then there is a risk of the evaporator
Expansion valve icing up and cooling performance diminishing.)
9.4.1 Fresh air filter

Fresh air filter, description
Fresh air filter is standard equipment on machines cab. It is located in
3 the external unit for heat exchange (heat exchange module) to the cab.
1
016870
Fresh air intake to cab with fresh air filter and filter
holder.
1. Cover
2. Fresh air filter
3. Fresh air intake

9:30 9 Frame, body, cab and accessories – Fresh air/recirculation damper
9.4.2 Fresh air/recirculation damper

Fresh air/recirculation damper, description
Fresh air/recirculation damper is an electrically operated damper fitted
in the fan module in the cab. The damper controls air selection, the
air is routed to the air vents in the cab from fresh air to recirculation
air from the cab.
Fresh air/recirculation damper, is operated by motor recirculation

(Y6120).
016872
Recirculation motor, replacement

2 For access to the centre screw to recirculation motor:
Remove the cab fan housing, see Cab fan, replacement, page
9:31.
1 2 3 3 Remove the connectors from the motor and loosen the centre nut
and screws that hold the recirculation motor.
4 Replace the recirculation motor.
Before reassembly: Connect the connectors and test the
recirculation motor and operate to fresh air mode.
NOTE
Make sure the hoses to the cab temperature sensor and filter
switch are fitted so that the airflow through them is not hindered.
016082
4
1. Motor, recirculation
2. Centre screw, access from the top of the cab
fan housing
3. Screw, recirculation motor
4. Connectors

9 Frame, body, cab and accessories – Cab fan 9:31
9.4.3 Cab fan

Cab fan, description
Cab fan (M6570) on the right side of the cab is located in the external
unit for fresh air intake into the cab (accessible from the right side of
the cab).
016871
Cab fan, replacement

2 Remove the screws and the outer front cover.
3 Remove the screws holding the cab's front cover, remove the
front cover.
015257

9:32 9 Frame, body, cab and accessories – Cab fan
4 Loosen the locking screws and remove the cover plate in front of
the fresh air filter.
015258
5 Remove the fresh air filter and brace.
016200
1
2
1. Brace
2. Fresh air filter
6 Remove the cover over the cab fan.
1
017460
1. Cover

9 Frame, body, cab and accessories – Cab fan 9:33
1 2 3 4 7 Remove the screws that hold the cab fan's air duct in the air
conditioning.
8 Loosen the hose to the filter switch.
016061
1. Screw, cab fan housing
2. Housing, cab fan
3. Hose, filter switch
4. Screw, air channel
9 Remove the screws and the grille in front of the recirculation filter.
Remove the recirculation filter.
016401
1 2
1. Grille in front of the recirculation filter
2. Screw, grille
10 Loosen the hose to the cab temperature sensor from the connector
on the fan unit.
11 Loosen the connector from the cab temperature sensor and pull
out the wiring through the fan unit's rubber grommet.
12 Loosen the connectors to the fan motor and filter switch.
13 Carefully tilt and lift out the cab fan housing, starting at the heat
exchanger.
14 Remove the screws that hold the cab fan's housing in the cab.
016402

9:34 9 Frame, body, cab and accessories – Heat exchanger heat
15 Remove the screws that hold the cab fan in the housing.
16 Replace the cab fan.
NOTE
Make sure the hoses to the cab temperature sensor and filter
switch are fitted so that the airflow through them is not hindered.
1 016062
1. Screw, cab fan
9.4.4 Heat exchanger heat

Heat exchanger heat, description
Pipes and fins in the heat exchanger transfer heat from the hot coolant
in the engine to the ventilation air in the cab.
The heat exchanger for heating is located in the external unit for fresh
air intake to the cab (between the tilt cylinders).
NOTE
Clamps should be installed on the hoses to prevent unnecessary
loss of coolant when any work is done on the coolant circuit.
1 Wear protective gloves and use a collection vessel to collect the
coolant that runs out.
016873
2
NOTE
1. Heat exchanger, cooling
After work is performed, check the coolant circuit for leaks and
2. Heat exchanger heat check the coolant level. Top up coolant if necessary.
Heat exchanger, heating, replacement

front cover.
015257

9 Frame, body, cab and accessories – Heat exchanger heat 9:35
3 Loosen the locking screws and remove the cover plate.

4 Drain the cooling system of coolant, see Maintenance manual.
WARNING
The cooling system is pressurised. Steam or hot
coolant may spurt out.
Risk or scalding or burn injuries!
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled before filling.
016403
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid skin contact, wear protective
glasses and protective gloves. In the event of skin
contact, wash your hands.
5 Clamp the hoses to and from the heat exchanger with pinch-off
pliers to prevent coolant escaping.
016066
1 2
1. Heat exchanger heat
2. Hose, heat exchanger heat

9:36 9 Frame, body, cab and accessories – Water valve
6 Loosen the hoses

7 Withdraw the heat exchanger from its rest position.
8 Replace the heat exchanger.
016067
1
1. Connection of heat exchanger, heat under the
cab
9.4.5 Water valve

Water valve, description
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 with diagnostic menu 9.4 Climate System
016877
Water valve, replacement

front cover.
015257

9 Frame, body, cab and accessories – Sensor coolant temperature 9:37
3 Loosen the locking screws and remove the cover plate.
016403
3 2 4 Install clamps on the hoses to prevent coolant from running out.
5 Undo the hose clamps and remove the hoses. Use a receptacle to
collect any coolant that runs out.
6 Undo the water valve connector.
7 Unscrew the water valve.
8 Fit in the reverse order
NOTE
After fitting the water valve, check the valve for leaks and check
the coolant level. Top up coolant if necessary.
NOTE
The water valve centre shaft has a groove that can be used for
fault tracing the heating system.
016068
1 2
1. Water valve
2. Hoses
3. Connectors
9.4.6 Sensor coolant temperature

Coolant temperature sensor, description
Sensor, coolant temperature, is fitted on the engine and detects
engine's coolant temperature. See supplier documentation, engine.
For placement, see each engine option:

Engine alternative Volvo TAD1360VE, component location, page
1:10.
Engine alternative Cummins QSM11, component positions ,
page 1:12.

9:38 9 Frame, body, cab and accessories – Compressor
9.4.7 Compressor
Compressor air conditioning, description
The compressor drives the air conditioning by working as a pump. It
draws in cold, low-pressure gas from the evaporator, compresses the
gas which then becomes warm, and then forces out high-pressure
gas to the condenser.
The compressor is driven by V-belts directly by the machine's engine.

Activation and deactivation of the compressor is handled by an
electromagnetic clutch, which is controlled by a thermostat.
The signal can be checked with the diagnostic menu, see 9.4 Climate
System 13/XX DIAGNOSE, page 8:62.
For placement, see each engine option:

Engine alternative Volvo TAD1360VE, component location, page
1:10.
Engine alternative Cummins QSM11, component positions ,
page 1:12.
Compressor, replacement
IMPORTANT
Working on the air conditioning requires special
authorisation.
NOTE
It is extremely important to prevent contamination and foreign
particles from getting into the refrigerant circuit. Carefully clean
the area where the cooling circuit is to be worked on, before
starting to dismantle.
Always replace the particle and moisture filters when performing
any work on the refrigerant circuit.
NOTE
For tightening torque of refrigerant hoses and pressure switch,
see section F Technical data.

9 Frame, body, cab and accessories – Compressor 9:39
unit, page 9:28.
4 Drain the AC system of R134a refrigerant.
1 2
016322
Engine alternative Cummins QSM11

1. Belt tensioner drive belt (automatic)
2. Belt tensioner drive belt AC compressor
(manual)
5 Release the belt tension and remove the compressor belt.

6 Loosen the hose connections and disconnect the inlet and outlet
hoses from the compressor. Plug the couplings in order to prevent
contaminants.
7 Remove the nuts holding the compressor.
8 Empty the oil from the old compressor (through inlet/outlet) and
measure the quantity.
9 Empty the oil from the new compressor. The compressor is filled
with cooling oil on delivery.
10 Refill the new compressor with the new oil in the same amount
drained from the old one.
In the event of refrigerant loss, there may also be a certain oil
1 loss because approx. 25% of the oil volume is taken up by the
refrigerant.
For oil volume and type in the system, see section F Technical
data.
014243
12 Turn the compressor over several turns by hand.

Engine alternative Volvo TAD1360VE 13 Using vacuum equipment, refill the system with R134a refrigerant
and test for leaks.
1. Belt tensioner recess for pull handles
14 Check the function of the system.

9:40 9 Frame, body, cab and accessories – Condenser unit
9.4.8 Condenser unit

Condenser unit, description
The condenser unit is fitted on the cooling unit behind the engine.
The condenser is a heat exchanger and its function is to convert the
hot high-pressure gas from the compressor into liquid form. Pipes
and flanges in the condenser battery absorb the heat, which is then
dissipated with a fan.
Refrigerant temperature in the condenser varies depending on the

ambient temperature and the air flow through the condenser. When the
refrigerant is condensed into liquid it is forced onward to the particle
and moisture filter.
1. Cooling unit IMPORTANT

2. Condenser
authorisation.
NOTE
particles from getting into the refrigerant circuit. Carefully clean the
area where the cooling circuit is to be worked on, before starting to
dismantle.
9.4.9 Particle and moisture filter

Particle and moisture filter, description
The filter, which contains a particle trap and a hygroscopic medium,
collects liquid refrigerant, binds moisture and filters out impurities. The
housing functions as an expansion tank in the cooling circuit.
1
016874
1. Particle and moisture filter

9 Frame, body, cab and accessories – Particle and moisture filter 9:41
Particle and moisture filter, replacement
IMPORTANT
authorisation.
NOTE
NOTE
Particle and moisture filters are not normally consumable
components in the refrigerant circuit.
It is recommended to replace the particle and moisture filters
when the refrigerant circuit has been opened, depressurised for a
long time or when one of the other refrigerant circuit components
has been replaced.
NOTE
unit, page 9:28.
4 Remove the front left-hand cover on the cab.
5 Drain the air conditioning of refrigerant R134a, with the intended

draining equipment.
6 Release the pipe fittings from the moisture filter.
7 Plug the hoses to avoid contamination of the refrigerant circuits.
8 Undo the hose clamps and remove the moisture filter.
9 Replace the moisture filter.
10 Connect the pipe fittings to the moisture filter.
11 Check for leaks and refill the machine with refrigerant R134a, with
the intended equipment.
For volume, see section F Technical data.
015266

9:42 9 Frame, body, cab and accessories – Pressure switch
12 Fit the front left-hand cover on the cab.
9.4.10 Pressure switch

Pressure switch, description
The pressure switch (B2460) is located on the particle and moisture
filters. In the event of a pressure drop, the pressure switch warns via
the KCU control unit (D7901) and cooling circuit ceases to function.
1
016875
1. Pressure switch
Pressure switch, replacement
IMPORTANT
authorisation.
NOTE
NOTE
unit, page 9:28.

9 Frame, body, cab and accessories – Expansion valve 9:43

draining equipment.

7 Undo the cable connectors.
8 Unscrew the pressure switch.
9 Screw in a new pressure switch and refit the cable terminals.
016566
11 Fit the front left-hand cover on the cab.
9.4.11 Expansion valve

Expansion valve, description
The expansion valve (evaporator) is the part in the circuit that separates
the high-pressure side from the low-pressure side. The refrigerant
arrives in liquid form at the expansion valve under high pressure and
leaves it under low pressure. After the expansion valve, the refrigerant
converts to a gaseous state and is transported to the compressor
once again.
The amount of refrigerant that passes through the expansion valve

varies depending on the heat load. The valve works from fully open to
016878
fully closed and searches between these for an optimal evaporation

point.

9:44 9 Frame, body, cab and accessories – Temperature deicing sensor
9.4.12 Temperature deicing sensor

Temperature deicing sensor, description
Temperature deicing sensor (B7753) is positioned on the manifold to
the heat exchanger for cooling.
03.00
05
006316
.00
Figure 1
1. Pipe
016074
2. De-icing sensor
NOTE
When the de-icing sensor is replaced on a horizontal pipe, it is
important that the de-icing sensor should be positioned between
03.00 and 05.00 o'clock (see figure 1).
It is also very important for climate unit function that the de-icing
sensor has full contact with the pipe, it is fixed to the pipe with a
cable tie and that insulation material is applied over the de-icing
sensor and pipe.
9.4.13 Heat exchanger, cooling

Heat exchanger, cooling, description
The heat exchanger for cooling consists of pipes carrying refrigerant
through the cooling fins. The heat from the cab's air is channelled via
the flanges to the refrigerant in the pipes.
The refrigerant circulates and returns to a gaseous state, becoming

cold, and is drawn from the heat exchanger for cooling back to the
compressor. The cycle has come full circle.
The heat exchanger for cooling is located in the external unit for fresh
air intake to the cab (between the tilt cylinders).
1
016873

2. Heat exchanger heat

9 Frame, body, cab and accessories – Heat exchanger, cooling 9:45
Heat exchanger, cooling, replacement
IMPORTANT
authorisation.
NOTE
NOTE
unit, page 9:28.
draining equipment.
front cover.
015257
015258

9:46 9 Frame, body, cab and accessories – Air distributor
7 Disconnect the fitting nuts to the expansion valve.

8 Pull out the plate with heat exchanger for cooling from its home
position.
9 Replace the heat exchanger for cooling.
11 Use new O-rings when installing and replace the old dryer and
moisture filter before refilling the cooling system.
016071
1 2 3 4 5
2. Screw, plate
3. Connections heat exchanger for cooling
4. Expansion valve
5. Plate
9.4.14 Air distributor

Air distributor, description
The air distributor distributes the air between the defroster and the floor
nozzles. It is fitted on top of the climate unit under the dashboard panel.
The air distributor contains dampers that are controlled by Motor air
distribution (Y6720) that controls the air distribution in the cab.
016876
Air distribution motor, replacement

front cover.
015257

9 Frame, body, cab and accessories – Defroster nozzles 9:47
015258
4 Disconnect the connector, remove the screws that hold the air
distribution motor and the centre screw to the motor.
5 Replace the air distribution motor.
6 Fit the connector and test run the new motor in defroster mode.
016083
1 2 3
1. Connector, air distribution motor
2. Air distribution motor
3. Screw
9.4.15 Defroster nozzles

Defroster nozzles, description
There are a number of adjustable defroster nozzles in the cab interior,
for example, five at the windscreen for defrosting and six adjustable
defroster nozzles in the dashboard panel. Adjustable flow and direction
(flow is proportional to fan speed).
A large air vent is located low in the cab (floor). This allows the
adjustment of the air flow from the lower part of the cab to defroster.
015218
Defroster nozzles to cab.

9:48 9 Frame, body, cab and accessories – Fan temperature sensor
Defroster nozzles, replacement

2 Angle the damper and pull out the defroster nozzle.
016058
9.4.16 Fan temperature sensor

Fan temperature sensor, description
Sensor fan temperature (B7752) is positioned after the heat exchanger
heat and measures the temperature of the air blown into the cab.
017461

9 Frame, body, cab and accessories – Interior temperature sensor 9:49
9.4.17 Interior temperature sensor

Interior temperature sensor, description
Interior temperature sensor (B7751) is located in the air stream by the
climate unit's recirculation inlet.
014762
9.4.18 Ambient temperature sensor

Ambient temperature sensor, description
Ambient temperature sensor (B7740) is located on the rear edge of the
roof. It detects the current outside temperature without being affected
by the heat from the vehicle.
016073

9:50 9 Frame, body, cab and accessories – Pause heater
9.4.19 Pause heater

Pause heater, description
Pause heating is an option for the heating unit, which uses residual
1 heat in the engine's cooling system to keep the cab warm.
An extra electrically operated heating system circulation pump (M6670)

pumps the coolant through the heating system when the engine is
2 switched off. The cab fan forces the air into the cab. The pause heater
is automatically switched off when the coolant temperature is below a
set value. The pause heater is activated with the pause heater switch.
016077
1. Pause heater switch, on the front part of the

right dashboard panel
2. Circulation pump, pause heater (M6670)

9 Frame, body, cab and accessories – Wiper/washer system 9:51
9.5 Wiper/washer system

Wiper and washer system, description
There are combined wipers on the cab for the windscreen and roof
2
windows and one wiper for the rear window. There function is to clean
the windows and maintain good visibility from the cab.
1
WARNING
Attempts to manually move the wiper arms damage the
wiper motor gear or shaft.
3 Damage to the wiper motor gear or axles.
Never attempt to manually move the wiper arms.
The wiper arms are mounted on a linkage system that is supported by

a carriage in a guide rail along the front edge of the roof which means
that the wiper blades move in parallel over the windows and give a
maximum clean area on the windows. The linkage system is activated
via a connecting rod, which is bearing mounted in a crank on a motor
mounted on the cab roof. The motor axle's fastening surface is tapered
015306
and made of hardened steel. The crank's fastening surface is made of

soft steel. The wiper arms' parking position can be adjusted freely by
1. Wiper front mounting the motor axle's crank in any position. On delivery, the wiper
2. Wiper roof motor is in the parking position.
3. Wiper rear

9:52 9 Frame, body, cab and accessories – Wiper/washer system
Wiper/washing system, combined wipers front

windscreen/roof windows, function description
1 2 3 4 8 9 13
D8 D9 D13
D1 D2 D3 D4
17
D7902 D7950
16 D16 D7901 D7971

5,10,14
D7 D6
D12 D11 D15 D15
016111
6,7 M 11,12 M 15 M 15 M

1 Combined wiper continuous front U = 24 V Cab overview, page 9:5.
windscreen/roof windows switch 11.5.3.2 KPU control unit (D7902), page
(S1190-FR) sends a voltage signal to 11:27.
KPU control unit (D7902).
D1: 9.5 Wiper & Washer Sys 1/XX
2 Combined wiper intermittent front U = 24 V Cab overview, page 9:5.
(S1520-FR) sends a voltage signal to 11:27.
3 Combined wiper continuous front U = 24 V Cab overview, page 9:5.
(S1190-UP) sends a voltage signal to 11:27.
4 Combined wiper intermittent front U = 24 V Cab overview, page 9:5.
(S1520-UP) sends a voltage signal to 11:27.
5 KCU control unit (D7901) feeds power I = XX A. 11.5.3.1 KCU control unit (D7901), page
to the wiper motor front windscreen/roof 11:25.
windows (M6503).
6 Wiper motor front windscreen/roof - Wiper motor, front and roof, description,
windows (M6503) powers the wiper page 9:57.
blades on the front and roof windows D6: 9.5 Wiper & Washer Sys 2/XX
7 The wiper motor's position is fed back to U = 0.5-4.5 V D7: 9.5 Wiper & Washer Sys 2/XX
Control unit KCU (D7901). This gives DIAGNOSE, page 8:64.
information for controlling the wiper
blade's position.
8 Wiper continuous rear window switch U = 24 V Cab overview, page 9:5.
(S1190-RE) sends a voltage signal to 11.5.3.2 KPU control unit (D7902), page
KPU control unit (D7902). 11:27.

9 Frame, body, cab and accessories – Wiper/washer system 9:53

9 Wiper intermittent rear window switch U = 24 V Cab overview, page 9:5.
(S1520-RE) sends a voltage signal to 11.5.3.2 KPU control unit (D7902), page
KPU control unit (D7902). 11:27.
10 KCU control unit (D7901) feeds power I = XX A. 11.5.3.1 KCU control unit (D7901), page
to the wiper motor rear window (M6502). 11:25.
11 Wiper motor rear window (M6502) - Wiper motor rear, description, page 9:55.
powers the wiper blade on the rear D11: 9.5 Wiper & Washer Sys 5/XX
window. DIAGNOSE, page 8:65.
12 The wiper motor's position is fed back to U = 0.5-4.5 V D12: 9.5 Wiper & Washer Sys 5/XX
Control unit KCU (D7901). This gives DIAGNOSE, page 8:65.
information for controlling the wiper
blade's position.
13 Washer switch (S1200) sends a voltage U = 24 V Cab overview, page 9:5.
signal to the KPU control unit (D7902). 11.5.3.2 KPU control unit (D7902), page
11:27.
14 KCU control unit (D7901) sends I = XX A. 11.5.3.1 KCU control unit (D7901), page
current to the washer motor front 11:25.
windscreen/roof windows (M6513) or
washer motor rear window (M6512).
15 Washer motor front windscreen/roof - Washer motor and reservoir, description,
window (M6513) or washer motor rear page 9:54.
window (M6512) washes the windows. D15: 9.5 Wiper & Washer Sys 3/XX
Washing is done on the windows where DIAGNOSE, page 8:65 and
the wipers are activated. 9.5 Wiper & Washer Sys 6/XX DIAGNOSE,
If none of the wipers are activated, page 8:66.
the combined wipers on the front
windscreen/roof windows and washing
on each window are activated.
If the machine is equipped with a
reversible seat the wiper on the rear
window is activated when the seat is in
the reversed position.
16 Contact level washer fluid (B2991) U = 24 V Washer motor and reservoir, description,
sends a voltage signal to the KCU page 9:54.
control unit (D7901) with a low washer D16: 9.5 Wiper & Washer Sys 3/XX
fluid level. DIAGNOSE, page 8:65.
17 KID control unit (D7950) shows the Checked by control 11.5.3.3 Control unit, KID (D7950), page
event menu for low washer fluid level. system, error shown with 11:29.
error code.

9:54 9 Frame, body, cab and accessories – Washer motor and reservoir
9.5.4 Washer motor and reservoir

Washer motor and reservoir, description
The wiper motors and washer fluid level sensor (B2991) are located in
the washer fluid reservoir. The reservoir is positioned externally, to the
left on the cab's left-hand side (accessible when the cover is removed).
There are non-return valves on the lines from the reservoir to the wiper
arms. The nozzles are mounted on the wiper arms.
Washer motor and reservoir, replacement

3 Undo the two screws and angle the washer fluid reservoir forward.
4 Drain the washer fluid into a receptacle.
1
015267
1. Washer fluid level sensor
5 Remove the hoses from the pumps.

1 6 Undo the connector on the electric cable for the pumps.
7 Remove the pumps from the reservoir. A rubber bushing seals
between the pumps and the reservoir.
8 Replace the pump.
3 9 Fit in reverse order.

10 Fill the reservoir up with screenwasher fluid.
2
015268
1. Reservoir
2. Pumps
3. Hoses

9 Frame, body, cab and accessories – Wiper motor rear 9:55
9.5.7 Wiper motor rear

Wiper motor rear, description
The wiper motor drives the wiper for the rear window. The wiper arm
is mounted directly on the motor. The motor produces the movement
of the wiper.
Wiper motor rear window (M6502) is supplied with voltage by Control

unit KCU (D7901), the wiper motor also sends a position signal back
to Control unit KCU (D7901). The signals can be checked with the
diagnostic menus, see 9.5 Wiper & Washer Sys 5/XX DIAGNOSE,
page 8:65.
Wiper motor rear, replacement

2 Open the cover and remove the nut and wiper arm.
Hold the wiper arm during removal so that torque is not transferred
to the motor which may then be damaged.
3 Remove the rubber cap and fastening nut.
4 Remove the lock nut.
015809
1 2 3 4
1. Rubber cap, fastening nut
2. Lock nut
3. Nut, wiper arm
4. Cover
5 Loosen the two screws and remove the plastic cover over the
wiper motor in the cab.
015808

9:56 9 Frame, body, cab and accessories – Wiper motor rear
1 2 6 Remove the plastic covers over the door pillar and rear section.
7 Carefully open the rear section's plastic cover.
015796
1. Plastic cover, rear section

2. Plastic covers, door pillar
8 Remove the wiper motor from the inside.

015815

10 Replace the wiper motor.
When installing it is important to make sure that the grooves are
free from metal shavings and similar. Also, the nuts must be
tightened so tight that the grooves are pressed into the bracket
and work as a drive. Hold the wiper arm when assembling so that
torque is not transferred to the motor which may be damaged
(16-20 Nm tightening torque).
NOTE
015816

free from burrs and similar. Also, the nuts must be tightened to
16-20 Nm, so that the grooves are pressed into the bracket and
work as drive flanges.

9 Frame, body, cab and accessories – Wiper motor, front and roof 9:57
9.5.8 Wiper motor, front and roof

Wiper motor, front and roof, description
Wiper motor (M6503) operates the wipers for the windscreen and roof
window and is fitted in the rear edge of the cab roof under the cover.
The wiper arms are fitted on a linkage that transfers the power from
the wiper motor.
Wiper motor (M6503) is supplied with voltage by Control unit KCU

(D7901), the wiper motor also sends a position signal back to Control
unit KCU (D7901). The signals can be checked with the diagnostic
menus, see 9.5 Wiper & Washer Sys 2/XX DIAGNOSE, page 8:64.
Wiper motor, front and roof, replacement

2 Remove the screws that hold the cover and remove the cover
3 Remove the nut and washer from the wiper motor axle.
Hold the wiper arm during removal so that torque is not transferred
to the motor which may then be damaged.
4 Lift off the crank together with the connecting rod from the wiper
motor axle.
5 Remove nuts and washers that hold the wiper motor plate on the
roof.
015866
7 Lift off the wiper motor plate with the wiper motor.
8 Remove the screws and washers that secure the wiper motor.
1 2 3 4
9 Replace the wiper motor.
Wiper motor, front and roof
1. Wiper motor
2. Wiper motor axle NOTE
3. Contact
4. Wiper motor plate free from burrs and similar. Also, the nuts must be tightened to
16-20 Nm, so that the grooves are pressed into the bracket and
work as drive flanges.

9:58 9 Frame, body, cab and accessories – Lighting system
9.6 Lighting system

Lighting system, description
The lighting system includes interior lighting, service lighting
(headlights, position lights, direction indicators, back-up lights, brake
lights and rear lights) working lights (cab, boom, attachment and
machine) and warning beacon.
The working lights are shut off automatically after 5 minute's idle in
order to prevent discharge of the batteries. Extra working lights are
shut off after 2 minutes. The lights are activated automatically again
when the operator sits in the seat, a gear is selected or the accelerator
pedal is pressed.
NOTE
It is important that the right type of bulb is used for each area. See
Lighting system, function description

The working lights are shut off automatically after 5 minute's idle in
order to prevent discharge of the batteries. Extra working lights are
shut off after 2 minutes. The lights are activated automatically again
when the operator sits in the seat, a gear is selected or the accelerator
pedal is pressed.
NOTE
1 2 3 4 5 6 7 8 9 37 11 12 12
14
13
D1 D2 D3 D4 D5 D6 D7 D8
D9 D12
D14
D13
D11
10, 35 15,16
D7902 D7901
D17 17 D18 18
D28 D7971 D791 1
28 20 32
M
D24 D21
D23 D26 D27 D21 D31 D22
D29 D25 D23
D33 D34
016880
23 26 27 21 19 D19 29 30 31 33 34
22 25 24 23 21

1 Work light on cab switch (S1050-1) sends a Switch in ON position: U D1: 9.6 Lighting Sys 11/XX
voltage signal to the KPU control unit (D7902). = 5 V, DIAGNOSE, page 8:69
off position: U = 0 V
2 Switch, working lights on boom (S1050-2) Switch in ON position: U D2: 9.6 Lighting Sys 14/XX
sends voltage signals to Control unit KPU = 5 V, DIAGNOSE, page 8:70
(D7902). off position: U = 0 V

9 Frame, body, cab and accessories – Lighting system 9:59
3 Switch, working lights on attachment (S1050-3) Switch in ON position: U D3: 9.6 Lighting Sys 16/XX
4 Switch, extra working lights on frame (S1050-4) Switch in ON position: U D4: 9.6 Lighting Sys 17/XX
5 Reversing light switch (S1032) sends a voltage Switch in ON position: U D5: 9.6 Lighting Sys 10/XX
signal to the KPU control unit (D7902). = 5 V, DIAGNOSE, page 8:69
6 Headlight switch (S1000) sends a voltage Switch in ON position: U D6: 9.6 Lighting Sys 1/XX DIAGNOSE,
signal to the KPU control unit (D7902). = 5 V, page 8:66
7 Revolving beacon switch (S1100) sends a Switch in ON position: U D7: 9.7 Signalling Sys 2/XX
voltage signal to the KPU control unit (D7902). = 5 V, DIAGNOSE, page 8:73 and 9.7
off position: U = 0 V Signalling Sys 3/XX DIAGNOSE, page
8:73
8 Warning light switch (S1090) sends a voltage Switch in ON position: U D8: 9.7 Signalling Sys 7/XX
signal to the KPU control unit (D7902). = 5 V, DIAGNOSE, page 8:74
9 Multi-function lever (S1600) sends a voltage High beam mode: D9: 9.6 Lighting Sys 1/XX DIAGNOSE,
signal to the KPU control unit (D7902). US1600/56d = 24 V page 8:66 and 9.6 Lighting Sys 6/XX
Direction indicator left: DIAGNOSE, page 8:68
US1600/L = 24 V
Direction indicator right:
US1600/R = 24 V
10 KPU control unit, (D7902) transmits "switch on Checked by control 11.5.3.2 KPU control unit (D7902),
lights" messages on the CAN bus. system, error shown with page 11:27
error code.
11 Interior lighting switch (S1160) sends a voltage Switch in ON position: U D11: 9.6 Lighting Sys 18/XX
signal to the KCU control unit (D7901). = 5 V, DIAGNOSE, page 8:71
12 The door NC switch (S2660-LE & S2660-RI) Door open: U = 24 V D12: 9.6 Lighting Sys 18/XX
sends a voltage signal to the KCU control unit DIAGNOSE, page 8:71
(D7901).
13 High/low beam switch (S1992) on the arm rest Switch in ON position: U D13: 9.6 Lighting Sys 1/XX
mini-wheel/joystick control sends a voltage = 24 V DIAGNOSE, page 8:66
signal to the KCU control unit (D7901).
14 Direction indicator switch (S1470) on the arm Left: US1470/3 = 24 V D14: 9.6 Lighting Sys 6/XX
rest mini-wheel/joystick control sends a voltage Right: US1470/1 = 24 V DIAGNOSE, page 8:68
signal to the KCU control unit (D7901).
15 KCU control unit, (D7901) transmits "switch on Checked by control 11.5.3.1 KCU control unit (D7901),
lights" messages on the CAN bus. system, error shown with page 11:25
error code.
16 KCU control unit (D7901) supplies voltage to Checked by control 11.5.3.1 KCU control unit (D7901),
the lights in and around the cab. system, error shown with page 11:25
error code.
17 Working lights cab (E4042-LE & E4042-RI) Light on: U = 24 V Working lights, cab, description, page
is switched on when working lights cab are 9:63
activated. D17: 9.6 Lighting Sys 11/XX
DIAGNOSE, page 8:69
18 Interior lighting (E4340-LE & E4340-RI) comes Light on: U = 24 V Interior lighting, description, page 9:64
on when a door is opened or when the interior D20: 9.6 Lighting Sys 19/XX
lighting is activated with the interior lighting DIAGNOSE, page 8:71
switch (S1160).

9:60 9 Frame, body, cab and accessories – Lighting system
19 The brake pressure sensor (B7681) sends U = 0.5-4.5 V Brake pressure sensor, description,
a voltage signal corresponding to the brake page 4:31
pressure to the KFU control unit (D7971). D22: 4.3 Power Assisted 3/XX
DIAGNOSE, page 8:36
20 KFU control unit (D7971) supplies voltage to Checked by control 11.5.3.4 KFU control unit (D7971),
the machine lights. system, error shown with page 11:31
error code.
21 Position lights (H4160-RL, H4160-RR, Light on: U = 24 V Running lights, description, page 9:61
H4160-FL & H4160-FR) are switched on when D21: 9.6 Lighting Sys 10/XX
the headlights are activated with the switch. DIAGNOSE, page 8:69
22 Reversing lights (E4050-LE & E4050-RI) white Light on: U = 24 V Back-up lights, description, page 9:62
come on when reverse gear is engaged and D21: 9.6 Lighting Sys 10/XX
when the reversing lights are activated with DIAGNOSE, page 8:69
the switch.
23 Direction indicators (H4220-FL, H4220-RL, Light on: U = 24 V Direction indicators, description, page
H4220-FR & H4220-RR) come on when 9:62
the direction indicators or warning lights are Warning lamp, Hazard, description,
activated. page 9:62
D25: 9.6 Lighting Sys 7/XX
DIAGNOSE, page 8:68 9.6 Lighting
Sys 8/XX DIAGNOSE, page 8:68 and
9.7 Signalling Sys 7/XX DIAGNOSE,
page 8:74
24 Tail lights (H4120-LE & H4120-RI) red come Light on: U = 24 V Tail lights, description, page 9:61
on when headlights are activated. D28: 9.6 Lighting Sys 4/XX
DIAGNOSE, page 8:67
25 Brake lights (H4110-LE & H4110-RI) come on Light on: U = 24 V Brake lights, description, page 9:62
when the brake is activated. D29: 9.6 Lighting Sys 5/XX
DIAGNOSE, page 8:67
26 Headlights low beam (E4000-LE & E4000-RI) Light on: U = 24 V Headlights, description, page 9:61
come on when the headlights are activated. D26: 9.6 Lighting Sys 3/XX
DIAGNOSE, page 8:67
27 Headlights high beam (E4020-LE & E4020-RI) Light on: U = 24 V Headlights, description, page 9:61
come on when high beam is activated. D27: 9.6 Lighting Sys 2/XX
DIAGNOSE, page 8:66
28 Revolving beacon (H4282) is switched on Light on: U = 24 V Revolving beacon, description, page
when the revolving working light is activated. 9:63
D24: 9.7 Signalling Sys 1/XX
DIAGNOSE, page 8:73
29 Working lights boom (E4043-LE-A & Light on: U = 24 V Work lights, boom, lights, page 9:64
E4043-RI-A) (four), are switched on when D30: 9.6 Lighting Sys 14/XX
working lights boom are activated. DIAGNOSE, page 8:70
30 Extra working lights boom (E4043-LE-B & Light on: U = 24 V Work lights, boom, lights, page 9:64
E4043-RI-B) are switched on when working D30: 9.6 Lighting Sys 14/XX
lights boom are activated. DIAGNOSE, page 8:70
31 Extra working lights frame (E4041-RI-A, Light on: U = 24 V Extra working lights frame, description,
E4041-RI-A, E4041-LE-A & E4041-LE-B) are page 9:64
switched on when extra working lights are D31: 9.6 Lighting Sys 17/XX
activated. DIAGNOSE, page 8:71
32 Control unit KAU (D7911) supplies voltage to Checked by control 11.5.3.8 Control unit KAU (D7911),
the attachment's lights. system, error shown with page 11:38
error code.
33 Working lights attachment (E4044-LE-A & Light on: U = 24 V Working lights, attachment, description,
E4044-RI-A) are switched on when working page 9:64
lights boom are activated. D33: 9.6 Lighting Sys 21/XX
DIAGNOSE, page 8:72

9 Frame, body, cab and accessories – Headlights 9:61
34 Extra working lights attachment (E4044-LE-B Light on: U = 24 V Working lights, attachment, description,
& E4044-RI-B) are switched on when working page 9:64
lights boom are activated. D34: 9.6 Lighting Sys 22/XX
DIAGNOSE, page 8:72
35 KPU control unit (D7902) lights the indicator - -
lights on the dashboard panel.
9.6.1 Headlights
Headlights, description
Headlights are located in the front part of the machine in order to give
1 2 3 4 3 5
the operator enhanced vision when manoeuvring in darkness, and to
provide surrounding traffic and the environment an indication of the
machine's position. Headlights have high beam and a low beam (to
avoid dazzling other road users).
016881
The headlights are turned on with a switch on the dashboard panel.
1. Back-up lights The headlights switch between high and dipped beam using the
multi-function lever.
2. Rear and brake lights
3. Direction indicators NOTE
4. Running lights
The turnable operator's station option includes headlights at both
5. Headlights ends of the machine. The headlights are activated in the relevant
direction so that the headlights are always illuminated in front of
the operator.
9.6.2 Running lights

Running lights, description
Position lights are fitted on the sides of each lamp housing in order to
1 2 3 4 3 5
give other traffic and the environment an indication of the machine's
position in darkness.
016881
1. Back-up lights
2. Rear and brake lights
3. Direction indicators
4. Running lights
5. Headlights
9.6.3 Tail lights

Tail lights, description
There are tail lights at the back of the machine to give others in traffic
1 2 3 4 3 5
and the surroundings an indication of the machine\qs position in the
dark.
NOTE
016881
The turnable operator's station option includes tail lights at both

ends of the machine. The tail lights are activated in the relevant
1. Back-up lights
direction so that the tail lights are always illuminated behind the
2. Rear and brake lights operator.
4. Running lights
5. Headlights

9:62 9 Frame, body, cab and accessories – Brake light
9.6.4 Brake light

Brake lights, description
There are brake lights at the back of the machine to give others in
1 2 3 4 3 5
traffic and the surroundings an indication that the machine is braking
and is thus reducing speed.
NOTE
016881
The turnable operator's station option includes brake lights at both
ends of the machine. The brake lights are activated in the relevant
1. Back-up lights
direction so that the brake lights are always illuminated behind the
2. Rear and brake lights operator.
4. Running lights
5. Headlights
9.6.5 Back-up lights

Back-up lights, description
There are reversing lights at the rear of the cab roof to indicate to other
1 2 3 4 3 5
traffic users and the surroundings that the machine is reversing. In
addition, this provides the operator enhanced view when operating
in darkness.
016881
Reversing lights are activated when reverse is engaged.
1. Back-up lights NOTE

2. Rear and brake lights The turnable operator's station option includes reversing lights at
3. Direction indicators both ends of the machine. The reversing lights are activated in the
relevant direction so that the reversing lights are always illuminated
4. Running lights behind the operator.
5. Headlights
9.6.6 Direction indicators

Direction indicators, description
There are indicators on both the front and the rear of the machine,
1 2 3 4 3 5
to give other road users and the environment an indication that the
machine is about to change direction of travel, i.e. turn.
The indicators are controlled by using the indicator switch (lever), and
016881
is indicated with a green indicator lamp on the steering panel.
1. Back-up lights NOTE

2. Rear and brake lights For the option reversible operator position, the function of the travel
3. Direction indicators direction selector switches so that the direction is correct in relation
to the driver's seat position.
4. Running lights
5. Headlights
9.6.7 Warning lamp, Hazard

Warning lamp, Hazard, description
The machine is equipped with hazard warning flashers. By pressing a
switch, all the direction indicators can be made to flash simultaneously,
to show others that there is danger, such as a mechanical failure.
Flashlights are available as an option .

9 Frame, body, cab and accessories – Revolving beacon 9:63
9.6.8 Revolving beacon

Revolving beacon, description
A revolving beacon is located on the rear of he machine's boom
and is used to provide surrounding traffic and the environment an
indication that a working vehicle is moving and at work. An indication to
bystanders to exercise caution.
The revolving beacon is controlled by selecting with the revolving

beacon switch.
017405
Revolving beacon, pole mounted, replacement

2 Undo the wing nut which fixes the revolving beacon to the pole.
3 Lift the rotating warning beacon off.
4 Install the new revolving beacon.
5 Tighten the wing nut.
017405
9.6.9 Working lights, cab

Working lights, cab, description
Working lights on the cab provide visibility when handling a load in
darkness.
The working lights are turned on with a switch on the dashboard panel.

9:64 9 Frame, body, cab and accessories – Work light boom
9.6.10 Work light boom

Work lights, boom, lights
Work lights on the cab provide enhanced visibility when handling a
load in darkness.
As an option, the boom can be equipped with two extra working lights.
9.6.11 Working lights, attachment

Working lights, attachment, description
Working lights on the attachment provide increased visibility when
handling a load in darkness.
As an option, the attachment can be equipped with extra working

lights, the number and location of which vary depending on type of
attachment.
9.6.12 Interior lighting

Interior lighting, description
The interior lighting lights up the inside of the cab, and is turned on
with an interior lighting switch and door switches when the doors are
opened. The interior lighting comes on for a limited time, when a door
is opened and the machine is turned off.
There is background illumination in all switches, function keys and

rotary controls. This is so that the driver will be able to read their
functions and settings in darkness.
A reading lamp is an accessory for the writing panel combined

document compartment. The reading lamp is an LED lamp with a
clamp and comes attached to the writing panel. The reading lamp has
an internal battery and is turned on with a switch on the lamp housing.
The combined writing panel with document compartment has brackets
to be hung on a door handle, supported against the steering wheel or
fitted on the inner handle.
9.6.13 Extra working lights frame

Extra working lights frame, description
The machine can be equipped with additional working lights located

on the frame (normally on the lamp hoods) in order to provide better
visibility for work in the dark.
As an option, the extra working lights on the fenders can be controlled

together with the high beam.

9 Frame, body, cab and accessories – Signalling system 9:65
9.7 Signalling system

Signalling system, description
The signal system includes revolving beacon, back-up lights, direction
indicators, horn, back-up alarm, buzzer for automatic spreading and
buzzer in the cab.
NOTE
Signalling system, function description

NOTE
1 2 3 4 5 21 20 7
D5
D1 D2 D4 8
D3
19 D7
6
D7902 D7950
D16 D7971 D7901 D8

16 15 9,10
M
D11
D17 D18 D13

D12
016096
17 18 11 12 13 14
Pos Description Signal description Reference

1 Revolving beacon switch (S1100) Switch in ON position: U = D1: 9.7 Signalling Sys 2/XX DIAGNOSE, page
sends a voltage signal to the KPU 5 V, 8:73 and 9.7 Signalling Sys 3/XX DIAGNOSE,
control unit (D7902). off position: U = 0 V page 8:73
2 Warning light switch (S1090) sends Switch in ON position: U = D2: 9.7 Signalling Sys 7/XX DIAGNOSE, page
a voltage signal to the KPU control 5 V, 8:74
unit (D7902). off position: U = 0 V
3 The travel direction selector in U = 24 V Travel direction selector and parking brake,
position for activated parking brake description, page 2:9
(S1310) sends a voltage signal to the D3: 4.5 Park Brake Sys 1/XX DIAGNOSE,
KPU control unit (D7902). page 8:37
4 Multi-function lever (S1600) sends a Signal button pressed in: D4: 9.7 Signalling Sys 1/XX DIAGNOSE, page
voltage signal to the KPU control unit US1600/31b = 24 V 8:73 and 9.6 Lighting Sys 6/XX DIAGNOSE,
(D7902). Direction indicator left: page 8:68
US1600/L = 24 V
Direction indicator right:
US1600/R = 24 V
5 Horn switch (S1490) sends a voltage Switch in ON position: U = D5: 9.7 Signalling Sys 1/XX DIAGNOSE, page
signal to the KPU control unit 24 V 8:73
(D7902).
6 KPU control unit, (D7902) transmits Checked by control 11.5.3.2 KPU control unit (D7902), page 11:27
"activation" messages on the CAN system, error shown
bus. with error code.

9:66 9 Frame, body, cab and accessories – Signalling system
Pos Description Signal description Reference

7 Make-contact (closing switch) Operator in seat: U = 24 V Sensor operator in seat, description, page 9:23
operator-in-seat (B2300) sends a D7: 9.3 Seat 1/XX DIAGNOSE, page 8:58
voltage signal to KCU control unit
(D7901) when there is a load on the
driver's seat.
8 Direction indicator switch (S1470) Left: US1470/3 = 24 V D8: 9.6 Lighting Sys 6/XX DIAGNOSE, page
on the arm rest mini-wheel/joystick Right: US1470/1 = 24 V 8:68
control sends a voltage signal to the
KCU control unit (D7901).
9 KCU control unit (D7901) transmits Checked by control 11.5.3.1 KCU control unit (D7901), page 11:25
"switch on lights" messages on the system, error shown
10 KCU control unit (D7901) supplies Checked by control 11.5.3.1 KCU control unit (D7901), page 11:25
voltage to the lights in and around system, error shown
the cab. with error code.
11 Reversing lights (E4050-LE & Light on: U = 24 V Back-up lights, description, page 9:62
E4050-RI) white come on when D11: 9.6 Lighting Sys 10/XX DIAGNOSE,
reverse gear is engaged and when page 8:69
the reversing lights are activated with
the switch.
12 Horn (H8500) sounds when the horn Horn active: U = 24 V Horn, description, page 9:67
is activated. D12: 9.7 Signalling Sys 1/XX DIAGNOSE,
page 8:73
13 Relay loud horn (K3016) is activated UK3016/30 = 24 V Horn, description, page 9:67
when horn is activated. UK3016/85 = 0 V D13: 9.7 Signalling Sys 1/XX DIAGNOSE,
Horn activated: page 8:73
UK3016/86 = 24 V
UK3016/87 = 24 V
14 Loud horn (H8500-2) sounds when Horn active: U = 24 V Horn, description, page 9:67
the horn is activated.
15 The KFU control unit (D7971) voltage Checked by control 11.5.3.4 KFU control unit (D7971), page 11:31
feeds the lamps. system, error shown
with error code.
16 Revolving beacon (H4281 & H4282) Light on: U = 24 V Revolving beacon, description, page 9:63
is switched on when the revolving D16: 9.7 Signalling Sys 2/XX DIAGNOSE,
working light is activated. page 8:73 and 9.7 Signalling Sys 3/XX
DIAGNOSE, page 8:73
17 Direction indicators (H4220-FL, Light on: U = 24 V Direction indicators, description, page 9:62
H4220-RL, H4220-FR & H4220-RR) Warning lamp, Hazard, description, page 9:62
come on when the direction indicators
or warning lights are activated. D17: 9.6 Lighting Sys 7/XX DIAGNOSE, page
8:68 and 9.6 Lighting Sys 8/XX DIAGNOSE,
page 8:68
18 Back-up alarm (H9650) is activated Reverse gear selected: U Reverse alarm, description, page 9:68
when reverse gear is selected. = 24 V D18: 9.7 Signalling Sys 5/XX DIAGNOSE,
page 8:74
19 The buzzer is voltage fed by the KPU Checked by control Buzzer, description, page 9:68
control unit (D7902). system, error shown 11.5.3.2 KPU control unit (D7902), page 11:27
with error code.
20 KID control unit (D7950) alerts the - 11.5.3.3 Control unit, KID (D7950), page 11:29
driver to certain event menus.
21 Indicator lights inform the driver A click is heard when Cab overview, page 9:5
if the functions that are active or the event menu is shown
need action by the driver or service in combination with an
personnel. indicator light.
Only certain pop-ups have
sound.

9 Frame, body, cab and accessories – Horn 9:67
9.7.1 Horn
Horn, description
Electromagnetic horn, operated from the multi-function lever (S1600)
or Horn switch (S1490).
The horn is located behind the left side, outer front cover.
The loud horn has an electric compressor and is operated with the
same switch that activates the standard horn.
017464
9.7.2 Warning lamp, Hazard

Warning lamp, Hazard, description
See Warning lamp, Hazard, description, page 9:62.
9.7.3 Revolving beacon

Revolving beacon, description
See Revolving beacon, description, page 9:63
9.7.4 Warning parking brake

Warning parking brake, description
A buzzing sound is activated when the operator leave the seat without
activating the parking brake.
A sensor in the seat indicates whether the seat is occupied.
The buzzer is located in the Control unit KPU (D7902), see 11.5.3.2
KPU control unit (D7902), page 11:27.

9:68 9 Frame, body, cab and accessories – Back-up alarm
9.7.5 Back-up alarm

Reverse alarm, description
When reverse direction is selected, a warning sound and the reversing
lights are activated. This is to indicate to other road users and the
environment that the machine is reversing. An indication to bystanders
to exercise caution.
The reverse alarm receives an input signal from the transmission and
the output signal goes to the reverse alarm and reversing lights.
The reverse alarm is fitted on the rear counterweight. Alarm volume is

determined by the ambient sound level.
017418
Reverse alarm, replacement

2 Unplug the connector from the reverse alarm.
3 Remove the screws which secure the reverse alarm.
4 Replace the reverse alarm.
017418
9.7.7 Buzzer
Buzzer, description
The buzzer is located in the Control unit KPU (D7902) which is fitted
in the right-hand dashboard panel's front section, see 11.5.3.2 KPU
control unit (D7902), page 11:27.
A click sound is made to alert the driver of some event menus when:
• the parking brake is not applied and the engine is switched off and
the driver is not sitting in the seat (continuous sound)
• the parking brake is not engaged and the ignition key lock is in
operating mode, but the driver is not sitting in the seat (continuous
sound)
• low accumulator pressure (continuous sound)
• overload (pulsing, low frequency sound)
• activated direction indicators (ticking sound, high/low frequency)

9 Frame, body, cab and accessories – Entertainment and communication 9:69
9.8 Entertainment and

communication
Entertainment and communication, description
This section describes items for supporting the driver or facilitating
communication for the driver.
Entertainment and communication consist of the following:

• Radio with CD
• Voltage converter
• Rear view camera with monitor in the cab, see Rear view
camera system, description, page 9:83.
9.8.1 Radio with CD

Radio with CD, description
The cab can be equipped with a radio. It is powered by battery voltage.

On the right dashboard panel front section is the switch for the radio
with CD.
The converter is located beside the electrical distribution box, see

Voltage converter, description, page 9:69.
Radio antenna, description

The cab roof provides provisions for the installation of a radio and/or
communication radio.
The radio antenna is fitted in the rear edge of the cab, above the rear
window on the right-hand side of the cab. The antenna is made of
a flexible material.
9.8.7 Voltage converter

Voltage converter, description
The voltage converter is located under a protective cover to the right

behind the operator\qs seat.
Its function is to convert the voltage (from 24 V to 12 V) so that it can

be used for communication radio, computer, etc.
On request, the machine can be prepared with extra 12/24V outlets in

the cab .
016013
Placement of the voltage converter, access from

inside the cab.

9:70 9 Frame, body, cab and accessories – Voltage converter
Voltage converter 12/24V, replacement

1 2 2 Remove the plastic covers over the door pillar and rear section.
015796
1. Plastic cover, rear section

3 Release the catch and open out the fuse holder.

015857

9 Frame, body, cab and accessories – Voltage converter 9:71
4 Remove the converter from its bracket.

5 Disconnected the cables.
6 Replace the converter.
015858
1 2 3
1. Bracket, voltage converter
2. Voltage converter
3. Cables

9:72 9 Frame, body, cab and accessories – Glass/windows/mirrors
9.9 Glass/windows/mirrors
Glass/windows/mirrors, description
The cab's windscreen is made of tinted laminated glass. The roof
window is a safety detail and is therefore always made of polycarbonate
plastic.
1
The mirrors are all convex. Interior rear view mirror with extra large
4 viewing angle available as an option. Exterior rear view mirrors are
fitted in the rear edge of the front fenders.
2 As an option, the machine's rear view mirrors can be specified with

electric heating, electrical control from the operator's station and fitted
3 on the lamp hoods on the front fenders.
As an option the machine can be equipped with a rear view camera

and monitor in the cab to improve visibility.
016300
1. Roof window
2. Windscreen (front window)
3. Side windows
4. Rear window
Window adhesive, handling advice

The windows are fastened with elastic glass adhesive, polyurethane
(1K PU adhesive).
NOTE
With regard to safety and function, Cargotec does not guarantee
the bonding of windows using other bonding methods than the
method approved by Cargotec.
NOTE
The purpose of this instruction is to describe the process when
replacing the windscreen and roof windows.
The PU adhesive is a high performance elastic glass adhesive of
a single component type and is commonly used in connection
with securing windows on vehicles. The adhesive cures from the
surface approx. 4 mm/day by means of the air's relative humidity
and temperature. The adhesive is usually fully cured after 1-2 days
at room temperature and 50% Rh.
The truck can be put into service before the adhesive is cured.
The time after bonding until the truck can be put into service is
called "Fixing time" but varies with the ambient conditions and in
part by the weight of the screen and driving conditions.
Fixing time in hours at respective temperatures and relative
humidity:
At <5°C/80%Rh - 17°C/30%Rh, Approx. 2 hours.
At <17°C/30%Rh - 23°C/50%Rh, Approx. 1.5 hours.
The front windscreen is heaviest and the truck should not be driven
until the above conditions are carefully considered.

9 Frame, body, cab and accessories – Windscreen 9:73
9.9.1 Windscreen
Windscreen, description
The windscreen consists of tinted laminated safety glass and is glued
to the cab frame.
For location, see Glass/windows/mirrors, description, page 9:72.
Windscreen, replacement
NOTE
Read the handling instructions for product 924506.0003 used
to bond glass windows.
NOTE
Replacing/bonding windows at temperature <5 °C or >35 °C;
Contact Cargotec support.

2 Remove the interior and, where necessary covers and windscreen
wipers.
3 If the window is not already broken, cover the windscreen inside
and out with masking tape to minimise the spread of broken glass
in the cab.
Also cover body parts, ventilation ducts and the like.
015718
4 Remove the broken window.

015719

9:74 9 Frame, body, cab and accessories – Windscreen
5 Cut away and remove all parts of the old windscreen.
015720
6 When the broken window has been removed, smooth out the
old adhesive bed with a smoothing knife or the like. Cut down
the adhesive bed to 1-2 millimetres thick, then remove any loose
adhesive.
NOTE
Do not cut off the old adhesive joint completely, the new joint
fuses with the existing joint and creates a strong bond.
015721
7 Protect the cab interior with masking tape.

015724
8 Lift the new windscreen into place and fit into the cab frame, use
spacers to set it at the right height.
015722

9 Mark the position of the screen with masking tape, this is helpful
when the screen is finally put in place in the adhesive bed, cut off
the tape and remove the windscreen again.
016406
10 Mark with a pen on the inside of the screen where the cab frame
connects, this is so it's possible to mask the windscreen sight part
and protect it from adhesive.
NOTE
It is essential that the screen fits and does not touch the cab
frame, but that there is an evenly distributed expanding space
around the screen edges.
If the screen is forced into position against the cab frame this will
create tension which will damage the screen material.
015723
11 Prepare the new windscreen for bonding.

a) Check the new windscreen to ensure there is no damage, cracks
or scratches.
b) Mask up the joint width to be glued in accordance with the previous
markings.
Also mask the outer edge of the screen's outside, in order to
protect areas not bonded.
c) Clean the surface to be bonded with 924506.0004, this is to
remove any "silicone contamination" which impairs the adhesive's
adhesion properties.
"Silicone contamination" is established by spraying cleaning agent
924506.0008 on the surface to be bonded.
If the cleaning agent does not flow evenly over the surface, but
015725
instead crawls the surface is "silicone contaminated" and must be

treated with 924506.0004 as set out above. If the cleaning agent
flows out evenly over the surface, this procedure can be ignored.
d) Apply 924506.0001 in a thin layer on surfaces with a ceramic
coating to be bonded, apply in one stroke and wipe off with a
lint-free cloth.
Then allow the agent on the screen to vent for a few minutes
before the next step.
NOTE
The screen is now ready to be bonded to the cab body within
two hours.
If it takes longer before bonding, the treatment with 924506.0001
must be repeated.
NOTE
When bonding in environments with fluctuating temperatures
the time may vary.
e) The windscreen is now fully treated and ready for bonding.

9:76 9 Frame, body, cab and accessories – Windscreen
12 Blow clean and activate the adhesive bed on the cab frame with
924506.0001.
016408
13 Treat clean plate surfaces and surfaces where paint shows through
the adhesive bed with 924506.0007.
015713
14 Cut the adhesive nozzle so that the bead of adhesive on

application forms a triangle shape.
015714

4 3
2xH
H
015842
B 2 B
1 Screen
2 Cab frame
3 Correct shape of adhesive bead
4 Incorrect shape of adhesive bead
H Height of the bead of adhesive
B Width of the bead of adhesive
15 Use an appropriate application tool such as Sika Application Gun

Set and apply a triangular shaped bead 924506.0003, with the
point outwards, on the cab frame.
Minimum bead width is 10 mm.
Start/stop bonding at the top edge of the screen in order to
minimise the risk of leakage.
015726
16 Place the windscreen on the spacers and align the windscreen

after tape markings.
Position and press down slightly in the adhesive joint, fix it if
necessary.
NOTE
This must be done no later than 20 minutes after applying the
adhesive.
015727

9:78 9 Frame, body, cab and accessories – Side window
17 Spray the joint with soapy water and smooth it out with a tool or
finger. Top seal adhesive joints if necessary with 924506.0003.
Use 924506.0009 to remove excess uncured adhesive.
Alternatively, white spirit or equivalent petroleum-based solvent
can be used.
Remove the strips of masking tape.
IMPORTANT
Mark the window panes with "New adhesive. Do not
touch".
015728
18 Let the adhesive joint cure.
NOTE
The adhesive joint cures about 4 mm/day, this varies depending
on temperature and humidity.
NOTE
When bonding in environments with fluctuating temperatures
the time may vary.
19 Refit the windscreen wipers, covers and interior.

20 Clean the windscreen with cleaning agent 924506.0008 or a
similar mild window cleaner.
9.9.2 Side window

Side window, description
The side windows are screwed into the door frame.
A sealing joint with 924506.0003 should be applied over the gap

between the glass and the door's metal edge. The area is cleaned
with 924506.0008 and masked round the gap, to obtain an even and
neat joint.
9.9.3 Roof window

Roof window, description
The polycarbonate roof window is a safety detail, intended to protect the
operator from falling objects. The polycarbonate window is elastic and
virtually unbreakable. Safety is maintained within a temperature range
from +120 °C to -45 °C (becomes brittle first at -110 °C, glass transition
temperature +145 °C). The roof window has a patented surface layer
that increases its durability and resistance to UV light and chemicals.
Polycarbonate screens, replacement
NOTE
Read the handling instructions for product 924506.0003 used
to bond glass windows.
NOTE
Replacing/bonding windows at temperature <5 °C or >35 °C;
Contact Cargotec support.

9 Frame, body, cab and accessories – Roof window 9:79
2 Remove the interior and, where appropriate windscreen wipers,

exterior roof cover, radio antenna, condenser to enable the roof
window to be replaced.
3 Prepare the new window for bonding.
CAUTION
Strong dissolvents, e.g. acetone, must not come
into contact with a window made of polycarbonate
plastic. Dissolvents have a chemical effect on the
polycarbonate plastic which reduces the strength of
the roof.
a) Check the new window to ensure there is no damage.

Clean the surface to be bonded with 924506.0004, this is to
remove any "silicone contamination" which impairs the adhesive's
adhesion properties.
b) Mask the joint width to be bonded, in order to protect the surfaces
that are not bonded.
NOTE
Alternatively, the protective film on the window can be marked
and cut away on the parts to be bonded.
015705
c) Flatten the surface to be bonded with emery cloth or similar, grain

size >200.
Blow clean and dry the surface so there is no sanding dust
remaining.
015706
d) Apply 924506.0001 in a thin layer on surfaces to be bonded, apply

in one stroke and wipe off with a lint-free cloth. Then allow the
agent on the screen to vent for a few minutes before the next step.
NOTE
The screen is now ready to be bonded to the cab body within
two hours.
If it takes longer before bonding, the treatment with 924506.0001
must be repeated.
015707

9:80 9 Frame, body, cab and accessories – Roof window
e) Apply a covering layer of 924506.0006 the surfaces to be bonded,

shake the container before use. Apply with a brush or primer
applicator, allow 924506.0006 to ventilate for ten minutes.
f) Remove the mask tape, the new roof window is now fully treated
and ready for fitting.
015708
4 Remove the broken window.
015709
5 When the broken window has been removed, smooth out the
old adhesive bed with a smoothing knife or the like. Cut down
the adhesive bed to 1-2 millimetres thick, then remove any loose
adhesive.
NOTE
Do not cut off the old adhesive joint completely, the new joint
fuses with the existing joint and creates a strong bond.
015710
6 Lift the new roof window into place and fit into the cab frame.
Mark the position of the screen with masking tape, this is helpful
when the screen is finally put in place in the adhesive bed, cut off
the tape and remove the roof window again.
NOTE
It is essential that the screen fits and does not touch the cab
frame, but that there is an evenly distributed expanding space
around the screen edges.
If the screen is forced into position against the cab frame this will
create tension which will damage the screen material.
015711
7 Blow clean and activate the adhesive bed on the cab frame with
924506.0001.
015712

9 Frame, body, cab and accessories – Roof window 9:81
8 Treat clean plate surfaces and surfaces where paint shows through
the adhesive bed with 924506.0007.
015713
9 Cut the adhesive nozzle so that the bead of adhesive on
application forms a triangle shape.
015714
4 3
2xH
H 015842
B 2 B
1 Screen
2 Cab frame
3 Correct shape of adhesive bead
4 Incorrect shape of adhesive bead
H Height of the bead of adhesive
B Width of the bead of adhesive

9:82 9 Frame, body, cab and accessories – Roof window
10 Use an appropriate application tool (e.g. Sika Application Gun Set)

and apply a triangular shaped bead 924506.0003, with the point
outwards, on the cab frame, minimum bead width 10 mm.
Start/stop bonding at a high point on the body to minimise the risk
of leakage.
015715
11 Align the roof window with the tape markings.

Position and press down slightly in the adhesive joint, fix it if
necessary.
NOTE
This must be done no later than 20 minutes after applying the
adhesive.
015716
12 Spray the joint with soapy water and smooth it out with a tool or
finger. Top seal adhesive joints if necessary with 924506.0003.
Use 924506.0009 to remove excess uncured adhesive. The glass
windows white spirit or a similar petroleum solvent can be used.
CAUTION
Strong dissolvents, e.g. acetone, must not come
into contact with a window made of polycarbonate
plastic. Dissolvents have a chemical effect on the
polycarbonate plastic which reduces the strength of
015717
the roof.
IMPORTANT
Mark the window panes with "New adhesive. Do not
touch".
13 Let the adhesive joint cure.
NOTE
The adhesive joint cures about 4 mm/day, this varies depending
on temperature and humidity.
14 Refit the windscreen wipers, condenser, covers, radio antenna,

mirrors and interior.

9 Frame, body, cab and accessories – Rear window 9:83
15 Clean the roof window with cleaning agent 924506.0008 or a

similar mild window cleaner.
9.9.4 Rear window

Rear window, description
See Windscreen, description, page 9:73.
The rear window is bonded to the cab frame.
9.9.5 Rear view mirror

Rear view mirror, description
The machine is equipped with rear view mirrors on both sides of the
machine, either on the fenders or on the lamp hoods ( ) and in the
cab.
Exterior rear view mirrors are also available as electrically heated

and/or electrically adjustable from the operator's station.
9.9.8 Rear view camera and load camera

Rear view camera system, description
The machine can be equipped with two different systems with rear
view camera.
• Reversing camera.
• Rear view camera with distance warning.
Rear view camera systems are standalone systems, which are

connected to the following signals in the cab.
• X039-3: Voltage feed (+ 24 V)
• X039-5: Grounding
• X036-4: Reverse gear activated
9.9.8.1 Reversing camera
Reversing camera, description
The rear view camera is fitted in a recess in the rear counterweight

for improved visibility during reversing. The rear view camera sends
colour images and audio to the monitor in the cab; see Monitor, rear
view camera, description, page 9:84.
017407

9:84 9 Frame, body, cab and accessories – Rear view camera and load camera
9.9.8.2 Monitor, rear view camera
Monitor, rear view camera, description
The monitor conveys images and sound from the rear view camera.
C A .S E
L
1 The picture is in colour and the brightness is adjusted automatically
according to the light conditions in the cab. The monitor supports
M ENU
signals from four different cameras.

2
VO L
The monitor is mounted on a hinged bracket to the right in front of the
3 door in the cab. As an option, the monitor can be specified mounted
on the left-hand side.
BRI
4 007416
5 On machines with rear view camera system with distance warning the
monitor also warns with audio and visually in the image from the rear
1. Selection of camera view camera if objects come within the surveillance area behind the
2. Menu machine during reversing. Distance warning uses separate sensors,
3. Brightness see Sensor, back-up warning, description, page 9:84.
4. Volume setting
5. Switching ON/OFF
9.9.8.3 Sensor, back-up warning
Sensor, back-up warning, description
On machines with rear view camera with distance warning the sensor
for back-up warning is connected to the rear view camera system and
this way gives a visual warning of objects behind the machine in the
image from the rear view camera.
Distance warning uses two ultrasound sensors fitted by the

counterweight on the rear of the machine in order to measure the
distance to objects behind and warn the operator. The sensors are
activated during reversing.
017419
Sensor, back-up warning device

9 Frame, body, cab and accessories – Cab structure and suspension 9:85
9.10 Cab structure and suspension

Structure and suspension, description
The cab has a flat floor with a bracket for the driver's seat. It is mounted
in a cab substructure via strong rubber dampers fitted on the underside
of the cab. This minimises vibrations from the frame to the cab. Each
damper mounting has one rubber bushing and one bolt.
There are different types of cab suspension:

• Manual sliding cab, description, page 9:90
• Hydraulic sliding cab, description, page 9:91
NOTE
Cab suspension does not affect cab version.
9.10.1 Cab frame

Cab frame, description
The cab's frame is made of high-strength steel sheet profiles. The
cab is dimensioned to handle impacts and, to some degree, protect
the driver against dropped loads.
The cab is equipped with door mouldings. The door moulding is a

continuous strip, mounted on and along the outer edge of the inside of
the door, to seal against the cab.
The door moulding are "clip-on types", with a permanently vulcanised

tubular moulding. The door moulding can only be replaced when the
plastic components have been loosened or removed. The moulding
should be glued together when assembled and where the seam faces
downwards.
016914

9:86 9 Frame, body, cab and accessories – Doors
9.10.2 Doors
Doors, description
The cab has two doors. The left-hand door is the driver's door and the
right-hand door is the emergency exit. The door has:
• support rail (inside)
• opening handle (inside and outside)
• key lock
• opening window.
• gas spring damping that prevents the door from being damaged
when it is opened
016926
Door stop with gas spring damping, replacement

2 Place the door in fully open position.
1 2 3 Remove the spring clip from the piston rod head.

4 Secure the door position and lift off the piston rod head.
015874
3
1. Spring clip
2. Piston rod head
3. Ball joint

9 Frame, body, cab and accessories – Doors 9:87
1 2 5 Remove the plastic covers over the door pillar and rear panel.
015796
1. Rear panel
1 6 Open the rear panel and unscrew the nut holding the gas damper.
7 Replace the gas damper.
8 Fit in reverse order. Lock the screws with thread locking fluid
before fitting.
015875
1. Lock nut

9:88 9 Frame, body, cab and accessories – Doors
Door, replacement
1 2 1 Machine in service position, see section B Safety.

2 Place the door in fully open position.
3 Remove spring clip that fastens gas damper in the door.
4 Secure the door position and lift off the piston rod head.
Unscrew the ball joint if it is to be reused.
5 Unscrew the set screws on the hinges.
6 Hold the door, and knock out the hinge axles.
7 Replace the door.
Normally the ball joint should be placed in the same hole on the
old door. If the ball joint is moved then the hole for the previous
location must be treated with anti-corrosion paint or a screw with a
015871
low head that has clearance when opening/closing the door.
3 4 5 Secure the thread on ball joint with locking fluid.
1. Gas damper
2. Spring clip
3. Stop screw
4. Axle, hinge
5. Ball joint

9 Frame, body, cab and accessories – Cab substructure 9:89
9.10.3 Cab substructure

Cab substructure, description
The cab is mounted on a cab substructure via strong rubber insulators
fitted on the underside of the cab. This minimises vibrations from the
frame to the cab.
The cab substructure is fitted on the machine's chassis (frame) via a

mounting. The body mounting depends on whether the machine is
equipped with:
• manual sliding cab
• hydraulic sliding cab
• hydraulic vertically adjustable cab
8 There are joints at the rear of the cab for the hoses for brake pedal,
1
control valve cab heating and refrigerant AC combined into a single
2 9 interface, in order to facilitate hose replacement.
10 The connections for brake pedal, control valve are colour coded in
3
order to avoid mixing them up. The refrigerant connections are in
4 11 different sizes and cannot be mixed up. Before starting work on the
climate system, read the general instructions, see General instructions
5 for working on the air conditioning unit, page 9:28.
6
017466
1. Supply brake pedal [PB] (red)

2. Tank return brakes [TB] (blue)
3. Brake pressure to wheel brake [AB] (white)
4. Control signal steering right [R0] (green)
5. Tank return steering valve [T0] (grey)
6. Control signal steering left [L0] (brown)
7. Supply steering valve, [P0] (black)
8. Cab heating
9. Cab heating
10. Refrigerant AC
11. Refrigerant AC
9.10.3.1 Cab undercarriage, sliding cab
Cab undercarriage, sliding cab, description

The cab substructure is fitted on the machine's chassis (frame) via a
mounting. The body mounting consists of four ball bearing metal rollers
that run in rails above the machine's frame.
016912

9:90 9 Frame, body, cab and accessories – Sliding cab
9.10.4 Sliding cab

Manual sliding cab, description
Manual sliding cab means that the cab can be moved forward
to facilitate access for service and maintenance in the engine
compartment.
A
The cab is pushed forward and back by hand. Two cable chains on
each side ensure that hoses and cables to and from the cab are not
damaged when the cab is moved. The cab is secured in the rear
position during operation with two locking catches at the rear edge
of the cab.
DANGER
The cab is very heavy and the machine must never be
moved without first securing the cab. It is important to
that the locking catches are intact.
Secure the cab on both sides, with the locking catches
016232
B C and pins before starting to operate the machine.

Replace damaged lock handles.
A. Position locking catch
B. Lock pin
C. Locking catch for securing the cab

9 Frame, body, cab and accessories – Sliding cab 9:91
Hydraulic sliding cab, description
The cab can be slid forward in order to facilitate access for service and
maintenance in the engine compartment.
Hydraulic sliding cab also means that the cab can be moved
hydraulically during operation in order to improve driver visibility. The
cab is slid forward and back by a hydraulic motor that is coupled
to a chain attached in the cab undercarriage. The cab's position is
automatically locked by the hydraulic motor when sliding cab is not
in use.
Damping
A length sensor detects when damping should be activated. When

The gear on the hydraulic motor can be disengaged in order to move

the cab manually. For instructions, see Operator's manual.
DANGER
The cab is very heavy and the machine must not be
moved without first securing the cab.
Fit the screws on the gear for the hydraulic motor for
sliding cab and the protective cover before starting
to operate.

Hydraulic sliding cab, function description
Reference
Doors Closed Doors, description, page 9:86.
1 D1
2
D7902 D7950
D7971 D7901
6 5, 7, 16 4, 15
UDS D7940
3
D7
D7930 D3
8 D14
m
P1
LS A 14
B
TP
LSP1 A H 13, 18
LSP2
10
8
LSPR 9, 12, 17
LSP3 LSHY
LSP3X P T T P LSO
LSM
C11
016883
11

1 Switch (S177) sliding cab sends voltage U = 24 V Cab overview, page 9:5
signals to Control unit KPU (D7902). D1: Diagnostic menu, see 9.10 Cab
suspension 1/XX DIAGNOSE, page 8:76
2 Control unit KPU (D7902) sends cab 11.5.3.2 KPU control unit (D7902), page
forward or cab backward on the CAN 11:27
bus.
3 Contact closed door (S2660-LE & U = 24 V Doors, description, page 9:86
S2660-RI), sends signals to Control unit D3: Diagnostic menu, see 9.6 Lighting Sys
KCU (D7901) when the door is closed. 18/XX DIAGNOSE, page 8:71
4 Control unit KCU (D7901) sends doors Checked by control 11.5.3.1 KCU control unit (D7901), page
closed on the CAN bus. system, error shown with 11:25
error code.
5 Control unit KFU (D7971) sends request Checked by control KFU control unit (D7971), description, page
for raised engine speed on CAN bus system, error shown with 11:31
drive-train. error code.
6 Control unit, engine (D7940) increases Checked by control 11.5.3.6 Control unit, engine (D7940), page
the engine speed. system, error shown with 11:35
error code.


7 Control unit KFU (D7971) activates I = 250–440 mA KFU control unit (D7971), description, page
Solenoid valve cab forward/up (Y6016) 11:31
or Solenoid valve cab backward/down D7: Diagnostic menu, see 9.10 Cab
(Y6017). suspension 2/XX DIAGNOSE, page 8:76 or
9.10 Cab suspension 3/XX DIAGNOSE, page
8:76
8 Solenoid valve cab forward/up (Y6016) - Control valve cab movement, description,
or Solenoid valve cab backward/down page 9:96
(Y6017) pressurises the valve slide in D7: Diagnostic menu, see 9.10 Cab
Control valve cab movement. suspension 2/XX DIAGNOSE, page 8:76 or
9.10 Cab suspension 3/XX DIAGNOSE, page
8:76
9 Control valve cab movement sends load - Control valve cab movement, description,
signals to Valve block servo pressure page 9:96
and pressurises Valve block support jack
cylinder.
10 Valve block servo pressure sends the - Valve block servo pressure, description, page
load signal to hydraulic oil pump 3. 10:25
Shuttle valves in Valve block servo
pressure select the strongest load signal
if other functions are activated at the
same time.
beam.
12 Control valve cab movement pressurises - Control valve cab movement, description,
hydraulic motor sliding cab. page 9:96
13 Hydraulic motor, sliding cab pulls the cab - Hydraulic motor sliding cab, description, page
forward or backward. 9:98
14 Sensor cab position (B7254) sends U = 0-5 V Sensor cab position, description, page 9:101
voltage signals proportional to the cab's D14: Diagnostic menu, see 9.10 Cab
position to Control unit KCU (D7901). suspension 1/XX DIAGNOSE, page 8:76
15 Control unit KCU (D7901) sends Checked by control 11.5.3.1 KCU control unit (D7901), page
information about the position of the cab system, error shown with 11:25
on the CAN bus. error code.
16 When the cab's position approaches the - KFU control unit (D7971), description, page
end position Control unit KFU (D7971) 11:31
reduces the control current to Solenoid D7: Diagnostic menu, see 9.10 Cab
valve cab forward/up (Y6016) or Solenoid suspension 2/XX DIAGNOSE, page 8:76 or
valve cab backward/down (Y6017) on 9.10 Cab suspension 3/XX DIAGNOSE, page
Control valve cab movement. 8:76
17 Control valve, cab movement, reduces - Control valve cab movement, description,
the hydraulic pressure to valve block page 9:96
sliding cab.
18 Hydraulic motor sliding cab reduces the - Hydraulic motor sliding cab, description, page
speed of sliding cab. 9:98
Hydraulic diagram cab movement and support jacks, see Hydraulic

diagram cab movement and support jacks, page E:13.
Hydraulic sliding cab, calibration

1 Machine in service position.
2 Start key in operating position.

10:23
014981
0
10:23 4 Enter the code for calibration with or . Confirm each figure
with .
0 WRI TE PI N CODE
NOTE
0 0 The code determines which service menus should be activated.
015625
5 Select 9. Frame, Cab & Accessories by scrolling with or

and confirm with .
9 . Fr a me , c a b & a c c e s s or i e s
017473
6 Select 9.10 Cab Suspension by scrolling with or and confirm

* FAME CAB & ACCESSORI ES *
with .
9. 1 Co n t r ol s & i ns t r ume nt s
9. 2 Sa f e t y & Eme r g e n c y Eq u i p.
9. 3 Se a t
9. 4 Cl i ma t e Sy s t e m
9. 5 Li g h t i n g Sy s t e m
9. 7 Si g n a l l i n g Sys t e m
9. 8 En t e r t a nme n t & Com.
9. 9 Gl a s s Wi n d o ws & Mi r r o r s
9. 1 0 Ca b s u s p e n s i o n
017474
9. 1 1 Ca b i n t e r i or

* FAME CAB & ACCESSORI ES *

9. 1 Co n t r ol s & i ns t r u me nt s
9. 2 Sa f e t y & Eme r g e nc y Eq u i p .
9. 3 Se a t
9. 4 Cl i ma t e Sy s t e m
9. 5 Li g h t i n g Sys t e m
9. 7 Si g n a l l i n g Sys t e m
9. 8 En t e r t a nme nt & Co m.
9. 9 Gl a s s , Wi n do ws & Mi r r o r s
9. 10 Ca b s u s p e ns i o n
017475
9. 11 Ca b i n t e r i o r

8 Navigate to the calibration menu 9.10 Cab Suspension, menu 1

with / . See Navigation to a menu, work instruction, page 8:98
for an explanation of navigation.
Row 1 shows the cab's position.
Row 2 shows the saved value for the cab's rear position.
9 Run the cab back to its rearmost position. Press Save to store
this value.
The value in row 1, Cab in rear position, is saved in row 2.
10 Navigate to Calibration menu 9.10 Cab Suspension, menu 2 with

/ .
Row 1 shows the cab's position.
Row 2 shows the saved value for the cab's front position.
11 Run the cab forward to its front position. Press Save to store
this position.
The value in row 1, Cab in front position, is saved in row 2.
12 Leave Calibration by scrolling out with .
9.10.4.1 Cab substructure
Cab substructure, description

See Cab substructure, description, page 9:89.
Hydraulic oil pump, description
Hydraulic sliding cab is supplied with pressure from hydraulic oil pump
3, see Axial piston pump with variable displacement, description, page
10:10.

9.10.4.3 Control valve cab movement

Control valve cab movement, description
1 2 3 4 5 6 7
The hydraulic sliding cab is controlled by a separate section in the
control valve, cab movement.
The control valve is an electro-hydraulically controlled, proportional
and pressure-compensated directional control valve. Electrically
controlled pressure and reducing valves convert electric current to
servo pressure. The servo pressure controls the spring-centred valve
slides that control pressure and flow for the function in question. The
valve slide has a limitation to the flow so that several functions can
be used simultaneously.
The control valve is fitted on the right-hand side of the hydraulic plate in
the engine compartment and is controlled by Control unit KFU (D7971).
Control valve, cab movement, is made up of several sections, each
section controls one function. The following functions are controlled by
control valve, option frame:
016811
Valve slide, sliding cab

The valve slide controls the direction and speed of the sliding cab by
1. Load signal (LS)
controlling hydraulic motor pressure, sliding cab.
2. Connection hydraulic motor (B)
The valve slide is controlled by servo valve front and servo valve rear.
3. Connection hydraulic motor (A)
4. Pressure feed (P) Servo valve sliding cab forward
5. Tank return (T) Servo valve sliding cab forward controls servo pressure to valve slide
6. Solenoid valve cab backward/down (Y6017) sliding cab so that this controls oil pressure to hydraulic motor sliding
7. Solenoid valve cab forward/up (Y6016) cab forward.
Servo valve sliding cab forward is controlled electrically by Solenoid
valve cab forward/up (Y6016) that is activated by Control unit KFU
(D7971).
The signal can be checked with the diagnostic menu, see 9.10 Cab
suspension 2/XX DIAGNOSE, page 8:76.
Servo valve sliding cab backward
Servo valve sliding cab backward controls servo pressure to valve slide
steering so that this controls oil pressure to hydraulic motor sliding
cab forward.
Servo valve sliding cab back is controlled electrically by Solenoid
valve cab backward/down (Y6017) that is activated by Control unit
KFU (D7971).
Control valve cab movement, replacement
NOTE
Safety.

NOTE

1 2 3 4 5 6 7 3 Mark and disconnect the hydraulic hoses from the control valve.
NOTE
from impurities.
5 Remove the control valve.
on a clean and protected surface.
6 Transfer parts to the new control valve.
NOTE
correctly.
016811
NOTE
1. Load signal (LS)
2. Connection hydraulic motor (B) mixed up.
3. Connection hydraulic motor (A)
4. Pressure feed (P)
8 Fit the valve.
5. Tank return (T)
6. Solenoid valve cab backward/down (Y6017) marking.
7. Solenoid valve cab forward/up (Y6016) 10 Connect the hydraulic hoses to the control valve in according to
the marking.
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.

CAUTION
product damage.
manual.

9.10.4.6 Hydraulic motor sliding cab
Hydraulic motor sliding cab, description
The hydraulic motor is positioned at the front on the right-hand side

of the cab chain. The hydraulic motor draws the chain, which in turn
pulls the cab forward and back.
The gear on the hydraulic motor can be disengaged in order to move

the cab manually. For instructions, see Operator's manual.
DANGER
016924

to operate.
Hydraulic motor, sliding cab, changing
NOTE
Safety.

NOTE
3 Remove the protective cover.

4 Slacken the chain, loosen the chain tensioner and the adjusting
screw.
5 Disconnect the chain from its mounting.
6 Remove the hydraulic hoses from the motor.
1. Protective cover
2. Hydraulic motor
3. Chain tensioner

7 Remove the ring gear. Remove the screw in the centre of the gear
and pull out the ring gear.
8 Remove the hydraulic motor from its mounting.
9 Change the hydraulic motor.
017416
11 Check that the screws (A) on the hydraulic motor's gears are intact
A and tightened.
DANGER
to operate.
015583
hydraulic system.
NOTE
the lock ring.

manual.
9.10.4.7 Chain sliding cab

Chain sliding cab, description
1 2
3 The chain pulls the cab forward and back and is attached into the front
and rear edges of the cab substructure. The chain tension is adjusted
4 by moving the hydraulic motor for sliding cab.
5
016925
1. Rear gear
2. Rear mounting chain (in cab undercarriage)
3. Front mounting chain (in cab undercarriage)
4. Chain sliding cab
5. Front gear mounted on the hydraulic motor
for sliding cab

Chain and chain wheel, sliding cab, changing

2 Slacken the chain, loosen the chain tensioner and the adjusting
screw.
3 Disconnect the chain at the front edge.
4 Disconnect the chain at the rear edge.
5 Change chain.
7 Adjust the chain with the adjusting screw.
8 Tighten the chain tensioner.
1. Protective cover
2. Hydraulic motor
3. Chain tensioner
9 Check that the screws (A) on the hydraulic motor's gears are intact
A and tightened.
DANGER
to operate.
015583

9.10.4.9 Sensor cab position
Sensor cab position, description
Sensor, cab position (B7254) measures cab position and is used in

order to activate end position damping, calculate the load curve and
control LC limitation. The sensor is located in the front edge on the
left-hand side. The sensor is a wire sensor, which measures the
position of a wire connected to the front edge of the left-hand rail for
sliding cab.
Sensor, cab position (B7254) is supplied with voltage by, and sends a
voltage signal proportional to the position to Control unit KCU (D7901).
017465

9:102 9 Frame, body, cab and accessories – Cab interior
9.11 Cab interior

Cab interior equipment, description
The cab is designed for optimum operator comfort. Switches, controls,
warning and indicator lamps are grouped on the dashboard panels to
provide the operator with a good driving environment.
Recyclable materials have been used for all parts.

• Dashboard panels
• Interior parts, plastic
• Interior parts, textile
• Insulation
9.11.1 Instrument and control panels

Instrument and control panels, description
The cab contains the following instrument and control panels.
1. Inner front panel
2. Steering column cover
3. Steering panel
4. Display with function keys
5. Right dashboard panel, front section
6. Right dashboard panel, middle section
7. Right dashboard panel, rear section
8. Pedal cover
9. Joystick control/mini-wheel

9 Frame, body, cab and accessories – Instrument and control panels 9:103
Instrument and control panels, function description

1 4 7
D3
D1 D4 D7
D2
3 M
D6
2,5,8
D5 D7902 D7950
6 M
D9 D7971 D7901
D8
9 M
016110
1 Length adjustment forwards of right front Switch in ON position: U D1: 9.1 Controls & Instr 4/XX
control panel switch (S1056-1) or backwards = 24 V DIAGNOSE, page 8:57.
(S1056-2) sends a voltage signal to the KPU
2 KPU control unit (D7902) governs the control U = 0.5-4.5 V D2: 9.1 Controls & Instr 5/XX
motor panel forwards/backwards (M6941) DIAGNOSE, page 8:57.
which sets the panel in the desired position.
3 The position of the control motors is fed back U = 0.5-4.5 V D3: 9.1 Controls & Instr 5/XX
to the KPU control unit (D7902). This gives DIAGNOSE, page 8:57.
information for control of the panel position.
4 Height adjustment up of right, control panel Switch in ON position: U D4: 9.1 Controls & Instr 6/XX
switch (S1057-1) or down (S1057-2) sends a = 24 V DIAGNOSE, page 8:57.
voltage signal to the KPU control unit (D7902).
motor panel up/down (M6942) which sets the DIAGNOSE, page 8:58.
panel in the desired position.
7 Height adjustment up of steering wheel switch Switch in ON position: U D7: 9.1 Controls & Instr 2/XX
(S1058-1) or down (S1058-2) sends a voltage = 24 V DIAGNOSE, page 8:56.
signal to the KPU control unit (D7902).
motor panel up/down (M6943) which sets the DIAGNOSE, page 8:56.
panel in the desired position.

9:104 9 Frame, body, cab and accessories – Interior fittings, plastic
9.11.2 Interior fittings, plastic

Interior fittings, plastic, description
The interior plastic components of the cab are made of recyclable
material.
Interior plastic components, replacement

Steering column cover
015776
3 Remove the screws and adjuster lever.

4 Remove the front cover.
Let the gaiter over the travel direction selector and parking brake
remain in place.
015780
1 2 3
1. Cover
2. Adjuster lever
3. Screw, adjuster lever

9 Frame, body, cab and accessories – Interior fittings, plastic 9:105
5 Remove the rear cover.
015782
1 2 3
1. Cover
2. Screw
Plastic cover over wiper motor

2 Loosen the two screws and remove the plastic cover over the
wiper motor in the cab.
015808


Right dashboard panel, middle section

2 Remove the panel's screws.
3 Turn the panel over and disconnect the contacts. Note how the
connectors are connected.
4 Remove the control lever.
5 Remove the switches from the panel.
Right dashboard panel, rear section

1 2 Remove the screws.

016195
2
1. Silicone panel
2. Screw

9 Frame, body, cab and accessories – Interior fittings, plastic 9:107
3 Loosen the springs and carefully turnover the storage box.
015781
1 2 4 Carefully separate the navigation wheel and silicon panel's
connectors.
015761
4 3
1. Contact, silicone panel
2. Nut, silicone panel
3. Nut, navigation wheel
4. Contact, navigation wheel
Front section
2 For better access, move the steering wheel to the rearmost
position and lift the steering column to the highest position.
Loosen one end of the actuator motor from the steering column
and block up the steering column in the highest possible position.
3 Unscrew the four screws.
4 Carefully remove the dashboard panel.
2
016002
1
1. Front section
2. Screws

Cover by pedals
1 2 1
015856
1. Screws
2. Cover
Lowermost covers on the rear pillars

2 Loosen the locking pins that attach the plastic covers on the door
1 2 pillar. Remove the screw holding the plate.
On the right-hand door pillar the holder for the cab tipping lever
needs to be dismantled.
3 Remove the door pillar's lower plastic covers.
015899
4 3
1. Snap lock, rear section
2. Locking pins, door pillar
3. Plate, door pillar
4. Locking pins, during mat edge

9 Frame, body, cab and accessories – Interior fittings, textile 9:109
Rear section
2 Remove the plastic cover over the rear wiper motor, see Plastic
cover over wiper motor, page 9:105.
3 Loosen the locking pins that attach the plastic cover on the door
1 2 pillar. Remove the screw holding the plate.
4 Remove the door pillar's lower plastic cover.
5 Fold back the floor mat to access the lower locking pins.
6 Unscrew the snap lock.
7 Remove the rear section.
015899
4 3
1. Snap lock, rear section
2. Locking pins, door pillar
3. Plate, door pillar
4. Locking pins, during mat edge
9.11.3 Interior fittings, textile

Interior fittings, textile, description
The interior textile components of the cab are made of recyclable
material.
Interior textile components, replacement

2 Remove the covers sitting in the door openings, see Lowermost
covers on the rear pillars, page 9:108.
1 2 3 Dismantle the radio console's plastic cover.

016003
5 4 3 2
1. Plastic cover, radio console
2. Screw, roof panel
3. Speaker
4. Lamp
5. Radio

9:110 9 Frame, body, cab and accessories – Floor covering
1 2 4 Carefully pull out the radio with radio's special tool.

Loosen the radio connectors and antenna cable.
5 Remove the radio console from the roof.
6 Carefully unscrew the speakers and remove the connectors.
7 Carefully remove the interior lighting and separate its connectors.
8 If the roof panel is replaced, move all the equipment installed in
the roof to the new roof panel.
9 Remove the screws securing the roof panel.
10 Remove the roof panel.
016004
1. Screw
2. Connectors
9.11.4 Floor covering

Floor covering, description
The floor covering is recyclable and is made of wear and water resistant
material.
Floor covering, replacement

2 Open the doors on both sides.
3 Undo the screws which hold the sill moulding in the cab entry,
and remove the sill moulding.
4 Undo and remove all equipment in the cab which is screwed
through the floor matting, such as the seat, pedal assembly and
steering column.
5 Replace the floor matting.
016410
9.11.5 Insulation
Insulation, description
The cab insulation consists of recyclable material.
The insulation material consists of both self-adhesive foam plastic

material for noise and heat insulation and of self-adhesive matting
(heavy material for good sound insulation at low noise frequencies).

9 Frame, body, cab and accessories – Sun visors 9:111
9.11.6 Sun visors

Sun visors, description
Sun visors can be specified for the front window (windscreen), roof
window and the rear window:
1. Sun visors, front and rear window: Adjustable up and down with
the cord on the right-hand side. Stops in the chosen position.
2. Sun visor, roof window: Extends forward to fasten in two hooks in
the front edge of the window or is continuously adjustable.
017440
Sun visors windscreen

Pulled from the side and in towards the centre for
better upward visibility.
017442
Sun visor rear window
017441
Sun visor roof window

9:112 9 Frame, body, cab and accessories – Frame
9.12 Frame
Frame, description
The function of the body is to serve as the supporting structure for
the machine's components. The body is built around a frame with
welded mounts for boom, lift cylinders, steering axle, drive axle, side
panel, tanks, exhaust system and footsteps. Fenders, counterweights,
steering axle, drive axle and mounts for engine, transmission and cab
are bolted to the frame.
The space in the rear section of the frame is used for counterweights,
the number and size of which are adapted to the machine in question.
The body is a modular construction and consists of front section, rear

section and a beam pair. This design provides advantages in terms of
rigidity and strength.
There are mounting points in the frame for engine, transmission, drive
016913
axle, steering axle, fuel and hydraulic tanks, cab, boom, and body parts.
The space in the rear section of the frame is used for counterweights,
the number of which is adapted to the machine in question. The
counterweights are designed to allow as good visibility rearwards as
possible.
The front wings are bolted into the frame (which has advantages when
delivering the machine).

9 Frame, body, cab and accessories – Body structure 9:113
9.13 Body structure

Body structure, description
The function of the body is to be part of the frame. There are fenders to
deflect dirt, footsteps and hand rails to facilitate access onto the body,
engine hood to deflect dirt and objects from the engine compartment
and a counterweight to balance the machine's lifting capacity.
The body is regarded as being the following:

• Wings
• Engine compartment cover
• Footstep
• Counterweights
• Battery compartment
9.13.1 Wings
Wings, description
There are wings over the wheels to protect from dirt thrown up by the
wheels during operation.
The fenders can be equipped with extra mudguards when the

machine's work environment requires such .
The front fenders can be fitted with a non-slip plate .
9.13.2 Hood engine compartment

Hood engine compartment, description
The machine's engine compartment is protected by tread plates which
act as an engine hood. The tread plates are divided into several
sections, the hoods are secured with rubber bushings or with screws.
The tread plates are designed for walking on and are ribbed to provide
sure footing.
9.13.3 Footsteps and hand rail

Footsteps and hand rail, description
The machine's running boards are made of stamped stainless steel
plate that is designed to be walked on with footholds. The footsteps are
bolted into brackets on the frame.
There are hand rails by the cab steps for the cab and the platform
by the cab.
As an option, the machine can be specified with steps, and hand

rails are also available for the left-hand front fender.

9:114 9 Frame, body, cab and accessories – Counterweight
9.13.4 Counterweight
Counterweights, description
The machine has counterweights to balance the machine's lift capacity
and these may therefore vary in quantity and weight.
The machine has counterweights in the following locations:

• Under the steering axle.
• Furthest back on the machine there are vertical counterweights
secured in the rear edge of the frame; the outer has a towing eye.
Between the outer counterweight and frame, there are smaller
counterweights whose dimensions and quantity are adapted to
balance the machine's lifting capacity.
• Upper horizontal counterweight.
Under the horizontal counterweight, there are smaller
counterweights whose dimensions and quantity are adapted to
balance the machine's lifting capacity.
DANGER
The counterweights are factory fitted and are adapted
according to the machine's properties.
The machine's driving characteristics change if the
counterweights are removed or added!
Never change the quantity of counterweights.
9.13.5 Battery compartment

Battery compartment, description
The battery compartment is located behind the cover lid on the rear
left-hand side of the machine (behind the fuel tank). The cover lid is
opened with a lockable T-handle.
The compartment has two sections separated by a fixed shelf. The

upper section contains the starter batteries. On machines with SCR
system, the lower section contains control electronics for emission
control. On machines without SCR system, the compartment can be
used for storage.
NOTE
The compartment with starter batteries must not be used as a
storage space.
016304
9.13.8 Tool kit

Tool kit, description
The machine can be equipped with a tool kit.

9 Frame, body, cab and accessories – Lifting lugs 9:115
9.13.9 Lifting lugs

Lifting and lashing points, description
To transport the machine it is equipped with lifting points and lashing
points in several places:
• Rear of the frame at the steering axle (lashing point for securing on
a transport vehicle)
• Rear of the frame under the rear boom mounting (welded lifting
points for lifting the machine)
• Front of the frame above the drive axle (holes for securing on a
transport vehicle)
• Front of the frame above the drive axle (welded lifting points for
lifting the machine)
• On the sides of the attachment (for lifting the attachment or
securing loose attachment on a transport vehicle)
• Rear of the lift boom (for lifting the boom or securing loose boom
of loose attachment on a transport vehicle)
• Front of the lift boom (for lifting the boom or securing loose boom
on a transport vehicle)

9:116 9 Frame, body, cab and accessories – Central lubrication
9.14 Central lubrication

Central lubrication, description
Central lubrication lubricates the machine's lubrication points

automatically during operation in accordance with pre-programmed
intervals and replaces parts of lubrication during preventive
maintenance. Central lubrication is activated and the time interval
starts when the engine is started and the speed is above 0.5 km/h, or
when a hydraulic function is active. When the time interval (pause) has
counted out, the pump unit is restarted and runs in accordance with a
predetermined running time.
The machine has two separate central lubrication systems, one for
the machine and one for the attachment. Central lubrication pause
and running times can be adapted according to requirements, contact
Cargotec Service.
Central lubrication consists of the following components:

Example illustration, components central lubrication • Pump unit (M6930), with lubricant reservoir.
1. Central lubrication sensor (B7242) • Distribution blocks, which distribute and doses the grease between
the different lubrication points.
2. Lubricant nipple, manual lubrication of the
system The distribution blocks lubricate progressively, i.e. one point at a
time. If a point cannot be lubricated properly, e.g. due to a blocked
3. Safety valve line, subsequent points will not be lubricated. The grease will be
4. Lubricant nipple for filling pushed out through the safety valve on the pump unit.
5. Distribution block • Lines, between main unit and distribution blocks and between
distribution blocks and grease nipples.
• Grease nipples, at the lubrication points.
• Central lubrication sensor (B7242).
The sensor is fitted on the distribution block at the pump unit and
sends signals to the control system. Faults in central lubrication
are indicated by error codes in the display.
Signals can be monitored with the diagnostic menu, see 9.14 Central
Lubr 1/XX DIAGNOSE, page 8:77.
NOTE
The central lubrication does not lubricate all lubrication points,
some still need to be lubricated during preventive maintenance.

9 Frame, body, cab and accessories – Pump unit 9:117
9.14.1 Pump unit

Pump unit, description
The pump unit consists of a reservoir with agitator and filler nipple, as
well as pump housing with built-in motor and pump element.
The unit works by means of lubrication cycles (pause and run-time

and read time). A pressure relief valve is fitted to the pump element,
ensuring that the pressure in the system does not become too high.
Control of central lubrication is performed from the control system.

Signals can be monitored with the diagnostic menu, see 9.14 Central
Lubr 1/XX DIAGNOSE, page 8:77.
Pump unit, central lubrication

1. Safety valve
2. Lubricant nipple for filling
9.14.2 Distribution block

Distribution block, description
The number of distribution blocks can vary depending on how many
(and which) lubrication points are selected. However, the first
distribution block (i.e. the block closest to the pump unit) is always
included.
The distribution blocks consist of progressively controlled pistons.

These are powered by the lubricant and have no springs and seals. The
lubricant is pressurised and then drives the pistons in the distributor.
The pistons move in a predetermined way, and this pattern of

movement is repeated time after time. Each piston must have complete
its movement before the next piston can move. The pistons are
interdependent. It is technically impossible for a connected lubrication
point to be missed.
Example illustration, components central lubrication

1. Central lubrication sensor (B7242)
system
3. Safety valve
5. Distribution block

9:118 9 Frame, body, cab and accessories – Lines
9.14.3 Lines
Lines, description
The lubricant is carried to the lubrication points through hoses.
1. Lines, central lubrication

2. Lubricant nipples
9.14.4 Lubricant nipples

Lubrication points, description
The lubrication points have lubricant nipples with couplings to which
the lines are connected. The couplings can be straight or angled.
1. Lines, central lubrication

2. Lubricant nipples

9 Frame, body, cab and accessories – Sensor, central lubrication 9:119
9.14.5 Sensor, central lubrication

Sensor, central lubrication, description
Sensor, central lubrication (B7242), is fitted on the distribution block at
the pump unit and sends signals to the control system. Faults in central
lubrication are indicated by error codes.
Example illustration, components central lubrication

1. Central lubrication sensor (B7242)
system
3. Safety valve

9:120 9 Frame, body, cab and accessories – Paint/coatings
9.15 Paint/coatings
Paint/coatings, description
The machine is painted with paint which is applied by brush or spray.
For colour code (RAL), see machine card.
Check the machine frequently for stone chips, dents and paint
scratches, repair them at once to prevent corrosion on the metal
underneath. Only use touch-up paint for small stone chips and
scratches. More extensive paint damage should be repaired by a paint
workshop.
NOTE
Before touching up, the surfaces to be touched up must be
thoroughly cleaned.
Contact Cargotec for information about other surface treatment and

colours.

10:1
Contents 10 Common hydraulics

10 Common hydraulics ........................................................................................ 10:3
10.2 Safety valves..................................................................................................10:4
10.2.1 Accumulator drain valve ............................................................................10:4
10.2.3 Pipes and hoses........................................................................................10:4
10.2.4 Pressure relief valve..................................................................................10:5
10.3 Tanks and accumulators ................................................................................10:6
10.3.1 Tank...........................................................................................................10:6
10.3.2 Pipes and hoses........................................................................................10:6
10.4 Pumps............................................................................................................10:7
10.4.1 Gear pump with fixed displacement ..........................................................10:8
10.4.2 Axial piston pump with variable displacement.........................................10:10
10.4.3 Pipes and hoses......................................................................................10:22
10.5 Hoses, pipes and valves ..............................................................................10:23
10.5.1 Pipes and hoses......................................................................................10:23
10.5.2 Priority valve............................................................................................10:23
10.5.5 Collecting block, unfiltered returns ..........................................................10:24
10.5.7 Valve block servo pressure .....................................................................10:25
10.5.8 Accumulator servo circuit ........................................................................10:29
10.6 Temperature control, cleaning and hydraulic oil...........................................10:30
10.6.1 Tank heater .............................................................................................10:31
10.6.2 Hydraulic oil cooler ..................................................................................10:32
10.6.3 Cooling fan ..............................................................................................10:33
10.6.4 Sensor hydraulic oil temperature.............................................................10:33
10.6.5 Radiator bypass valve .............................................................................10:34
10.6.6 Breather filter hydraulic oil tank ...............................................................10:35
10.6.7 Hydraulic oil filter .....................................................................................10:36
10.6.9 Fine filter hydraulic oil..............................................................................10:37
10.6.10 Pipes and hoses......................................................................................10:37
10.6.14 Servo filter ...............................................................................................10:37
10.7 Other ............................................................................................................10:38
10.7.1 Hydraulic cylinders ..................................................................................10:38

10:2

10 Common hydraulics – Common hydraulics 10:3
Common hydraulics, description
Hydraulic functions that are common to several of the machine's
main functions are found under the function common hydraulics. For
example, the hydraulic oil pumps that supply load handling, steering
and certain cab functions with hydraulic pressure.
The brake system is completely separate and can be found under the
section 4 Brakes.
Pressure plate
On the machine there is a pressure plate with the most important
pressure information stamped in. The pressure plate is fitted on the
left-hand side of the frame in front of the cab steps.
Pressure levels vary with the equipment and are therefore unique
to each machine. When checking the pressure, pressures must be
consistent with the values specified on the pressure plate.
11 2
10 3
9 4
8 5
7 6
016826
The appearance of the pressure plate may vary, but the symbols are the same.
1. Feed pressure control valve, attachment 7. Max. pressure hydraulic oil pump 1
2. Feed pressure control valve lift jacks 8. Max. pressure hydraulic oil pump 2
3. Gas pressure brake accumulators 9. Max. pressure hydraulic oil pump 3
4. Gas pressure servo accumulator 10. Hydraulic oil pressure accumulators brake system
5. Servo pressure lift and extension 11. Oil pressure steering
6. Max. brake pressure

10:4 10 Common hydraulics – Safety valves
10.2 Safety valves

10.2.1 Accumulator drain valve
Accumulator drain valve, description
Relief valve brake system, drains the stored pressure in the brake
system's accumulators.
For information about depressurising the machine, see Hydraulic and

The accumulator drain valve is fitted on the accumulator charging

valve. See Accumulator charging valve, description, page 4:16.
016821
Open the drain valve

Relief valve top lift, drains the pressure in the hydraulic line to the
attachment's pressure feed. This line is pressurised after the engine
has been switched off due to non-return valves in the hydraulic oil
pump. The valve must be closed during normal operation.
For information about depressurising the machine, see Hydraulic and

The relief valve is fitted on the pressure feed to the attachment on

hydraulic oil pump 2. See Relief valve top lift, description, page 7:52.
016255
The illustration depicts an open valve

Pipes and hoses, general

10 Common hydraulics – Pressure relief valve 10:5
10.2.4 Pressure relief valve

Pressure limiting valve, description
The pressure relief valve protects the hydraulic system against
excessive feed pressure from the hydraulic oil pumps.
1 2
The pressure limiting valve leads too high pressure in the hydraulic
oil supply to tank, protecting the hydraulic system against excessive
pressures.
The pressure relief valve is fitted on the priority valve for the steering
on the inside of the right-hand frame side.
016804
1. Tank return overpressure

2. Measuring outlet feed pressure steering
3. Pressure feed control valve lift, lower and
extension

10:6 10 Common hydraulics – Tanks and accumulators
10.3 Tanks and accumulators

10.3.1 Tank
Tank, description
3 The hydraulic oil tank forms part of the side panel on the right-hand side
of the machine. The oil filters for the working hydraulics are fitted inside
2 the tank. These are accessible through hatches on top of the tank.
1
Hydraulic oil is filled directly into the tank through the filler plugs on
the filter manhole covers. For oil capacity and grade, see section F
Technical data. The whole filter unit can be removed to facilitate access
for cleaning. There is a drain plug located at the bottom of the tank.
The tank is equipped with filtered breather that allows volume changes
in the tank, due to temperature variations and use.
The oil level is checked on the sight glass on the tank's side when all
hydraulic cylinders are in the bottom position.
015737
1. Hydraulic oil filler plug

2. Sight glass hydraulic oil
3. Breather filter hydraulic oil tank


10 Common hydraulics – Pumps 10:7
10.4 Pumps
Pumps, general
The machine's hydraulics are supplied from five pumps. Three of them
1 5 3 2 4 are for working hydraulics, one is for cooling and filtering the hydraulic
oil and one is for the brake system. The pumps are mounted on the
transmission's power take-off.
Hydraulic oil pump 1 (position 1), supplies the steering and the
control valve for lift and extension. On machines with support jacks,
hydraulic oil pump 1 also supplies the control valve for support jacks.
The priority valve ensures that there is always pressure for the steering,
the residual flow goes to the control valve for lift and extension. Fitted
on the pressure side is a spacer block with connections for different
functions and a non-return valve which prevents the oil from being fed
back through the pump instead of out in the hydraulic system.
Hydraulic oil pump 2 and Hydraulic oil pump 3 are two parts of a
double pump that is assembled together with hydraulic oil pump cooling
and cleaning (position 4) into one pump bank. Fitted on the pressure
connections from pump 2 and 3 is a distribution block with connections
for different functions, non-return valves and measuring outlets. The
016339
non-return valves prevent oil from being pumped around between the
pumps instead of out in the hydraulic system.
2. Hydraulic oil pump 2 Hydraulic oil pump 2 (position 2), supplies the control valve for lift and
extension. Hydraulic oil pump 2 (position 2) disengages at boom in.
4. Hydraulic oil pump cooling and cleaning Hydraulic oil pump 3 (position 3) supplies the control valves for lift
and extension, attachment, cab movement and cab lift.
Hydraulic oil pump cooling and cleaning (position 4) continuously
circulates the hydraulic oil through the cooler and hydraulic oil filter,
see Temperature control, cleaning and hydraulic oil, description, page
10:30.
Oil pump brake system (position 5) supplies the brake system's brake
and cooling circuit over an accumulator charging valve, see Oil pump
brake system, description, page 4:12.

10:8 10 Common hydraulics – Gear pump with fixed displacement
10.4.1 Gear pump with fixed displacement

Gear pump with fixed displacement, description
There are two gear pumps with fixed displacement. One supplies the
1 5 3 2 4 brake system with pressure, see Oil pump brake system, description,
page 4:12. The other gear pump circulates the hydraulic oil for the
working hydraulics through the cooler and filter.
The gear pump pumps oil via two gear wheels that rotate opposite each
other. One is driven by the pump's input shaft and the other rotates
freely. The gear pump's flow is directly dependent on the speed of
the input shaft.
Hydraulic oil pump cooling and cleaning is fitted on one of the

transmission's power take-offs. The pump's rotation speed is directly
dependent on engine speed. Pump flow increases with the engine
speed.
Oil pump brake system is installed. The pump speed is directly

dependent on the engine speed. Pump flow increases with the engine
speed.
016339

Hydraulic oil pump cooling and cleaning, replacement
NOTE
Safety.
1 Park the machine with the cab in the rearmost position and the
boom fully raised, and half extended.
CAUTION
Make sure that the oil level in the hydraulic oil tank is
below the mouth of the axial piston pump's suction
hose.
If there is not enough room to lift the boom, the hydraulic oil tank
must be drained, see Maintenance manual.
2 Switch off the system voltage.
NOTE

10 Common hydraulics – Gear pump with fixed displacement 10:9
4 Mark up and detach the hydraulic hoses from the pump.
NOTE
from impurities.
5 Remove the attaching bolts, pull the pump out backwards and
lift it away.
6 Transfer the connection adapters to the new pump.
016882
7 Brush sealing silicone on the sealing surface of the pump, see

8 Fit the pump on the transmission.
Fit the pump and check that the pump's splines engage in the
shaft in the transmission's power take-off.
Fit the pump's attaching bolts.
014367
9 Connect the hydraulic hoses to the pump.
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.

12 Check that hose connections and seal between gear pump and
axial piston pump are sealed tightly.
016882
manual.
NOTE
If the pump is replaced due to malfunction, change the oil and
filter in the hydraulic system as well.

10:10 10 Common hydraulics – Axial piston pump with variable displacement
10.4.2 Axial piston pump with variable

displacement
Axial piston pump with variable displacement,
description
The hydraulic oil pumps are of the type variable axial piston pump, and
1 5 3 2 4 are controlled by load signals depending on the flow demand from
each function.
Hydraulic oil pump 2 (position 2) and Hydraulic oil pump 3 (position

3) supply the control valve for lift and extension and also supply
the attachment's control valve. With boom in, hydraulic oil pump 2
is disengaged.
Hydraulic oil pump 1 (position 1), supplies the steering system and
the control valve for lift and extension. The priority valve ensures that
there is always pressure to the control system, residual flow goes to
the control valve for lift and extension.
There is a connection block on the pumps' pressure side with

non-return valves that prevent the oil being pumped around between
the pumps instead of out in the hydraulic system.
Fitted on connection block on Hydraulic oil pump 2 (position 2) and

016339
Hydraulic oil pump 3 (position 3) is branching to the attachment

hydraulics with a separate non-return valve. There is also a test socket
1. Hydraulic oil pump 1 on the connection block for checking the pump pressure.
2. Hydraulic oil pump 2 Fitted on the connection block on Hydraulic oil pump 1 (position 1) is
3. Hydraulic oil pump 3 branching to the pressure reducer in Valve block servo pressure. There
is also a test socket for this pump on this branching.

10 Common hydraulics – Axial piston pump with variable displacement 10:11
Axial piston pump with variable displacement,

D7902
1, 34 24 12
P P D7971
9, 19
LS
LS PP D7 D7 P1
EF
15
C30 C24 P
4, 10 17
LSM PT H A 21 C15
25 30 22
5, 18 P
P LS
29 LS P
6, 19, 26 2, 13, 23
LSPR
LSO
LSHY LSP3 LSP3X LSP2 T LSP1
C12
C7 C3
C8
6, No
101 8, 1 1 No 1 3, 14, 24, 28
7, 20, 27
016894
1 Control valve lift, lower and extension See pressure plate Servo Lifting/lowering, function description, page
sends a load signal to Valve block servo pressure lift and extension 7:14
pressure when a function is activated. on left frame member.
2 The shuttle valve in Valve block servo - Valve block servo pressure, description,
pressure that sends the load signal page 10:25
onward to hydraulic oil pump No. 1.
This shuttle valve selects between load
signal from lift, extension, steering or
support jacks .
3 Hydraulic oil pump 1 increases the flow. See pressure plate Max. Axial piston pump with variable displacement,
pressure hydraulic oil description, page 10:10
pumps on left frame
member.
4 Solenoid valve unloading main pump - Valve block servo pressure, description,
(Y6062) in rest position forwards the page 10:25
load signal to hydraulic oil pump No. 2
(position 8) and the shuttle valve
(position 5).
5 The shuttle valve sends the load signal - Valve block servo pressure, description,
onward to shuttle valve (position 6). page 10:25
This shuttle valve selects between load
signal from lift, extension or attachment
functions.
6 The shuttle valve sends the load signal - Valve block servo pressure, description,
onward to hydraulic oil pump No 3 page 10:25
(position 7).
This shuttle valve selects between the
load signal from shuttle valve 5 or cab
movement.


pumps on left frame
member.
pumps on left frame
member.
9 At boom in, Control unit KFU (D7971) U = 24 V KFU control unit (D7971), description, page
activates Solenoid valve pump unloading 11:31
(Y6062). D9: Diagnostic menu, 10.4 Pumps 2/XX
DIAGNOSE, page 8:78
10 Solenoid valve, pump unloading (Y6062) - Valve block servo pressure, description,
opens and routes the load signal from page 10:25
Control valve lift, lower and extension to
the tank.
11 Hydraulic oil pump No. 2 reduces the - Axial piston pump with variable displacement,
flow to standby. description, page 10:10
12 Control valve steering sends load See pressure plate Control valve steering, description, page
signals to Valve block servo pressure Steering pressure, on left 5:23
when the wheels should be turned. frame member.
13 The shuttle valve (position 2) in Valve - Valve block servo pressure, description,
block servo pressure that sends the page 10:25
load signal onward to hydraulic oil pump
No. 1.
14 Hydraulic oil pump No. 1 adapts the flow See pressure plate Max. Axial piston pump with variable displacement,
according to the load signal's pressure pressure hydraulic oil description, page 10:10
difference. pumps on left frame
member.
15 The priority valve controls the pressure See pressure plate Priority valve, description, page 5:14
from Hydraulic oil pump No. 1 to the Steering pressure, on left
steering valve. Any surplus capacity is frame member.
routed, if required, onward to Control
valve lift, lower and extension.
16 If any attachment function is activated U = 24 V Valve block servo pressure, description,
then Control unit KFU (D7971) activates page 10:25
Solenoid valve, top hydraulics (Y6003). D17: Diagnostic menu, see 10.4 Pumps
17 Solenoid valve top hydraulics (Y6003) - Valve block servo pressure, description,
controls an unloaded constant pressure page 10:25
to the shuttle valve (position 5). D17: Diagnostic menu, see 10.4 Pumps
The unloaded constant pressure is 1/XX DIAGNOSE, page 8:78
created with a reduction (position 21) on
the outlet from hydraulic oil pump No. 3
and acts as a load signal.
18 The shuttle valve (position 5) in - Valve block servo pressure, description,
Valve block servo pressure sends the page 10:25
load signal onward to Shuttle valve
(position 6).
block servo pressure sends the load page 10:25
signal onward to hydraulic oil pump
No. 3.
member.


21 Pressure reduction reduces the pressure - -
to the attachment to the load signal for
the attachment functions.
22 Control valve support jacks sends load - Support jacks, function description, page
signals to Valve block, servo pressure, 7:110
when the support jacks are lowered.
block servo pressure that sends the page 10:25
load signal onward to hydraulic oil pump
No. 1.
member.
25 Control valve cab movement sends load - Control valve cab movement, description,
signals to Valve block, servo pressure, page 9:96
when the cab is moved.
block servo pressure sends the load page 10:25
signal onward to hydraulic oil pump
No. 3.
member.
28 Pressure from Hydraulic oil pump No. 1 - Axial piston pump with variable displacement,
is routed to Valve block, servo pressure description, page 10:10
29 The pressure reducer in Valve block, See pressure plate servo Valve block servo pressure, description,
servo pressure, regulates the pressure pressure, on left frame page 10:25
to servo pressure and supplies Control member.
valve lift, lower and extension with servo
pressure.
30 The accumulator on Valve block, - Valve block servo pressure, description,
servo pressure, stores servo pressure page 10:25
for faster reactions after starting the
machine.

machine, page E:6.

Axial piston pump, checking
NOTE
Safety.
0:00pm
a operating temperature, approx. 50 °C.
75° C 50%
b c
50° C 50° C 016372

3 Connect a pressure gauge to measuring outlet on hydraulic oil

pump 1.
5 Check the stand-by pressure for one pump at a time in the
following order:
Hydraulic oil pump 1: 3.0 MPa
The settings apply to a standard machine, certain machines may
have higher standby pressure. For correct standby pressure, see
the pressure plate. However, the difference in pressure between
the different pumps must always be maintained.
6 Increase engine speed to approx. 1100 rpm and run the extension
function against end-position (overflow).
Run out the boom to max. and continue to request max. extension
2. Hydraulic oil pump 2 with the control lever. This will cause the extension function to
3. Hydraulic oil pump 3 overflow.
7 Check the max. pressure on hydraulic oil pump 1, the pressure

should correspond with the value on the pressure plate.
All pumps should give the same max. pressure. The sequence
between the pumps is of no importance.
9 Transfer the pressure gauge to the next pump and repeat steps
3-8 on all of the pumps.
016387
Pressure plate, max. pressure hydraulic oil pumps

Hydraulic oil pump 1, replacement
NOTE
Safety.
CAUTION
hose.
NOTE
4 Mark up and detach the hydraulic hoses from hydraulic oil pump 1.
NOTE
from impurities.
5 Attach hoisting equipment to the axial piston pump.

016869
6 Remove the axial piston pump.

Remove the retaining bolts and lift the pump away.
7 Clean the flange on the transmission, removing all silicone
remnants.
CAUTION
Contaminants can damage the transmission.
Product damage.
Be careful and make sure that no gasket remains fall
016889
down into the transmission.

8 Transfer the connection adapters to the new axial piston pump.
NOTE
correctly.
014357
9 Brush sealing silicone on the axial piston pump flange facing the
transmission, see section F Technical data.
10 Fit the axial piston pump in place.
Position the axial piston pump so that the pump shaft engages the
transmission's gearing. Fit the attaching bolts.
11 Connect the suction hose to the axial piston pump.
014358
12 Fill the pump with oil through the connections on the top.
CAUTION
The hydraulic oil pump will seize if the engine is started
before the pump is filled with oil.
Product damage.
Always fill the pump with oil before the upper
016890
connection is fitted.
13 Connect the hydraulic hoses to the axial piston pump in

NOTE
correctly.
14 Bleed the axial piston pump, see Axial piston pump with variable
displacement, venting, page 10:22.
CAUTION
Vent the axial piston pump before starting the engine.
The oil in the axial piston pump may cavitate and cause
product damage.

hydraulic system.
NOTE
the lock ring.

17 Check that the hose connections and seal between gear pump and
axial piston pump are airtight.
18 Check the pump pressures, see Axial piston pump, checking,
page 10:14.
manual.

Hydraulic oil pump 2 and 3, replacement
NOTE
Safety.
CAUTION
hose.
NOTE
4 Release the oil pump for the brake system from hydraulic oil pump
2 and 3.
5 Hang up the oil pump for the brake system.
6 Protect the connection on the oil pump for the brake system
against dirt with a plastic bag or similar.
016836
7 Mark the hydraulic hoses and disconnect them from the axial
piston pump.
NOTE
from impurities.
8 Attach hoisting equipment to the axial piston pump.

016862

9 Remove the axial piston pump.

Remove the retaining bolts and lift the pump away.
016866
10 Clean the flange on the transmission, removing all silicone

remnants.
CAUTION
Contaminants can damage the transmission.
Product damage.
Be careful and make sure that no gasket remains fall
down into the transmission.
11 Transfer the connection adapters to the new axial piston pump.
NOTE
correctly.
12 Brush sealing silicone on the axial piston pump flange facing the
transmission, see section F Technical data.

13 Fit the axial piston pump in place.

Position the axial piston pump so that the pump shaft engages the
transmission's gearing. Fit the attaching bolts.
14 Connect the suction hose to the axial piston pump.
15 Lift away the distribution block and fill the pump with oil through
the connections on the top of the pump.
CAUTION
The hydraulic oil pump will seize if the engine is started
before the pump is filled with oil.
Product damage.
Always fill the pump with oil before the upper
connection is fitted.
016866
16 Connect the remaining hydraulic hoses to the axial piston pump in

NOTE
correctly.
016862
17 If the spacer ring remains in place on the axial piston pump.

Remove the spacer ring between 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 Fit the spacer ring on the axial piston pump.

19 Brush sealing silicone onto the sealing face of the gear pump
against the spacer ring, see section F Technical data.
NOTE
Only use silicon on the side facing the gear pump.
016868
20 Fit the gear pump in place.
Place the gear pump on the axial piston pump and install the
attaching bolts.
Exercise caution that the O-ring on the spacer ring is correctly
aligned and that the gear pump's shaft engages the axial piston
pump's output shaft.
21 Bleed the axial piston pump, see Axial piston pump with variable
displacement, venting, page 10:22.
CAUTION
016836
Vent the axial piston pump before starting the engine.

The oil in the axial piston pump may cavitate and cause
product damage.
hydraulic system.
NOTE
the lock ring.

24 Check that the hose connections and seal between gear pump and
axial piston pump are airtight.
25 Check the pump pressures, see Axial piston pump, checking,
page 10:14.
manual.

10:22 10 Common hydraulics – Pipes and hoses
Axial piston pump with variable displacement, venting
NOTE
Safety.
1 Remove the hydraulic oil tank breather filter.

2 Connect compressed air at max. pressure max. 10 kPa to the
hydraulic oil tank's connection for breather filter.
CAUTION
Excessive pressure in the hydraulic tank damages the
hydraulic system.
Product damage.
Ensure that the pressure does not become too high by
adjusting the pressure regulator on the compressed
air before the tank is pressurised.
3 Detach the hoses to the hydraulic system's feed from the axial
piston pump (1 or 2 and 3) one at a time and allow the oil to flow
out. Tighten the connections when oil free of air is flowing out.
4 Remove the compressed air from the tank and fit the breather filter.
6 Let the engine run at idle speed for at least one minute. Check that
all connections are sealed tightly.
7 Lower the boom and raise it again very slowly so that the pump
operates under minimum load while air pockets are eliminated.


10 Common hydraulics – Hoses, pipes and valves 10:23
10.5 Hoses, pipes and valves

Hoses, pipes and valves, description
• Servo valve load handling and steering, incl. shuttle valves,
pressure reducers and solenoid valves. This converts pump
pressure to servo pressure and collects all control signals from the
different functions and prioritises between them in order to control
the hydraulic oil pumps in the best way.
• Collection block, unfiltered returns. This valve collects return
lines from different hydraulic valves that may not have any back
pressure and routes them directly to the tank.
• Priority valve. The priority valve ensures that the steering
function always has pressure before other hydraulic functions are
connected to the same hydraulic oil pump.

Hoses with ORFS couplings are used almost exclusively. For maximum
service life and function, the following should be observed when
replacing hoses.
1. To avoid stresses in the connection, there should be a length of
straight hose after the connection.
2. The hose must not be twisted. (A twist of 7% reduces service life
by 90%.)
3. Minimise the number of bends by using correct couplings.
4. Avoid sharp bends.
5. Keep the hoses clean internally. Leave the plugs in place as long
as possible when installing.
6. Check the position of the O-rings and tighten to the correct torque,
NOTE
Straight coupling requires a counterhold wrench to prevent damage
to the O-ring.
7. O-rings must not be oiled; O-rings must be dry during assembly.

Hose length
C/L Hose length

Hose length is measured on a hose laid out between the sealing
surfaces. On angled connections, measure from the sealing surface's
centre line [C/L] as illustrated.
Cleanliness
The function and service life of hydraulic components depend to a great
extent on how clean the hydraulic oil is. It is therefore very important to
prevent dirt from entering the brake and hydraulic system.
Some simple advice to keep the hydraulic system clean.
• Always clean the area around a component before starting to work.
• Plug hose connections immediately after disconnecting. If possible,
001015
use correct plugs for the connection type. If plugs are missing, use
clean plastic bags and cable ties or tape to seal the connection.
C/L line for measuring hose length
• Never re-use oil that has been drained from the machine.
• When filling hydraulic oil, fill through the tank's filler cover.
10.5.2 Priority valve

Priority valve, description
See Priority valve, description, page 5:14.

10:24 10 Common hydraulics – Collecting block, unfiltered returns
10.5.5 Collecting block, unfiltered returns

Multiblock, unfiltered return lines, description
The block collects several return lines from different valves and leads
these directly back to the tank.
The drain lines are very sensitive to back-pressure, if pressure builds

up in the drain lines the valves will not work properly.
The block is fitted on the rear of the lifting beam in front of the
transmission.
016961

10 Common hydraulics – Valve block servo pressure 10:25

Valve block servo pressure, description
1 2 3 4 Valve block, servo pressure, handles load signals from Control valve
lift, lower and extension and Control valve steering; and load signals to
the hydraulic oil pumps are handled in the servo valve.
Valve block servo pressure also supplies Control valve lift, lower and
5
extension with servo pressure.
6
14 The following functions are collected in Servo valve load handling and
7 steering:
13
• Pressure reducer
12 8
9 • Solenoid valve pump unloading (Y6093)
11 10 • Solenoid valve, engagement of hydraulics for top lift (Y6003)
• Shuttle valves
Pressure reducer, description

The pressure reducer reduces the pressure from the hydraulic oil
016842
pumps to servo pressure for the control valve.
Servo pressure is stored in an accumulator. A built-in non-return valve

1. Test outlet, servo pressure prevents pressure leakage from the accumulator when the machine is
2. Servo pressure from hydraulic oil pump 2 (PT) not in use.
3. Load signal from control valve steering (LSPR) Solenoid valve pump unloading, description
4. Load signal from control valve lift, lower and
extension (LSM) For boom in, only a small oil flow is required. Solenoid valve pump
unloading (Y6093) drains the control signal to hydraulic oil pump 2, to
5. Load signal to hydraulic oil pump 1 (LSP1)
tank. This means that only one pump unit builds up pressure. When
6. Extra load signal to hydraulic oil pump 3 the valve is not activated the control pressure from Control valve lift,
(LSP3X) lower and extension is routed through the solenoid valve to hydraulic
Load signal to hydraulic oil pump 3 (LSP3) oil pump 2.
7. Return to tank (T) Solenoid valve pump unloading (Y6093) is supplied with voltage by
8. Solenoid valve pump unloading extension in Control unit KFU (D7971) on activation.
(Y6093)
The signal can be checked with the diagnostic menu, see 10.4 Pumps
9. Solenoid valve, engagement of hydraulics for
top lift (Y6003) 2/XX DIAGNOSE, page 8:78.
10. Adjusting screw servo pressure Solenoid valve, engagement of hydraulics for top lift,
11. Pressure feed from hydraulic oil pump 2 description
12. Return to tank (T) Solenoid valve engagement of hydraulics for top lift (Y6003) routes an
13. Servo pressure to control valve lift, lower and unloaded constant pressure from the attachment's supply as a load
extension (H) signal to hydraulic oil pump 3 when attachment functions are activated.
When the solenoid valve is activated, pressure from the supply for the
14. Accumulator servo pressure
top lift hydraulics is routed through a shuttle valve to hydraulic oil pump
Not visible in illustration 3. When the solenoid valve is not activated, the load signal is drained to
the tank and the inlet from the supply for the top lift hydraulics is closed.
Load signal from Control valve cab movement
(LSHY) The valve is controlled electrically with Solenoid valve engagement of
hydraulics for top lift (Y6003) which is activated by Control unit KFU
Load signal to hydraulic oil pump 2 (LSP1)
(D7971).
The signal can be checked with the diagnostic menu, see 10.4 Pumps

10:26 10 Common hydraulics – Valve block servo pressure
Shuttle valve, description

A shuttle valve selects between two pressure signals and sends the
strongest. The shuttle valves are used to send load signals to the
hydraulic oil pumps. This means that the pumps are controlled by
the function that requires the highest pressure if several functions
are activated simultaneously. See Axial piston pump with variable
displacement, description, page 10:10.
Depending on options, there are two or three shuttle valves. The

shuttle valves choose between the following pressure signals:
1. Shuttle valve pump 1 selects between the pressure signal from
Control valve lift, lower and extension, the pressure signal from
Control valve steering and the pressure signal from Control valve
support jacks and sends the strongest pressure signal onward
to hydraulic oil pump 1.
2. Shuttle valve attachment selects between the pressure signal
from Control valve lift, lower and extension (through Solenoid
valve pump unloading) and the unloaded constant pressure from
the attachment's feed (through Solenoid valve engagement of
hydraulics for top lift). The shuttle valve sends the pressure signal
onward to Shuttle valve cab in order to control hydraulic oil pump 3.
3.
Shuttle valve cab selects between the pressure signal from
Shuttle valve attachment and the pressure signal from Control
valve cab movement and/or Control valve vertically adjustable cab.
The shuttle valve sends the pressure signal onward to hydraulic
oil pump 3.
This shuttle valve is installed if the machine is equipped with
support jacks, hydraulic sliding cab, or vertically adjustable cab.
Servo pressure, inspection and adjustment
NOTE
Safety.
0:00pm
1 Operate and warm up the machine so that the hydraulic oil is at
a operating temperature, at least 50 °C. As an alternative, operate
until the cooling fan is activated.
75° C 50% the oil temperature.
b c 2 Machine in service position, see section B Safety.
50° C 50° C
016372


10 Common hydraulics – Valve block servo pressure 10:27
3 Connect a pressure gauge (0-25 MPa) to the measuring outlet on

Servo valve load handling and steering.
016315
4 Start the engine and check the servo pressure. Compare with
the pressure plate.
Turn the steering wheel or activate a load handling function to
activate the hydraulic oil pumps. The servo pressure is higher than
the standby pressure of the hydraulic oil pumps.
01467
The appearance of the pressure plate may vary, but

the symbols are the same.
5 If necessary, adjust the pressure with the adjusting screw. Loosen

the lock nut and turn the adjusting screw.
NOTE
If the servo pressure is too high, a load handling function must be
activated so that servo pressure is used from the accumulator for
a reduction on the adjusting screw to be seen on the pressure
gauge. Sometimes the engine has to be shut off between the
checks.
Clockwise: reduce pressure.

Anticlockwise: increase pressure.
measuring outlet.
016844

10:28 10 Common hydraulics – Valve block servo pressure
Valve block servo pressure, replacement
NOTE
Safety.

NOTE
NOTE
from impurities.
5 Remove the valve block.

6 Transfer the parts to the new valve block.
NOTE
mixed up.
7 Fit the valve block and connect the hydraulic hoses and cable
harness in accordance with the marking
017468
hydraulic system.
NOTE
the lock ring.
9 Start the machine and carefully activate all load handling functions
one at a time
CAUTION
product damage.
cavitation.
manual.

10 Common hydraulics – Accumulator servo circuit 10:29

Accumulator servo circuit, description
The accumulator stores pressurised oil and ensures that there is servo
pressure for activating control valve functions. The accumulator is fitted
on Servo valve load handling and steering to the right on the lifting
beam in the engine compartment.
The accumulator is a diaphragm type and is divided into two spaces

by a diaphragm. One side of the diaphragm is pressurised by
nitrogen gas. The other side is pressurised by the hydraulic oil, which
compresses the nitrogen gas.
Furthest up on the accumulator is a test outlet for checking gas

pressure and filling gas.
016332
Accumulator servo circuit, replacement
NOTE
Safety.

NOTE
3 Detach the accumulator from its mounting.

4 Replace the accumulator.
hydraulic system.
NOTE
016334
the lock ring.
7 Start the machine and carefully activate all load handling functions
one at a time
CAUTION
product damage.
cavitation.
manual.

10:30 10 Common hydraulics – Temperature control, cleaning and hydraulic oil
10.6 Temperature control, cleaning

and hydraulic oil
Temperature control, cleaning and hydraulic oil,
description
The oil in the hydraulic system is cooled and cleaned by means of
circulation by a separate pump through the cooler and filter. The cooler
has a temperature-controlled electric fan that prevents overheating.
Temperature control consists of a hydraulic oil tank, hydraulic oil pump,

valve block, hydraulic oil cooler, cooling fan, hydraulic oil filter, fine filter,
hydraulic oil temperature sensor, and bypass valve.
The hydraulic oil pump pumps oil (from the tank) which is cooled in the
hydraulic oil cooler and cleaned by the oil filters in the tank. Some of
the oil is filtered by the fine filter. An electric cooling fan increases the
air flow through the cooler when the temperature needs to be lowered.
A bypass valve routes the hydraulic oil past the cooler directly to the
tank if the resistance through the cooler and filters is too high. The
temperature sensor controls fan activation and temperature indication
in the display.
Temperature control, cleaning and hydraulic oil,

9
D7950
D3 D7971
4 D4
2
8 M 5
1
7
6
°C
016886
Pos Description Signal value Reference

1 The hydraulic oil pump pumps oil from - Gear pump with fixed displacement,
the hydraulic oil tank. description, page 10:8
2 The hydraulic oil cooler cools the oil. - Hydraulic oil cooler, description, page 10:32
3 Sensor hydraulic oil temperature (B7760) U = 0.5-4.5 V Sensor, hydraulic oil temperature,
sends voltage signals proportional to the description, page 10:33
hydraulic oil temperature to Control unit D3: Diagnostic menu, see 10.6 Oil
KFU (D7971). Temp/Clean 1/XX DIAGNOSE, page 8:79
4 Control unit KFU (D7971) transmits Hydraulic fan active: 11.5.3.4 KFU control unit (D7971), page
temperature on the CAN bus and U = 24 V 11:31
supplies voltage to the cooling fan as D3: Diagnostic menu, see 10.6 Oil
necessary. Temp/Clean 1/XX DIAGNOSE, page 8:79
5 The cooling fan (M6680) increases air - Cooling fan, description, page 10:33
flow through the cooler.
6 The hydraulic oil filters clean the hydraulic - Hydraulic oil filter, description, page 10:36
oil.

10 Common hydraulics – Tank heater 10:31
Pos Description Signal value Reference

7 Some of the oil is pumped through the - Fine filter hydraulic oil, description, page
hydraulic oil fine filter for deep cleaning. 10:37
8 If resistance through the oil cooler and - Bypass valve, cooler, description, page
hydraulic oil filter becomes too high, the 10:34
cooler bypass valve opens and directs
the oil to the tank.
9 Control unit KID (D7950) shows hydraulic Checked by control 11.5.3.3 Control unit, KID (D7950), page
oil temperature in the display. system, error shown with 11:29
error code.

machine, page E:6.
10.6.1 Tank heater

Tank heater, description
The tank can be equipped with a tank heater. The tank heater is
designed for use in cold climates.
The tank heater is powered by high voltage. Heater output is adapted

through different connections and adaptation to different operating
voltages - 110, 230 or 400 V AC. Higher voltage generates higher
heater output. The heater is mounted in a hole in the connection cover
at the bottom of the tank's short side.
The tank heater has an adjustable thermostat that keeps the

016887
temperature at a constant level. The thermostat is fitted on the heating

element and is adjusted with a knob on the junction box.
The recommended temperature setting is 20-30 °C.
CAUTION
The tank heater is connected to high voltage (110 - 400
V).
High voltage.
Installation and reconnection of the tank heater may
with high voltage.

10:32 10 Common hydraulics – Hydraulic oil cooler
10.6.2 Hydraulic oil cooler

Hydraulic oil cooler, description
The working hydraulics use a through-flow cooler with electric cooling
fan (the same type of cooler as used for the brake system). The oil is
cooled when it passes through the cooler. The cooler is fitted inside the
side panel on the right-hand side behind the hydraulic oil tank.
016888
Hydraulic oil cooler, replacement
NOTE
Safety.

2 Drain the oil from the hydraulic oil tank, see Maintenance manual.
3 Mark up and detach the hydraulic hoses from the cooler. Let the
oil in the cooler drain into the receptacle.
NOTE
from impurities.
4 Disconnect the cable harness from the cooling fan.

5 Remove the attaching bolts and lift away the cooler.
6 Transfer the cooling fan to the new cooler.
7 Fit the cooler.
8 Connect the cable harness to the cooling fan.
9 Connect the hydraulic hoses to the cooler.
016888
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.
manual.

10 Common hydraulics – Cooling fan 10:33
10.6.3 Cooling fan

Cooling fan, description
The electric cooling fan is suctioning. The cooling fan is located at
the rear of the cooler. The fan draws air from the machine's outside
through the cooler. Openings in the side cover allows air to pass
through the cooler.
The cooler is supplied voltage by Control unit KFU (D7971) upon

activation when the engine is running. The cooling fan is activated
when oil temperature is 65 °C in the hydraulic oil tank and the fan is
deactivated when oil temperature is 55 °C.
016891
10.6.4 Sensor hydraulic oil temperature

Sensor, hydraulic oil temperature, description
Hydraulic oil temperature sensor (B7760) detects the temperature of
the hydraulic oil. The sensor is fitted on the hydraulic oil tank's rear
short side.
The sensor detects the oil temperature in the tank, and therefore takes
into account the accumulated heat in the hydraulic oil. This means
that the cooling fan may continue to run after the machine has been
parked and switched off.
Sensor, hydraulic oil temperature (B7760) is supplied with voltage by,

and sends voltage signals proportional to the oil temperature to Control
unit KFU (D7971).
016990
Sensor, hydraulic oil temperature, (B7760)

10:34 10 Common hydraulics – Radiator bypass valve
Sensor, hydraulic oil temperature, replacement
NOTE
Safety.

3 Disconnect the cable harness from Sensor, hydraulic oil
temperature (B7760).
4 Replace Sensor, hydraulic oil temperature (B7760).
NOTE
correctly.
5 Connect the cable harness to the sensor.

manual.
016990
Sensor, hydraulic oil temperature, (B7760)
10.6.5 Radiator bypass valve

Bypass valve, cooler, description
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.
016991

10 Common hydraulics – Breather filter hydraulic oil tank 10:35
Bypass valve, cooler, replacement
NOTE
Safety.
1 Machine in service position, section B Safety.

3 Disconnect the bypass valve from the tank.
NOTE
Note how the bypass valve is turned, the valve is marked with an
arrow that should be pointing in towards the tank.
4 Install the new bypass valve, turn the valve to face the same way
as the old one. Use Loctite when refitting the bypass valve.
manual.
016991
10.6.6 Breather filter hydraulic oil tank

Breather filter hydraulic oil tank, description
A breather filter of insert type is mounted on the hydraulic oil tank to
protect the tank from impurities. On the top of the filter housing is an
indicator that shows when the filter is clogged and needs to be changed.
016892

10:36 10 Common hydraulics – Hydraulic oil filter
10.6.7 Hydraulic oil filter

Hydraulic oil filter, description
The oil in the hydraulic system is cleaned by two return filters fitted
inside the hydraulic oil tank. The oil is pumped by the cooling pump
through the cooler and back through the filters. Some of the return oil
from the load handling functions also flows through the filters.
016893
Hydraulic oil filter, description (high-pressure filter)
As an option the machine can be equipped with two additional

high-pressure filters that are located directly after the axial piston
pumps. The filters are located in front of the transmission under the
lifting beam. The filters are used together with the hydraulic oil filters
in the tank.
003602

10 Common hydraulics – Fine filter hydraulic oil 10:37
10.6.9 Fine filter hydraulic oil

Fine filter hydraulic oil, description
The fine filter is located on the right-hand side. The filter is connected
to the hydraulic oil pump cooling and filtration. 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.
016992

10.6.14 Servo filter

Servo filter, general
See Servo filter, description, page 7:18.

10:38 10 Common hydraulics – Other
10.7 Other
10.7.1 Hydraulic cylinders
Fault tracing, leakage
Fault tracing, leakage
CAUTION
All fault tracing should be carried out with as low a
pressure in the system as possible so that internal
leakage can be detected. High pressure causes the
seals to close tighter, which prevents detection of
internal leakage.
1. Carefully check the source of the leakage before taking any action.
It may be possible to rectify the fault without disassembly.
2. Check for external leakage:
• At cylinder face end welds
• At sleeve coupling welds
• Between cylinder barrel and cylinder head
This could be due to a defective O-ring or damaged O-ring
sealing surfaces.
• Between cylinder head and piston rod
This could be due to a damaged piston rod or damaged or
worn piston rod seal.
3. Check for internal leakage. Pressurise the cylinder and check
whether the piston sinks back.
This could be due to a worn piston seal.
1. Piston rod
2. Scraper
3. Cylinder head
4. Piston rod seal
5. O-ring with support ring
6. Cylinder barrel
7. Sleeve coupling
8. Welded cylinder end face
9. Piston
10. Piston seal, double-acting
11. Example of weld

10 Common hydraulics – Hydraulic cylinders 10:39
Dismantling of cylinders
CAUTION
Before dismantling always check that the piston rod is
clean and free from all residual paint. Also check that
connections and couplings are free from burrs and
impact marks.
Make sure that the chamfer up to the chromium surface
of the piston rod is free from burrs and residual paint.
1 Remove the cylinder from its mounting and undo the connections.
2 Plug the cylinder connections and hoses without delay.
3 If the cylinder is opened - observe the strictest cleanliness!
Inspection of surfaces
Inspect the sealing surfaces. Always bearing mind the function of the
seals and the type of sealing surfaces they have. See the following
descriptions:
• O-ring groove, internal and external
• piston rod seal in the cylinder head
• sealing groove on the piston
• cylinder barrel surface
• piston rod surface. The piston rod is chromium plated with a layer
thickness of 20-50 my. Slight damage to the chromium plating may
not necessarily cause leakage directly.
• all slide surfaces (dynamic surfaces), e.g. cylinder barrel and
piston rod. These are always the hardest to seal.
CAUTION
When fitting the cylinder head:
Fit the cylinder head absolutely straight, ideally by
hand and do not hit with a mallet. If a mallet must be
used, use a plastic or rubber mallet and tap gently.
If the cylinder head is fitted crooked, the sealing lip
of the piston rod seal could be damaged, making an
improper seal. This applies to all types of piston rod
seals.

10:40 10 Common hydraulics – Hydraulic cylinders
Function and removal of the seals

Piston rod seal
Piston rod seal
2 The piston rod seal is the seal that sits in the groove in the cylinder
head and seals against the piston rod. This seal is very exposed to
wear since it is both a dynamic and a static seal, i.e. it seals against
1 a moving surface on the piston rod while the sealing surface with the
cylinder head is fixed. There are different types of piston rod seals:
• Single V-seal
• Pre-stressed V-seal with support ring
3 • Compressible seal
The single V-seal has a V-shaped section with two lips that seal
in opposite directions. The hydraulic pressure acts in the V-shape,
4 pressing the sealing lips out towards the sealing surfaces on the piston
6 rod and in the cylinder barrel. Even minor damage to the sealing lips
can generate large leaks. Examine the sealing lips by carefully using
a fingernail to feel around the seal. To remove, use a screwdriver to
prise the seal outward and bend it up (see illustration). It is extremely
important that the screwdriver is always inserted in the V-shape so that
it cannot touch and thereby damage a sealing surface. A mark from
a screwdriver on a sealing surface can have a devastating effect and
cause major leakage.
001497
1. Hydraulic pressure
2. Seal lip pressed out toward piston rod
3. Seal lip pressed inward toward cylinder head
4. Sealing surface, piston rod
5. Sealing surface, cylinder head
6. Screwdriver

2 The pretensioned V-seal also has an O-ring in the seal's V-shaped

space. The O-ring creates a strong seal at low hydraulic pressure
1 since the O-ring already presses the sealing lips out toward the sealing
surfaces when unloaded. It is just as sensitive to damage as the
V-seal. Examine in the same manner. To remove, use a screwdriver to
prise the seal outward and bend it up (see illustration). It is extremely
important that the screwdriver is always inserted in the V-shape so that
it cannot touch and thereby damage a sealing surface. A mark from
3 a screwdriver on a sealing surface can have a devastating effect and
7
cause major leakage.
6 4
001498
5
6. Screwdriver
7. O-ring
The compressible piston rod seal consists of a solid rubber profile

2
and provides a larger sealing surface than the V-seals. To remove, use
a screwdriver to prise the seal outward and bend it up (see illustration).
1 With this type of seal with sealing surfaces that cover so much of the
3 seal groove, it is particularly important that marks are not made with
the screwdriver.
6
4
5
001499
6. Screwdriver

Support ring and O-ring
Support ring and O-ring

The support ring and O-ring combination is used for sealing between
two fixed surfaces, such as between cylinder barrel and cylinder head.
The purpose of the support ring is to lend rigidity to the O-ring so that it
is not deformed. The O-ring is pressed against the support ring and the
sealing surface by the hydraulic pressure in the cylinder.
3
When the cylinder head is mounted in the barrel: Take extreme care
not to damage the O-ring.
4
2
001506
1
2. O-ring
3. Support ring
Scraper
Scraper
The purpose of the scraper is to scrape the piston rod clean and
øD+10 prevent impurities from entering the cylinder barrel.
1
The scraper must be fitted with a special fitting tool. This tool must
have a greater outer diameter than the scraper so that the press force
against the scraper ceases precisely when the scraper is pressed into
its position. If the scraper were to be pressed in further, the metal
2 capsule would be deformed (see lower illustration), which would impair
the function of the scraper.
4 To prevent the scraper from bottoming in its recess in the cylinder head,
the recess is slightly deeper than the width of the scraper.
3
øD
6
001496
1. Correct assembly tool

2. Scraper, correctly fitted
3. Cylinder head
4. Clearance between scraper and bottom of
cylinder head recess
5. Incorrect assembly tool
6. Deformed scraper

A screwdriver can be used for removal. This must always be applied

1 against the outer edge of the scraper (see illustration). Carefully tap the
screwdriver down between the scraper and the cylinder head and then
2 prise out the scraper. Polish away any damage to the cylinder head.
CAUTION
No tool may be applied from the inside. This could
give rise to burrs on the cylinder head which could in
3 turn damage the piston rod. Burrs may also damage
the piston rod seal when fitting the piston.
001551
1. Screwdriver
2. Scraper
3. Cylinder head
2 On the single-acting V-seal it is always the long side that seals

against the fixed surface and the short side that seals against the
moving surface.
1 To remove, use a screwdriver to prise the seal outward and bend it up
(see illustration). It is extremely important that the screwdriver is always
inserted in the V-shape so that it cannot touch and thereby damage a
sealing surface. A mark from a screwdriver on a sealing surface can
have a devastating effect and cause major leakage.
3
6 4
002370
5
2. Seal pressed out toward cylinder barrel
3. Seal pressed in toward piston
4. Sealing surface, cylinder barrel
5. Sealing surface, piston
6. Screwdriver

The seal must always be fitted as a single assembly together with the
support ring.
Always assemble by hand. No tools should be used as they could

easily damage the surface of the piston.
To facilitate assembly the seal can be heated in hot water to make it

soft.
Lubricate with hydraulic oil.
002950
Double-acting piston seal
Double-acting piston seal

The double-acting seal functions with pressure from both sides, e.g. in
5 4 3 1 6
a steering cylinder.
All of the interior surface of the cylinder barrel is a sealing surface and it
is therefore extremely important that it is completely free from damage.
Exercise caution when fitting the piston in the cylinder barrel, making
sure that the seal is not damaged by the cylinder barrel threads.
2
002951
1. Variable sealing surface to cylinder barrel

2. Fixed sealing surface with piston
3. Guide ring
4. Support ring
5. Piston head
6. Cylinder barrel
Dismantling:
1 Remove guide rings and support rings.
2 Move the seal body over to one side of the sealing groove.
3 Press up the material so that there is a gap between seal and
piston.
4 Without damaging the surface of the piston - cut off the seal with
a knife.
5 Carefully examine the seal to find any damage that could cause
leakage. This will be easier if you bend the seal sharply bit by bit
and feel over the sealing surface with a fingernail.
Assembly:
1 All double-acting piston seals are of similar design: a middle seal
body, then support rings and farthest out guide rings.
2 First fit the seal body, then the support rings and finally the guide
rings - all must be done by hand without tools to avoid damage.

Dismantling the steering cylinders

It can prove extremely difficult to extract the piston rod from the cylinder
barrel on steering cylinders. This is because the O-ring in the cylinder
head fastens in the lock ring groove in the cylinder barrel. It is therefore
best to remove the O-ring before trying to withdraw the piston rod from
the cylinder.
1 Unscrew the end washer at the cylinder head.
2 Unscrew the connecting nipple for the hydraulic hose.
3 Insert the piston rod with piston crown until the O-ring is visible
through the nipple hole.
4 Bend the end of a length of heavy-duty steel wire, piano wire or
similar into the shape of a hook. Use this to snag the O-ring.
5 Pull the O-ring up slightly and hold it with a pair of needle-nose
pliers.
6 Continue to pull the O-ring out through the hole.
7 Hold the O-ring steady and cut it with a knife.
8 Rotate the piston rod while pulling the O-ring out through the hole.
9 Remove the lock ring from the cylinder barrel.
10 Carefully extract the piston rod from the cylinder barrel.
002953

10:46

11:1
11 Common electrics
Contents 11 Common electrics

11 Common electrics ............................................................................................11:3
11.2 Electric protection .......................................................................................... 11:4
11.2.1 Battery disconnector ................................................................................. 11:4
11.2.2 Fuses ........................................................................................................ 11:5
11.2.6 Control breaker ......................................................................................... 11:9
11.3 Batteries....................................................................................................... 11:10
11.3.1 Starter battery ......................................................................................... 11:10
11.4 Alternator ..................................................................................................... 11:12
11.4.1 Alternator................................................................................................. 11:12
11.5 Distribution of electricity ............................................................................... 11:13
11.5.1 Voltage supply ......................................................................................... 11:13
11.5.2 Electrical distribution box......................................................................... 11:22
11.5.3 Control units ............................................................................................ 11:24
11.5.5 Cable harness ......................................................................................... 11:42
11.6 Communication ............................................................................................ 11:45
11.6.1 CAN bus .................................................................................................. 11:45
11.6.2 Redundant CAN bus ............................................................................... 11:48
11.6.3 CAN bus drive-train ................................................................................. 11:51
11.6.6 Communication between PC and machine ............................................. 11:51

11:2

11 Common electrics – Common electrics 11:3
11 Common electrics
Common electrics, general
Electrical functions that are common to several of the machine's main
functions are found under the function common electrics. For example,
voltage feed and CAN bus.

11:4 11 Common electrics – Electric protection
11.2 Electric protection

11.2.1 Battery disconnector
Battery disconnector, description
The starter batteries are connected to the machine's electrical system
via battery disconnector (S1440). The battery disconnector disconnects
all voltage feed from the batteries to the machine's electrical system
except that connected to the 50 A main fuse, see Fuses, description,
page 11:5.
For more information on the starter batteries, see Starter battery,

description, page 11:10
IMPORTANT
Never switch off the voltage with the battery
disconnector when the engine is running. This could
016895
damage the alternator.

The battery disconnector must not be used as control
breaker!
Battery isolator, replacement

2 Open the battery cover.
3 Disconnect the negative cable and then the positive cable from
the battery.
WARNING
Be careful to keep the positive and negative cables
apart to avoid short circuiting.
4 Replace the battery isolator.

016304

11 Common electrics – Fuses 11:5
11.2.2 Fuses
Fuses, description
CAUTION
Never use fuses with amperage that is too high.
Risk of damage or fire in cables!
Follow the instructions on the fuse plate for fuse type
and amperage.
The electrical system has two main circuits (30 and 15-voltage), see
Voltage feed, general, page 11:13. The main circuits are fuse-protected
several times with main fuses, distribution fuses and circuit fuses.
Main fuses
Main fuses
The main fuses splits the machine\qs voltage feed in smaller parts
to maintain as many functions as possible in case of damage in the
cabling.
The machine has two main fuses, 1 x 100 A that is supplied from
the battery disconnector and 1 x 50 A that is supplied directly from
the battery. Together, these two fuses disconnect all electrical power
to the machine.
F9952-1
016239
1 2
Fuses battery box (F9952-1)
1. Main fuse (100A)
2. Main fuse (50A)

11:6 11 Common electrics – Fuses
Distribution fuses
Distribution fuses
The distribution fuses divide the machine's voltage feed in smaller
parts in order to maintain as many functions as possible in the event
of damage in the cable harness.
X500-1 X401-1 The machine's electrical system has distribution fuses in the electronic
box on the frame (6 x 50 A), on the frame (2 x 50 A), at the rear boom
mounting and at the front of the inner boom (2 x 50 A).
F9954-1
F9952-2
016302
F9952-2 Distribution fuses battery voltage

F9954-1 Distribution fuses ignition voltage
X401-1 Distribution fuses attachment

11 Common electrics – Fuses 11:7
Circuit fuses
Circuit fuses
The fuses are grouped in fuse holders located in the electronic box in
the cab, which is located behind the rear panel, and the electronic box
1 on the frame on the left-hand side of the machine.
There is a fuse plate by the electronic box that describes the various
fuses.
2
016303
1. Circuit fuses cab (F9968)

2. Circuit fuses frame (F9958)
Main fuse, replacement

3 Remove the plastic cover.
4 Check and replace the fuses if necessary.
CAUTION
and amperage.
5 Fit the protective cover.

6 Switch on the system voltage with the battery disconnector
F9952-1
016239
1 2
Fuses battery box (F9952-1)
1. Main fuse (100A)
2. Main fuse (50A)

11:8 11 Common electrics – Fuses
Distribution fuse, replacement

Distribution fuses
3 For fuses in the electronic box on the frame: Remove the cover for
X500-1 X401-1 the electronic box on the frame.
CAUTION
and amperage.
6 Fit the protective cover.

F9954-1
F9952-2
016302
F9952-2 Distribution fuses battery voltage

F9954-1 Distribution fuses ignition voltage

11 Common electrics – Control breaker 11:9
Circuit fuse, replacement

1
3 For fuses in the electronic box on the frame: Remove the cover for
the electronic box on the frame.
CAUTION
and amperage.
2 6 Fit the protective cover.

016303
1. Circuit fuses cab (F9968)

2. Circuit fuses frame (F9958)
11.2.6 Control breaker

Control breaker, description
The control breaker is located in the cab on the right dashboard panel,
front section.
See Control breaker voltage, function description, page 11:19.
When the switch is activated, all hydraulic functions are disconnected

and machine speed is limited.
016150
Control breaker placement

11:10 11 Common electrics – Batteries
11.3 Batteries
11.3.1 Starter battery
Starter battery, description
Two series-connected batteries (G9930) are located behind a hatch on
the machine's rear left-hand side (by the fuel tank).
The battery's negative terminal is connected to the frame and the

positive terminal is connected to the battery isolator.
The batteries are charged by the alternator, see Alternator, description,

page 11:12.
WARNING
Battery electrolyte contains corrosive sulphuric acid.
Risk of corrosive injuries! Health hazard!
Use protective glasses and protective gloves when
working with the batteries. Immediately remove any
electrolyte on bare skin. Wash with soap and plenty of
water. If the electrolyte has found its way into your
eyes, rinse immediately with lots of water and contact
a doctor immediately.
016304
WARNING
Risk of explosion!
Personal injury!
During charging, hydrogen gas forms around the
batteries. Sparks could ignite the hydrogen gas,
causing an explosion. Disconnect the battery with the
battery disconnector.
WARNING
Short-circuiting of battery.
Risk of explosion! Fire hazard! Risk of personal injury!
The battery's terminals must not be connected to each
other or to common grounding point (frame).

11 Common electrics – Starter battery 11:11
Starter battery, replacement

2 Disconnect the cables from the battery terminals. Start with the
negative (minus) cable.
3 Replace the batteries.
4 Connect the cables to the battery terminals. Connect the negative
cable last of all.
NOTE
Take great care when reconnecting the cables to prevent short
circuiting.
016304

11:12 11 Common electrics – Alternator
11.4 Alternator
11.4.1 Alternator
Alternator, description
The alternator (G6600) generates current during operation and supplies
this to the batteries. The alternator produces AC current and has an
integrated charge regulator.
The alternator is driven by the engine via a belt. Any errors are
indicated by an error code for the charging system's voltage. Low
battery charge is indicated by the event menu for low battery charge.
Control System 2/XX DIAGNOSE, page 8:31 or 11.4 Alternator 1/XX
014036
Alternator, engine alternative Volvo TAD1360VE

016308
Alternator (engine alternative Cummins QSM11)
Alternator, replacement
See Supplier documentation, engine.

11 Common electrics – Distribution of electricity 11:13
11.5 Distribution of electricity

Distribution of electricity, general
This section describes the distribution of electric power and
communication between the control units.
System communication has three main sections:

• Dual voltage supply of control units, where one voltage supply can
go down while maintaining the diagnosis function.
• Redundant CAN bus communication (one CAN bus loop can go
down without losing system functionality).
See 11.6.2 Redundant CAN bus, page 11:48.
• CAN bus communication for drive train (the drive train has its own
communication system).
See 11.6.3 CAN bus drive-train, page 11:51.
11.5.1 Voltage supply

Voltage feed, general
The machine's components are supplied with voltage at different times
depending on requirements, the machine has the following voltage
feeds:
• Battery voltage (30): see Battery voltage (30), description, page
11:14.
• Ignition voltage (15): see Ignition voltage (15), description, page
11:17.
• Redundant voltage feed: See Redundant voltage feed of control
units, description, page 11:15.
• Control breaker voltage: See Control breaker voltage, description,
page 11:19.
Start-up of electrical systems, description

When the machine is not in use, and no function is switched on, the
machine's electrical system is in a de-energised state, i.e. neither the
power electronics nor control units are energised. When starting the
machine the voltage supply is activated and the redundant CAN bus is
initiated. Start-up is managed by the KCU control unit (D7901). The
first prerequisite in order for the machine to perform the activity is to
first establish the redundant voltage supply for control units and then
establish CAN bus communication to manage the control signals for
functions.
Control units establish communication if any of the following happens.

• Driver's door opens
• Interior lighting comes on
• Warning lamp activates
• Ignition key lock in position I
• Operator in seat

11:14 11 Common electrics – Voltage supply
Start-up
On start-up the following happens.
1. Start-up signal to the KCU control unit (D7901).
2. Control unit KCU (D7901) initiates connection of the redundant
voltage feed, see Redundant voltage feed of control units, function
3. Control unit KCU (D7901) initiates ignition voltage, see Ignition
voltage (15), function description, page 11:17.
4. Control unit KCU (D7901) initiates redundant CAN bus, see
Redundant CAN bus, start-up, page 11:49.
5. Control unit KFU (D7971) initiates CAN bus drive-train, see 11.6.3
CAN bus drive-train, page 11:51.
11.5.1.1 Battery voltage (30)
Battery voltage (30), description

The battery voltage is supplied from the starter batteries when the
battery disconnector is in position I.
Red fuse holder contains circuit fuses for battery voltage. Black fuse
holder contains circuit fuses for ignition voltage. Green fuse holder in
RD1 BK1 GN1 electronic box frame contains circuit fuses that are supplied before
the battery disconnector. Green fuse holder in the cab holds fuses for
RD2 BK2 GN2
special functions and fuses that are supplied with ignition voltage.
RD3 BK3 GN3
RD4 BK4 GN4 Battery power voltage feeds:

RD5 BK5 GN5 • KCU control unit (D7901)
RD6 BK6 GN6 • Starter motor (M6540)
RD7 BK7 GN7 • Ignition switch relay (K3150)
RD8 BK8 GN8 • Start-up functions
• Control breaker relay (S2500)
• Engine
016306
• Transmission
• Radio (A9002)
Circuit fuses battery voltage
A few functions are also supplied with voltage when the battery
disconnector is in position 0 (Fuses GN5-GN8), these are:
• Control unit diesel heater (E6690)
• Control unit RMI (A9110)
• Timer diesel heater (D7440)

11 Common electrics – Voltage supply 11:15
11.5.1.2 Redundant voltage feed of control units
Redundant voltage feed of control units, description

The redundant voltage feed only supplies the control logic and buses
for the control units, and is wholly controlled by Control unit KCU
(D7901). The outputs for the control units remain de-energised and are
only supplied with voltage when the ignition voltage is activated.
The redundant voltage feed for each control unit is independent of

other control units. Control unit KCU (D7901) has four outputs for
voltage feed while other control units have two inputs for redundant
voltage feed. In the event of a malfunction of one voltage feed the
control unit is supplied by the other feed.
When all control units have redundant voltage feed and bus
communication, the system is ready to receive and process signals.
Redundant voltage feed is activated by:

• Switch interior lighting (S1160)
• Switch, flashing hazard lights (S1090)
• Switch, ignition switch (S1500)
• Seat switch (B2300)
• Break contact (opening switch) driver's door left (S2660-LE) or
Break contact (opening switch) driver's door right (S2660-RI)
• Heater cab (E6690)
Redundant voltage feed of control units, function

description
The redundant voltage feed of control units consists of the special
redundant voltage feed and the normal ignition voltage, see 11.5.1.3
Ignition voltage (15), page 11:17.

Battery disconnector In position 1 Battery disconnector, description , page 11:4
1 2 3 4 5 6 7
D1 D2 D3 D4 D7
D5 D6
D8 D11 D12
– +
8 11 12 D14
D7901 D7971 D7972
D9 D10 D13
D7950 D7902 D7911 D7912

016896
9 10 13 14


1 On activation of the Interior lighting switch U = 24 V Lighting system, function description, page
(S1160) a voltage signal is sent to the KCU 9:58
control unit (D7901). D1: Diagnostic menu, see 9.6 Lighting Sys
2 On activation of the Warning light switch U = 24 V Lighting system, function description, page
(S1090) a voltage signal is sent to the KCU 9:58
control unit (D7901). D2: Diagnostic menu, see 9.7 Signalling
3 On turning the ignition key lock switch U = 24 V D3: Diagnostic menu, see 11.5 Distr of
(S1500) to position I a voltage signal is sent Electr 1/XX DIAGNOSE, page 8:81
to the KCU control unit (D7901).
4 On activation of the Seat switch (B2300) a U = 24 V Sensor operator in seat, description, page
voltage signal is sent to the KCU control unit 9:23
(D7901). D4: Diagnostic menu, see 9.3 Seat 1/XX
DIAGNOSE, page 8:58
5 On activation of the driver's door left break U = 24 V D5: Diagnostic menu, see 9.6 Lighting Sys
contact (S2660-LE) or driver's door right 18/XX DIAGNOSE, page 8:71
break contact (S2660-RI) a voltage signal is
sent to the KCU control unit (D7901).
6 On activation of the Cab heater switch U = 24 V Engine heater, description, page 1:33
(E6690) a voltage signal is sent to the KCU D6: Diagnostic menu, see 9.4 Climate
control unit (D7901). System 19/XX DIAGNOSE, page 8:63
7 On activation of the Instep lighting switch U = 24 V D7: Diagnostic menu, see 9.6 Lighting Sys
(S1410) a voltage signal is sent to the KCU 6/XX DIAGNOSE, page 8:68
8 Control unit KCU (D7901) activates the U = 24 V 11.5.3.1 KCU control unit (D7901), page
output for CPU voltage supplying all the 11:25
control units. D8: Diagnostic menu, see 11.5 Distr of
9 Control unit KID (D7950) is supplied with - 11.5.3.3 Control unit, KID (D7950), page
CPU voltage and the control unit starts. 11:29
D9: Diagnostic menu, see 11.5 Distr of
10 Control unit KPU (D7902) is supplied with - 11.5.3.2 KPU control unit (D7902), page
11 Control unit KFU (D7971) is supplied with - 11.5.3.4 KFU control unit (D7971), page
Electr 4/XX DIAGNOSE, page 8:81.
12 Signal to Control unit KFU-2 (D7972) - 11.5.3.5 Control unit KFU-2 (D7972), page
activates CPU power input. 11:33.
13 Control unit KAU (D7911) is supplied with - 11.5.3.8 Control unit KAU (D7911), page
14 Control unit KAU-2 (D7912) is supplied with - 11.5.3.9 Control unit KAU-2 (D7912), page
CPU voltage and the control unit starts. 11:40.

11.5.1.3 Ignition voltage (15)

Ignition voltage (15), description
The ignition voltage supplies most of the functions in the machine,
except for the components in the working hydraulics.
The ignition voltage is supplied by Relay ignition voltage (K3150) that

routes voltage from the battery on activation. Relay ignition voltage
RD1 BK1 GN1 (K3150) is controlled by Control unit KCU (D7901)
RD2 BK2 GN2 The green fuse holder in the cab is divided between fuses GN1-GN4,
RD3 BK3 GN3 which are fuses for special functions, and fuses GN5-GN8, which are
RD4 BK4 GN4
supplied with ignition voltage.
RD5 BK5 GN5 Ignition voltage is activated by:
RD6 BK6 GN6 • Switch, ignition switch (S1500) to position I
RD7 BK7 GN7 • Switch, flashing hazard lights (S1090)
RD8 BK8 GN8
• Cab heater (E6690) (diesel heater)
016307
Circuit fuses ignition voltage
Ignition voltage (15), function description

Battery disconnector In position 1 Battery disconnector, description , page 11:4
Redundant voltage feed Activated Redundant voltage feed of control units, function
description, page 11:15
Redundant CAN bus Communication established Redundant CAN bus, description, page 11:48
D16
D7940
– + 1 2 3
D7 16
D3 D15
D1 5 D7930
6 15
D2
D10 D11
D790 1 D79 71 D7972
4, 7 10, 14 11
8 9 12 13
D79 50 D79 02 D79 11 D7912
D8
016897
D9 D12 D13

1 Ignition key lock switch (S1500) is turned to U = 24 V Cab overview, page 9:5
position I where after a voltage signal is sent D1: Diagnostic menu, see 11.5 Distr of
to KCU control unit (D7901). Electr 1/XX DIAGNOSE, page 8:81
2 Warning lamp activates where after a U = 24 V Lighting system, function description, page
voltage signal is sent to the KCU control unit 9:58
(D7901). D2: Diagnostic menu, see 9.7 Signalling


3 Cab heater (E6690) (diesel heater) is U = 24 V D3: Diagnostic menu, see 9.4 Climate
activated, on which a voltage signal is sent System 19/XX DIAGNOSE, page 8:63
to Control unit KCU (D7901).
4 KCU control unit (D7901) voltage feeds the U = 24 V 11.5.3.1 KCU control unit (D7901), page
Ignition voltage relay (K3150). 11:25
5 Ignition voltage relay (K3150) supplies U = 24 V -
voltage to fuse holder in the cab electrical
distribution box and in the frame electrical
distribution box.
6 The fuses feed voltage to control units, U = 24 V -
relays, solenoid valves and other electronic
components.
7 Control unit KCU (D7901) is supplied with U = 24 V 11.5.3.1 KCU control unit (D7901), page
ignition voltage and activates outputs for 11:25
requested functions. D8: Diagnostic menu, see 11.5 Distr of
8 Control unit KID (D7950) is supplied with U = 24 V 11.5.3.3 Control unit, KID (D7950), page
ignition voltage and shows information from 11:29
the machine's subsystems. D9: Diagnostic menu, see 11.5 Distr of
9 Control unit KPU (D7902) is supplied with U = 24 V 11.5.3.2 KPU control unit (D7902), page
10 Control unit KFU (D7971) is supplied with U = 24 V KFU control unit (D7971), description, page
11 Control unit KFU-2 (D7972) is supplied with U = 24 V 11.5.3.5 Control unit KFU-2 (D7972), page
ignition voltage and activates outputs for 11:33.
12 Control unit KAU (D7911) is supplied with U = 24 V 11.5.3.8 Control unit KAU (D7911), page
13 Control unit KAU-2 (D7972) is supplied with U = 24 V 11.5.3.9 Control unit KAU-2 (D7912), page
ignition voltage and activates outputs for 11:40.
14 Control unit KFU (D7971) sends signals U = 24 V KFU control unit (D7971), description, page
for ignition voltage to Control unit engine 11:31
(D7940) and Control unit transmission
(D7930)
15 Control unit transmission (D7930) is started U = 24 V 11.5.3.7 Control unit, transmission (D7930),
and establishes communication on CAN bus page 11:37
drive-train D15: Diagnostic menu, see 2.8 Control
System 2/XX DIAGNOSE, page 8:35
16 Control unit engine (D7940) is started and U = 24 V 11.5.3.6 Control unit, engine (D7940), page
establishes communication on CAN bus 11:35
drive-train D16: Diagnostic menu, see 2.8 Control
System 2/XX DIAGNOSE, page 8:35

11.5.1.4 Control breaker voltage

Control breaker voltage, description
Control breaker voltage supplies functions that require control breakers
e.g. working hydraulics.
Control breaker voltage is disconnected with Switch control breaker

(S2500). Control breaker voltage is controlled via the CAN bus by
Control unit KPU (D7902).
Conditions for activating control breaker voltage are:

• Start key in position I.
• Ignition voltage (15) activated.
016314
• Switch control breaker (S2500) is not activated.
Switch safety switch (S2500)
Control breaker voltage, function description

Redundant voltage feed Activated Redundant voltage feed of control units, function description,
page 11:15
Ignition voltage Activated Ignition voltage (15), function description, page 11:17
Redundant CAN bus communication 11.6.2 Redundant CAN bus, page 11:48
established
1, 4
D1
17 2, 5
D7901 D7950 D7902
D7971 D7972 D7911 D7912

3, 6, 14 3, 8 3, 10 3, 12
D7940
15
D7930 7 9 11 13 016144
16

1 Control breaker passive Control breaker in Control breaker, description, page 11:9
Switch, control breaker (S2500) sends home position U = 24 V D1: Diagnostic menu see 11.5 Distr of
voltage signals to Control unit KPU (D7902). Electr 24/XX DIAGNOSE, page 8:86
2 Control unit KPU (D7902) sends Control Checked by the control 11.5.3.2 KPU control unit (D7902), page
breaker passive on the CAN bus. system; error shown 11:27
with error code.
3 Control unit KFU (D7971), Control unit Checked by the control 11.5.3.4 KFU control unit (D7971), page
KFU-2 (D7972) , Control unit KAU system; error shown 11:31
(D7911) and Control unit KAU-2 (D7912) , with error code. 11.5.3.8 Control unit KAU (D7911), page
allow the connections for PWM safety group 11:38
1 and PWM safety group 2 to be activated.
11.5.3.9 Control unit KAU-2 (D7912), page
11:40
4 Control breaker activated Control breaker Control breaker, description, page 11:9
Switch, control breaker (S2500) stops depressed: U = 0 V D1: Diagnostic menu see 11.5 Distr of
sending voltage signals to Control unit KPU Electr 24/XX DIAGNOSE, page 8:86
(D7902).


5 Control unit KPU (D7902) sends Control Checked by the control 11.5.3.2 KPU control unit (D7902), page
breaker activated via the CAN bus. At the system; error shown 11:27
same time, Control unit KPU (D7902) sends with error code.
a request for the functions that are acted on
by the control breaker.
6 Control unit KFU (D7971), activation of Checked by the control 11.5.3.4 KFU control unit (D7971), page
connections connected to PWM safety system; error shown 11:31
group 1, PWM safety group 2 and PWM with error code. D6: Diagnostic menu see 11.5 Distr of
safety group 3. Electr 25/XX DIAGNOSE, page 8:87,
7 Functions connected to one of the safety I = 0 mA 11.5 Distr of Electr 26/XX DIAGNOSE,
groups are interrupted: page 8:87, 11.5 Distr of Electr 27/XX
DIAGNOSE, page 8:87, 11.5 Distr of Electr
• Joystick control/mini-wheel 28/XX DIAGNOSE, page 8:87 and 11.5
• Lift or lower Distr of Electr 29/XX DIAGNOSE, page
8:88
• Extension
• Support jacks
• Hydraulic sliding cab
• Hydraulic cab lift
8 Control unit KFU-2 (D7972), activation of Checked by the control 11.5.3.4 KFU control unit (D7971), page
connections connected to PWM safety system; error shown 11:31
group 1, PWM safety group 2 and PWM with error code. D8: Diagnostic menu, see 11.5 Distr of
safety group 3. Electr 30/XX DIAGNOSE, page 8:88,
9 Functions connected to one of the safety I = 0 mA 11.5 Distr of Electr 31/XX DIAGNOSE,
• Support jacks 33/XX DIAGNOSE, page 8:89 and 11.5
Distr of Electr 34/XX DIAGNOSE, page
8:89
10 Control unit KAU (D7911) interrupts I = 0 mA 11.5.3.8 Control unit KAU (D7911), page
activation of connections connected to PWM 11:38
safety group 1, PWM safety group 2 and D10: Diagnostic menu, see 11.5 Distr
PWM safety group 3. of Electr 40/XX DIAGNOSE, page 8:90,
11 Functions connected to one of the safety 11.5 Distr of Electr 41/XX DIAGNOSE,
• Side shift 43/XX DIAGNOSE, page 8:91, 11.5 Distr of
• Spreading (positioning) Electr 44/XX DIAGNOSE, page 8:91
• Rotation
• Tilt
• Levelling
• Twistlocks
• Functions on accessory attachment
12 Control unit KAU-2 (D7912) interrupts I = 0 mA 11.5.3.9 Control unit KAU-2 (D7912), page
activation of connections connected to PWM 11:40
safety group 1, PWM safety group 2 and D12: Diagnostic menu, see 11.5 Distr
PWM safety group 3. of Electr 35/XX DIAGNOSE, page 8:89,
13 Functions connected to one of the safety 11.5 Distr of Electr 36/XX DIAGNOSE,
• Levelling 38/XX DIAGNOSE, page 8:90, 11.5 Distr of
• Overheight legs
• Lift jacks
• Functions on accessory attachment
14 Control unit KFU (D7971) sends request for Checked by the control 11.5.3.4 KFU control unit (D7971), page
speed limitation on CAN bus drive-train. system; error shown 11:31
with error code.


15 Control unit, engine (D7940) limits the Checked by the control 11.5.3.6 Control unit, engine (D7940), page
engine speed. system; error shown 11:35
with error code.
16 Control unit transmission (D7940) gear Checked by the control 11.5.3.7 Control unit, transmission (D7930),
range. system; error shown page 11:37
with error code.
17 Control unit KID (D7950) shows Event Checked by the control 11.5.3.3 Control unit, KID (D7950), page
menu, control breaker. system; error shown 11:29
with error code.
11.5.1.5 Voltage converter
Voltage converter, description

The voltage converter (U9010) is located under a protective cover to
the left behind the operator's seat.
The voltage converter converts 24 V to 12 V. 12 V power is available

for accessories through a connector in the cab electrical distribution
box and through two outlets in the cab.
The voltage converter is connected via four flat-pin terminals

XU9010:1-4
XU9010:1 24V primary side
XU9010:2 and XU9010:3 Ground
XU9010:4 12V secondary side
016167
Placement voltage outlet in the cab
Voltage converter, replacement

2 Remove the covers behind the driver's seat.
3 Mark up and disconnect the cable harness from the converter.
4 Replace the voltage converter.
5 Connect the cable harness in accordance with the marking.
016166
Placement of the voltage converter

11:22 11 Common electrics – Electrical distribution box
11.5.2 Electrical distribution box

11.5.2.1 Electrical distribution box, cab
Electrical distribution box, cab, description
1 2 Electronic box, cab, is mounted on the rear wall of the cab, on the
left-hand side. Located there are:
• KCU control unit (D7901).
• Fuses.
• Connectors
8 3
• Relays.
4 • Voltage converter 24 V to 12 V
• Connector service contact (X050), see Communication between
PC and machine, description, page 11:51.
016132
7 6 5 • Connector customer accessories (X046) see below.
1. Terminal, frame-ground connections

2. Fuses
3. Connector X046
4. Connector X050
5. Power connection to KCU control unit (D7901)
6. Connectors KCU control unit (D7901)
7. KCU control unit (D7901)
8. Connectors
Customer accessory connector (X046)
Customer accessory connector (X046)

Connector customer accessories (X046) is intended for connecting the
3 2 1 customer's own accessories so that they can be connected safely and
so that they do not interfere with other functions on the machine. The
4 connector is the type 9-pin Universal Mate-n-lock. For part number
see Spare parts catalogue.
5 The connector X046 contains the following connections:
1. 24 V ignition voltage 10 A
016916
6 9 8 7
2. 24 V, battery voltage 10 A
9-pin Universal Mate-n-lock, pin numbers
3. Ground
4. 12 V, ignition voltage 20 A, when the machine is equipped with
a voltage converter
5. Ground
6. Ground
7. Empty
8. Empty
9. Empty

11 Common electrics – Electrical distribution box 11:23
11.5.2.2 Electrical distribution box frame
Electrical distribution box, description

1. Circuit fuses battery voltage (F9958-RD)
1 2 3 4
5 2. Circuit fuses ignition voltage (F9958-BK)
6 3. Circuit fuses ignition voltage (F9958-GN)
7 4. Diagnostic outlet J1939/Cummins
5. Diagnostic outlet Volvo
10
6. Diagnostic outlet transmission ZF
7. Control unit, transmission (D7930)
8. Distribution fuses ignition voltage (F9954-1)
9. Distribution fuses battery voltage (F9952-2)
9
10. Relay ignition voltage (K3150)
8
The electronic box is fitted on the side of the machine. Also located
there are:
• Fuses
• Outlet for programming Control unit, transmission (D7930)
• Distribution fuses
016305
• Transmission control unit

• Power relays for voltage feed to the machine's functions

11:24 11 Common electrics – Control units
11.5.3 Control units

Control units, location
1 2 3 4
11
016923
10 9 8 7 6
1. 11.5.3.8 Control unit KAU (D7911), page 11:38 8. 11.5.3.6 Control unit, engine (D7940), page 11:35
2. 11.5.3.3 Control unit, KID (D7950), page 11:29 engine alternative Cummins QSM11
3. 11.5.3.2 KPU control unit (D7902), page 11:27 9. 11.5.3.5 Control unit KFU-2 (D7972), page 11:33
4. 11.5.3.1 KCU control unit (D7901), page 11:25 10. 11.5.3.4 KFU control unit (D7971), page 11:31
5. 11.5.3.7 Control unit, transmission (D7930), page 11:37 11. 11.5.3.9 Control unit KAU-2 (D7912), page 11:40
6. Control unit SRC (UDS)
7. 11.5.3.6 Control unit, engine (D7940), page 11:35
engine alternative Volvo TAD1360VE

11 Common electrics – Control units 11:25
11.5.3.1 KCU control unit (D7901)
KCU control unit (D7901), description

KCU control unit (D7901) is the central control unit of the control
system. KCU control unit (D7901) sends activation signals to other
units, and controls and monitors their functions. It administrates work in
the control unit network.
KCU control unit (D7901) controls the redundant power supply and
manages communication via the redundant CAN bus. The KCU control
unit (D7901) receives, via KPU control unit (D7902), signals from the
4
switches in the cab.
The cab control unit has two LEDs that indicate the control unit's
function.
LED Status Description

3
Green Short flash The control unit is voltage fed by CPU
2 power.
017412
(1 Hz, 0.1 s)
1
Long flash Ignition key lock switch is in position I
1. Red LED (1 Hz, 0.5 s) and the Ignition voltage is switched on.
2. Green LED
Alternating If both CPU power and ignition power
3. Power supply connections short flash/long are switched on the LED flashes
flash with both short and long pulses
4. Connectors
simultaneously.
Lit The control unit is voltage fed.
Ignition key lock switch is in position I.
The display is lit and the system is
ready for the start of machine functions.
Red Short flash RedCAN wiring error on the unit.
(1 Hz, 0.1 s)
Long flash In the event of active error.
(1 Hz, 0.5 s)
Lit No CAN communication with other
control units, BusOff or Driver Error.
Green/red LED microcomputer start-up program

Green Flashes (2.5
Hz)
Unit with interrupted download.
Red Flashes (2.5
Hz)
Green Flashes (10 Hz) Unit has initiation error in the flash
loader and no application software is
Red Flashes (10 Hz) loaded.
Green Flashes
Download of HEX file (program flash).
Red Out
Green Lit
Download in progress (erase sector).
Red Out
Green Out Download in progress (erase sector
Red Out ready).
Green Out Download in progress (download

Red Out ready).

KCU control unit (D7901), replacement

1 Connect the Kalmar Service Tool to the machine and select
"Create Machine Image". This creates a saving of the machine's
settings and operating data.
1 2 3 Remove the plastic covers over the door pillar and rear panel.
4 Carefully fold out the rear panel.
015796
1. Rear panel
4 5 Disconnect the cable harness from the control unit.

The two power cables are fitted with screws under cable seals.
The multi-pole connectors are fitted with a screw in the centre
of each connector.
6 Remove the attaching bolts and the control unit.
7 Check that the new control unit corresponds with the machine's
forklift number (Z-number).
8 Fit in the reverse order. Make sure that the correct torque is
used when tightening screws and nuts, take special care with the
fastening of power cables, which can break with a too large torque.
"Repair Machine Wizard". This programs the new control unit and
resets the settings.
10 Calibrate the following functions:
015797
• Hydraulic sliding cab, see Hydraulic sliding cab, calibration,

page 9:93.
1 2 3
1. Power cables
2. Connectors
3. KCU control unit (D7901)
4. Screws

11.5.3.2 KPU control unit (D7902)
KPU control unit (D7902), description

KPU control unit (D7902) manages the functions of most switches in
the cab, such as the multi-function lever, direction indicator switches,
start button. It also manages the key panel for the control system and
its panel for warning and indicator lights.
1 function.
2
016044
(1 Hz, 0.1 s) power.
1. Green LED Long flash Ignition key lock switch is in position I

(1 Hz, 0.5 s) and the Ignition voltage is switched on.
2. Red LED
short flash/long are switched on the LED flashes
simultaneously.
(1 Hz, 0.1 s)
(1 Hz, 0.5 s)

Green Flashes (2.5
Hz)
Red Flashes (2.5
Hz)
Green Flashes
Red Out
Green Lit
Red Out
Red Out ready).

Red Out ready).

KPU control unit (D7902), replacement

1 4 Open the cover.
015799
2
1. Screws
2. Cover
5 Disconnect the connectors.

6 Unscrew the nuts.
7 Replace the control unit.
1 forklift number (Z-number).
9 Fit in the reverse order. Check that all connectors are properly
inserted and all the pins are fitted in place in the connectors.
015798

2 3 • Joystick control, see Lever steering, calibration, page 5:7.
1. Nut
2. KPU control unit (D7902)
3. Connectors

11.5.3.3 Control unit, KID (D7950)
KID control unit (D7950), description

Control unit KID (D7950) displays to the operator information sent by
the control system, such as speed, in the form of messages, status,
error indications, etc.
There is an indicator light for active errors on the steering panel, which
comes on when serious errors exist in the control system. Error codes,
event menus and information are shown on the display.
See the operator's manual for detailed information about the display.
016045
KID control unit (D7950), replacement

1 3 Loosen the clamp and angle out the KID control unit.
2
015793
1. Control unit KID

2. Clamp

015794

5 Disconnect the connectors.

6 Replace the control unit.
7 Fit in the reverse order. Check that all connectors are properly
inserted and all the pins are fitted in place in the connectors.
015795

11.5.3.4 KFU control unit (D7971)
KFU control unit (D7971), description

KFU control unit (D7971) manages input data from sensors and sends
control signals to relays and solenoid valves for among others start-up,
hydraulic functions, parking brake, fans, central lubrication and lighting.
The control unit also acts as an interface to the CAN bus drive-train.
The control unit is fitted on the inside of the left-hand frame member
above the drive axle.
4 The cab control unit has two LEDs that indicate the control unit's
function.

3
2 Long flash Ignition key lock switch is in position I
017412
1 (1 Hz, 0.5 s) and the Ignition voltage is switched on.
1. Red LED Alternating If both CPU power and ignition power

2. Green LED flash with both short and long pulses
3. Power supply connections simultaneously.
4. Connectors Lit The control unit is voltage fed.
(1 Hz, 0.1 s)
(1 Hz, 0.5 s)

Green Flashes (2.5
Hz)
Red Flashes (2.5
Hz)
Green Flashes
Red Out
Green Lit
Red Out
Red Out ready).

Red Out ready).

KFU control unit (D7971), replacement

3 Remove the hoods over the engine compartment.
4 Disconnect the cable harness from the control unit.
of each connector.
• Load sensor, see Load sensors, calibration, page 8:13.
7:17.

11.5.3.5 Control unit KFU-2 (D7972)
Control unit KFU-2 (D7972), description
Control unit KFU-2 (D7972) processes input data from sensors and
sends control signals to relays and solenoid valves for e.g. support
jacks.
The control unit is fitted on the inside of the left-hand frame member
above the drive axle.
4
function.

3 power.
(1 Hz, 0.1 s)
2
017412
1 Long flash Ignition key lock switch is in position I

(1 Hz, 0.5 s) and the Ignition voltage is switched on.
1. Red LED
2. Green LED short flash/long are switched on the LED flashes
3. Power supply connections flash with both short and long pulses
simultaneously.
4. Connectors
(1 Hz, 0.1 s)
(1 Hz, 0.5 s)

Green Flashes (2.5
Hz)
Red Flashes (2.5
Hz)
Green Flashes
Red Out
Green Lit
Red Out
Red Out ready).

Red Out ready).

Control unit KFU-2 (D7972), replacement

of each connector.

11.5.3.6 Control unit, engine (D7940)
Control unit, engine, description (engine alternative

Volvo TAD1360VE)
Control unit, engine, (D7940) is part of drive-train control and handles
1 engine function, fuel injection, etc.
Control unit engine (D7940) is connected to CAN bus drive-train,

2
together with the Control unit transmission (D7930) that is connected to
Control unit KFU (D7971). In turn, Control unit KFU (D7971) forwards
3 drive-train information to other units.
The control unit is fitted on the engine has no function keys or display.
All functions are controlled via the CAN bus and an external control
system.
007424
The diagnostic socket for communication directly with the engine via the
Engine control unit diagnostic tool is located in electronic box, frame, see Communication
1. Cooling duct for control unit (fuel) between PC and machine, description, page 11:51.
2. Connector A (black) The control unit monitors the following values in order to optimise
3. Connector B (grey) engine performance.
• engine speed
• camshaft position
• boost pressure
• charge air temperature
• coolant temperature
• oil pressure
• oil temperature
• oil level
• crankcase pressure
• water in fuel
• fuel pressure
• coolant level
• AdBlue temperature
• Control unit SCR (UDS)
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the
correct fuel volume and to check the condition of the engine.

Control unit, engine, description (engine alternative

Cummins QSM11)
1 2 3
Control unit, engine, (D7940) is part of drive-train control and handles
engine function, fuel injection, etc.
Control unit engine (D7940) is connected to CAN bus drive-train,

together with the Control unit transmission (D7930) that is connected to
drive-train information to other units.
The control unit is fitted on the engine has no function keys or display.
007423 All functions are controlled via the CAN bus and an external control
system.
1. Connector OEM The diagnostic socket for communication directly with the engine via the
diagnostic tool is located in electronic box, frame, see Communication
2. Connector Actuator
between PC and machine, description, page 11:51.
3. Connector Sensor
The control unit monitors the following values in order to optimise
engine performance.
• engine speed
• boost pressure
• charge air temperature
• coolant temperature
• oil pressure
• oil temperature
• coolant level
• water in fuel
• air pressure
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the
correct fuel volume and to check the condition of the engine.
Control unit, engine, replacement

See supplier documentation, engine.

11.5.3.7 Control unit, transmission (D7930)
Control unit, transmission, description

Control unit, transmission (D7930) is part of drive-train control and
handles transmission function, selection of gear at load and engine
speed, etc.
Control unit, transmission (D7930) is connected to CAN bus drive-train,

together with the Control unit engine (D7940) that is connected to
drive-train information to other units.
The diagnostic socket for communication directly with the transmission

via the diagnostic tool is located in electronic box, frame, see
Communication between PC and machine, description, page 11:51.
Control unit, transmission (D7930)
Control unit, transmission, replacement

2 Open the cover lid on electronic box, frame.
3 Undo the outer attaching bolts for Control unit transmission
(D7930) and leave the bolts in place.
4 Lift up the intermediate plate so that the rear of the control unit is
visible.
Control unit, transmission (D7930)
5 Disconnect the cable harness from Control unit, transmission

(D7930).
6 Remove the inner attaching bolt and remove the control unit.
7 Fit the new the control unit and fit the rear attaching bolt.
Ensure that the outer screws guide into the grooves on the control
unit.
8 Connect the cable harness to Control unit transmission (D7930).
9 Lift the intermediate wall into place.
10 Tighten the outer attaching bolts for Control unit transmission
(D7930).
12 Calibrate the transmission; see Transmission, calibration, page
2:17.

11.5.3.8 Control unit KAU (D7911)
Control unit KAU (D7911), description

Control unit KAU (D7911) processes input data from sensors and
sends control signals to lights and solenoid valves on the attachment.
The control unit is fitted by Control valve attachment on the rear section
of the attachment.
function.
4

3 and the Ignition voltage is switched on.
(1 Hz, 0.5 s)
2
017412

1 short flash/long are switched on the LED flashes
1. Red LED
simultaneously.
2. Green LED
3. Power supply connections
4. Connectors The display is lit and the system is
(1 Hz, 0.1 s)
(1 Hz, 0.5 s)

Green Flashes (2.5
Hz)
Red Flashes (2.5
Hz)
Green Flashes
Red Out
Green Lit
Red Out
Red Out ready).

Red Out ready).

Control unit KAU (D7911), replacement

of each connector.
Control unit KAU (D7911)
1. Power cables used when tightening screws and nuts, take special care with the
2. Multi-pole connectors
3. Attaching bolts

11.5.3.9 Control unit KAU-2 (D7912)
Control unit KAU-2 (D7912), description
Control unit KAU-2 (D7912) processes input data from sensors

and sends control signals to solenoid valves on the attachment for
controlling the combi attachment.
function.
4

3 and the Ignition voltage is switched on.
(1 Hz, 0.5 s)
2
017412
1 Alternating If both CPU power and ignition power

1. Red LED flash with both short and long pulses
simultaneously.
2. Green LED
3. Power supply connections
4. Connectors
(1 Hz, 0.1 s)
(1 Hz, 0.5 s)

Green Flashes (2.5
Hz)
Red Flashes (2.5
Hz)
Green Flashes
Red Out
Green Lit
Red Out
Red Out ready).

Red Out ready).

Control unit KAU-2 (D7912), replacement

of each connector.

11:42 11 Common electrics – Cable harness
11.5.5 Cable harness

Cables, description
The cables are drawn in a cable harness along the side of the frame
and held in place with straps, belts and rubber clamps.
There are very few joints in the cables between the consumers and the
fuse box. The intention is to reduce the risk of faults.
When working on the machine, the following points must be followed in

order to maintain the function and safety of the machine:
• Disconnect the voltage with the battery disconnector or by
detaching the negative terminal from the batteries before working
on the electrical system. Note that there are functions that are
supplied directly from the battery.
• A cable harness that is exposed or replaced must be routed and
clamped in the same way as from the factory. The routing and
clamping of the cable harness are fully tested, and deviation from
this may result in damage to the machine or cable harness.
• Never clamp a cable harness to fuel pipes, fuel hoses, hydraulic
pipes or hydraulic hoses.
DANGER
Incorrect clamping of a cable harness.
Fire hazard
Never clamp a cable harness to fuel pipes, fuel hoses,
hydraulic pipes or hydraulic hoses. Chafing damage
may result in leakage, short circuit and fire.
• Never route the cable harness so that it runs over sharp edges
or where it is exposed to radiant heat from hot components or
exhaust gases.
• Make it a habit to inspect the cable harness in conjunction with
repairs. Repair damaged cable harnesses immediately to avoid
bigger problems.
• When repairing the cable harness, use the intended tools for
separating connectors and crimping the contacts.
IMPORTANT
AdBlue on wiring.
be replaced.

11 Common electrics – Cable harness 11:43
Cable harness, splicing points

Connectors in the machine are numbered in series according to
X001 - X199 X400 - X499
location in the machine.
Connectors that connect to a component are numbered as the

component but with an X in front, for example XS1500 for the connector
that connects to Ignition switch (S1500).
017401
X500 - X599
X200 - X399

11:44 11 Common electrics – Cable harness
Location of joints in the cable harness
Location of joints in the cable harness

Shown below is the approximate location of the connectors that join
different parts of the cable harness and branching points (splice) in
the cable harness.
All branching points in the cable harness are extended in connectors

with strappings, contact with strappings is unique to each branching
point and must not be mixed up.
DANGER
Each branching point has a contact with strappings
whose coupling is unique. If the contacts are
connected in the wrong location, the machine's
functions may be activated incorrectly.
Extreme danger!
Never use strappings to change round contacts for
troubleshooting purposes, and always ensure that
a detached contact is reconnected to the correct
connector.
X237 X210, X228, X278

X090R X090L X400A,
X400B,
X401,
X402,
X055, X030-0041 X403
X056
X029 X098
X054, X099
X060, X045-X050 X276
X061
X200, X238-X240 X222, X207, X209
X098, X099
X269, X247, X255 X211, X229,
X272 X256, X273 X241-X243, X246,
X252-X254, X257, X271
X503A, X504, X560-1 X503B,
X567, X571 X560-2 X566
X572
X501A, X501B
X507A, X507B
X500-10, X500-20
X561, X562, X563,
X564, X565, X568, X573
017402
X574 X569

11 Common electrics – Communication 11:45
11.6 Communication
Communication, general
The machine communications are managed by a CAN bus system. The
CAN bus system consists of control units connected into a network.
The idea of a network is to share information. Signal values a re sent

to the control unit, which for example, is connected to a sensor, other
control units can use the signal for their functions.
The network consists of control units and segments. Segments are the
CAN bus between the control units.
11.6.1 CAN bus

CAN bus, description
1 2 Communication between the control units takes place using so-called

"CAN buses" (Controller Area Network) based on the ISO 11898
standard and CAN specification 2.0B.
120 ohm 120 ohm

The CAN bus is a fast control bus with logical hardware circuits. A
simple technology that is highly reliable (low error frequency), which is
a requirement for control signals to be able to regulate systems based
on varying conditions and requirements.
5 5 CAN specifies:
• that the signal traffic is carried by "twisted pair" cables.
3
• that termination resistors (position 1) are necessary (adapted to
4 cables' impedance) so that the pulse train (position 4) should
2 obtain a sharp signal.
U [V]
• that the signal valve is given as the potential difference between

the cables, CAN + and CAN - (position 2 and 3).
3
• form of signal messages.
000026
t [S]
Messages are sequential and signal is high (voltage

high) or low (voltage low).
1. Termination resistor (120 ohm)
2. CAN + (voltage high)
3. CAN - (voltage low)
4. Pulse
5. Control unit

11:46 11 Common electrics – CAN bus
Message
Message
There are two types of messages:
A
• CAN Standard, has identity field of 11 bits
• CAN Extended, has identity field of 29 bits
B C D E F G CAN works in messages sent in frames of 8 bytes (64 bits). A complete
000027
message is approx. 100 bits long. The illustration depicts how a
t [S] message is structured.
Messages are sequential and signal is high (voltage Start bit (B)
high) or low (voltage low).
A. Length message Indicates that the transmission of a frame, i.e. a message, is now
beginning.
B. Start bit
Identity field (C)
C. Identity field/Priority
D. Control field (length of data segment) Indicates what kind of information the message contains, e.g.
E. Data segment measurement information on engine speed.
F. Checksum for error detection Does not indicate address to control unit. CAN does not work with
G. Acknowledge bit addressing. All control units receive messages and send them on.
Control field (D)
Indicates how the length of the data segment that follows.
Data segment (E)
Contains the information to be conveyed to control units in the network.
Checksum for error detection (F)
Calculates a checksum for the message. This makes it possible for the
receiving control unit to detect errors in the sent message.
Acknowledge (G)
The transmitting control unit sets a bit to logical one (1) when the
message is sent. The first control unit to receive the message sends it
on and sets the bit to logical zero (0).

11 Common electrics – CAN bus 11:47
Communication
Communication
The CAN network consists of control units and segments. The segment
(bus) is a twisted pair cable that leads CAN + and CAN - signal levels
from control unit to control unit.
Each control unit measures the potential difference of its two inputs.
3,5 V The potential difference generates logical zero and logical one. The
illustration depicts an approved interval according to the standard for
potential levels. CAN + has a recommended value of 3.5 V and CAN
- has 1.5 V. As a worst case scenario, the potential difference can be
U [V]
0,5 V only 0.5 V and still be approved. In practice, a potential difference of

2 V is recommended for reliable communication.
Pulse trains can only be observed using an oscilloscope, not with an

1,5 V analogue or digital multimeter.
When a message is sent, all control units in the network listen.

Messages are saved in the control unit and relevant information is
processed. The control unit that receives the message first confirms
receipt (sets an acknowledge bit). The transmitting control unit then
000028
t [S] knows that the message has been received by at least one control unit.
Potential levels CAN + and CAN - One control unit at a time sends the message. Other control units listen
and wait until the bus is available. If two messages are to be sent
simultaneously then the sending of the message with the lowest priority
(highest value in identity field) is concluded. This means that messages
do not need to be re-sent in the event of a communication conflict but
only in the event of a bus error (erroneous message).
The CAN bus exchanges around 100 messages per second in the
network.
Different bus systems can be used e.g. random sending or primary

(master) / secondary (slave).
HLP High Layer Protocol

CAN only specifies messages and how communication shall take
place, i.e. one protocol. In order to manage the network the CAN
protocol needs to be supplemented by a HLP which specifies:
• flow control
• transport of data above a length of 8 bits in 8 bit messages
(division)
• how control units are addressed in the network
• how bits in the message's data field should be interpreted

11:48 11 Common electrics – Redundant CAN bus
11.6.2 Redundant CAN bus

Redundant CAN bus, description
Redundant CAN bus means that each control unit has two connections
D7901 N R D7971 N R D7972 N
for communication, CAN-N (normal) and CAN-R (redundant). The CAN
R Nod 1 Nod 2 Nod 3
bus is connected in series between the control units. This means the
R
D7912 CAN bus can handle the loss of a segment. If several segments fail
N Nod 6 then one or several of the control units lose contact with the network
N and work independently, but usually with limited capacity to perform
016309
D7950 R N D7902 R N D7911 R their function. The signals can be checked with diagnostic menu.
Nod 12 Nod 11 Nod 7
The network is based on a node being central, in this case DynRedCAN

King KCU D7901, and the governing unit (master). This node has
the lowest node number. Other nodes in the network are secondary
(slaves) and manages the dedicated areas, e.g. hydraulic unit.
CAN bus faults are indicated with an error code and a warning in the
display. If several CAN bus segments are faulty, the system only shows
an error code for the first faulty out segment. The machine can still be
run, in some cases with a limited function.
A condition for communication is that the ignition voltage is active.
The following occurs:

• Most suitable route for an enclosed communication system is
analysed.
• Communication is established segment for segment.
NOTE
The number of active segments depends on the number of control
units that are active in the machine in question, which depends on
the machine's equipment level (option).
• Termination resistors in the control nodes ensure communication

segment by segment. This is indicated as a rapid clicking sound
when starting (key to position I in the ignition key lock) that can be
heard in the operator's station.
• When all nodes and segments have closed loops then the
communication is established in the system.
The redundant CAN bus can handle the loss of a segment. The link
is analysed during start-up and continuously during operation. If a
segment is incorrect, the message is sent another way. If several
segments are lost, one or more control units lose communication
and work independently, often with significantly limited functionality.
CAN bus faults are indicated with an error code and a warning in the
display. The communication loop can be disrupted by cable damage
for example, and then communication is established via an alternative
route. Open circuits and errors are shown in the diagnostic menus for
RedCAN, diagnostic menu 1 – 9
11.6 Communication 1/XX, page 8:92, 11.6 Communication 2/XX,

page 8:92, 11.6 Communication 3/XX, page 8:93, 11.6 Communication
4/XX, page 8:93, 11.6 Communication 5/XX, page 8:93, 11.6
Communication 6/XX, page 8:93, 11.6 Communication 7/XX, page
8:94, 11.6 Communication 8/XX, page 8:94 and 11.6 Communication
9/XX, page 8:94.
Technical specification:
• 11 bit identity field
• 250 kbit/s
• Termination 120 Ohm (in the control units)

11 Common electrics – Redundant CAN bus 11:49
Redundant CAN bus, start-up
Condition Refer- Reference

ence
value
Battery disconnector In position Battery disconnector, description , page 11:4.
1
Redundant voltage feed Activated Redundant voltage feed of control units, function description, page 11:15.
1, 8, 9 7 6
D7901 D7950 D7902
N R N R N R X050
2 3 4 5
D7971 D7972 D7912 D7911
R N R N R N R N
016922
The illustration shows two alternatives for how the couplings are
changed depending on the number of control units on the machine:
Solid lines show the CAN-bus with a minimal number of control units.
Dotted lines show the CAN-bus with a maximal number of control units.

1 Control unit KCU (D7901) establishes Checked by control 11.5.3.1 KCU control unit (D7901), page
redundant CAN bus communication by system, error shown 11:25
sending a request on the CAN bus via with error code.
CAN-N to Control unit KFU (D7971).
Termination resistor in the control unit
protects against interference in the event
of open circuit in the segment and thereby
ensures communication on the second CAN
connection.
2 Control unit KFU (D7971) responds with Checked by control 11.5.3.4 KFU control unit (D7971), page
node number (Node 2) to Control unit KCU system, error shown 11:31
(D7901) via CAN-R and sends the request with error code.
onward via CAN-N.
Depending on the machine's equipment, the
control unit that is next in the loop varies.
connection.
3 Control unit KFU-2 (D7972) responds with Checked by control 11.5.3.5 Control unit KFU-2 (D7972), page
node number (Node 3) to Control unit KFU system, error shown 11:33
onward via CAN-N.
connection.

11:50 11 Common electrics – Redundant CAN bus

4 Control unit KAU-2 (D7912) responds with Checked by control 11.5.3.9 Control unit KAU-2 (D7912), page
node number (Node 6) via CAN-R and system, error shown 11:40
sends the request onward via CAN-N. with error code.
connection.
5 Control unit KAU (D7911) responds with Checked by control 11.5.3.8 Control unit KAU (D7911), page
node number (Node 7) via CAN-R and system, error shown 11:38
sends the request onward to Control unit with error code.
KPU (D7902) via CAN-N.
connection.
6 Control unit KPU (D7902 ) responds with Checked by control 11.5.3.2 KPU control unit (D7902), page
node number (Node 11) to Control unit KAU system, error shown 11:27
onward to Control unit KID (D7950) via
CAN-N.
connection.
7 Control unit KID (D7950) responds with Checked by control 11.5.3.3 Control unit, KID (D7950), page
node number (Node 12) Control unit KPU system, error shown 11:29
onward to Control unit KCU (D7901) via
CAN-N.
connection.
8 Control unit KCU (D7901) receives Checked by control 11.5.3.1 KCU control unit (D7901), page
information about the control units that system, error shown 11:25
responded and the order in which they with error code. Diagnostic menu, see 11.6 Communication
responded. The information is compared 1/XX, page 8:92, 11.6 Communication
with the set-up file and if the information 2/XX, page 8:92, 11.6 Communication
is correct the CAN bus is signalled as 3/XX, page 8:93, 11.6 Communication
functioning and the control units are allowed 4/XX, page 8:93, 11.6 Communication
to communicate with each other. 5/XX, page 8:93 and 11.6 Communication
If a control unit has not responded, then 6/XX, page 8:93.
Control unit KCU (D7901) uses both CAN-R
and CAN-N to keep communication open
and an error code is set.
9 Each time a control unit requests information Checked by control Diagnostic menu, see 11.6 Communication
from another control unit, a response is sent system, error shown 7/XX, page 8:94, 11.6 Communication
that the information is received. If a control with error code. 8/XX, page 8:94 and 11.6 Communication
unit is not responding then an error message 9/XX, page 8:94.
is sent to Control unit KCU (D7901).
In the event of errors, as the first action,
Control unit KCU (D7901) attempts to
re-establish communication with a new
request.

11 Common electrics – CAN bus drive-train 11:51
11.6.3 CAN bus drive-train

CAN bus for drive-train, description
1 2 Communication with Control unit engine (D7940) and Control unit

transmission (D7930) is separated from the redundant CAN bus.
Control unit KFU (D7971) forwards the communication between the
machine's control system and engine and transmission.
3 4 5
The CAN bus for the drive-train is based on the standard SAE J1939
where selected messages are used to control the engine and
D7971 D7940 D7930 transmission. SAE J1939 is a standard from SAE (Society of
Automotive Engineers) for data communication in vehicles. The
standard regulates hardware interface, bit times and message
composition.
The engine and transmission control units are supplied by respective

engine and transmission suppliers. The machine can be equipped
with different transmission and engine models. Messages from the
transmission and engine are built up according to a standard structure.
The signals from Control unit transmission (D7930) can be checked

016151
6 7 with the diagnostic menus, 2.8 Control System 2/XX DIAGNOSE, page
8:35 and 2.8 Control System 3/XX DIAGNOSE, page 8:36.
1. Engine
The signals from Control unit engine (D7940) can be checked with the
2. Transmission diagnostic menus 1.9 Control System 1/XX DIAGNOSE, page 8:30, 1.9
3. KFU control unit (D7971) Control System 2/XX DIAGNOSE, page 8:31, 1.9 Control System 3/XX
4. Control unit, engine (D7940) DIAGNOSE, page 8:31 and 1.9 Control System 4/XX DIAGNOSE,
page 8:31.
5. Control unit, transmission (D7930)
6. Redundant CAN bus
7. CAN bus for drive-train
11.6.6 Communication between PC and machine

Communication between PC and machine, description
The machine has an outlet for communication between control units
and a PC.
The rear of the cover on Control unit KID (D7950) includes a USB
socket for connecting a computer with Kalmar Service Tool (KST)
installed. Kalmar Service Tool is used for resetting the service interval,
upgrading and reprogramming the machine's control units (not engine
and transmission).
016149
USB-outlet for KID control unit (D7950)

11:52 11 Common electrics – Communication between PC and machine
Electronic box frame contains diagnostic socket for CAN bus drive-train
1 (J1939), engine and transmission.
016305
1. Diagnostic outlet Volvo

2. Diagnostic outlet J1939/Cummins
3. Diagnostic outlet transmission ZF
Connector service contact (X050)
Connector service contact (X050)

Connector service contact (X050) is fitted in electronic box, cab. The
connector can be used for connecting service tools or troubleshooting
the machine.
The connector is the type 9-pin Universal Mate-n-lock. For part number
see Spare parts catalogue.
016169
Service contact X050
Connector service contact (X050) contains the following connections:

1. CAN bus option (R+)
3 2 1
2. CAN bus option (R-)
4 3. Ignition voltage, 24 V 10 A
4. Battery voltage 24 V 10 A
5 5. Ground
6. Searchlight (E4370)
016916
6 9 8 7 7. Searchlight (E4370)
9-pin Universal Mate-n-lock, pin numbers 8. Status signal, relay ignition voltage (K3150)
9. Status signal, redundant voltage feed CPU Power

D:1
D Error codes
Contents D Error codes

D Error codes ........................................................................................................D:3
1 Engine............................................................................................................... D:11
2 Transmission ...................................................................................................D:51
8 Control system ................................................................................................D:63

D:2

D Error codes – Error codes D:3
D Error codes
Error codes, explanation
The error codes are explained in table form for Engine, Transmission
as well as Control system. They are sorted according to error code
number.
The error code table has the following information:
10:23
• Code, error code's number, shown in field d on the display.
ACTI VE ERRORS 1 / 10 • Node, specifies which control unit generated the error. See Tabell
Node, explanation, page D:63.
0 d • Description, explanation of the error code and when it\qs
generated.
• Limitation, in case of certain error codes certain functions are
0
impaired or limited to protect the machine and operator.
• Action, information of what should be checked to find the cause
of the error code.
016080
0
• Diagnostic menu, reference to suitable diagnostic menu to rectify
the problem, read signal value or check the function.
Active error codes are shown in Active errors
In addition to the explanation of the display figure, the description
Field d: Error code. of the diagnostic menus contains reference to circuit diagrams that
are found in section E Schematics and reference to function group
10:23 for further information about functions and components.
ERROR HI STORY 1/ 12
• The reference leads to the function or component that the error
code is linked to, this field should be used to seek more information
1
0 d if necessary. Various types of information can be located via each
201 2- 06 - 23 1 0: 2 3 reference.
2 Sections 0-12 contain a description of the function and its
d
0 201 2- 06 - 22 1 4: 1 5 components, component locations and work instructions for
3
different tasks.
d
201 2- 06 - 22 1 3: 0 1
016081
Inactive and active error codes are shown in Error

history
Field d: Error code.

D:4 D Error codes – Error codes
Error code menu, description

The control and monitoring system's display is divided into a number of
fields where the information is shown (see the figures to the left).
• Field a: Error code level. Shown with a symbol.
• Field b: Driver's action. Shown with a symbol.
• Field c: Component that generated the error code. Shown with
a symbol.
• Field d: Error code.
• Field e: Number of errors. For Error history the number is limited
to the last 50 errors.
• Field f: Number of errors on each error code level.
• Field g: Date and time.
10:23 Field a: Error code level

ACTI VE ERRORS e
f The control and monitoring system gives error code information in three
levels which are indicated with a symbol on the display unit.
0 d
Symbol Action
STOP
0 a b c
Indicates a serious malfunction that may
jeopardise the operator's safety or cause machine
015229
0 failure. The error code must be attended to

immediately.
WARNING
Indicates malfunction in machine that should be
10:23 taken care of as soon as possible.
ERROR HI STORY e
f
1 INFORMATION
0 a d c
g Information to the operator about something that
2 11 1 / 5 160 - / 3
should be rectified, e.g. broken light bulb. Rectify
0 the cause at an appropriate time. Instructions how
20 11 - 09 - 19 1 0: 2 3
to rectify can usually be found in the Operator's
3 0/ 0- / 0 manual, chapter 6 Inspection and maintenance.
00 00 - 00 - 00 0 0: 0 0
015230
0
Field b: Driver's action
Inactive error codes are shown in Error history The control system provides information about what action the driver
should take. The information is indicated by a symbol on the display.
Symbol Action
Carry out action in accordance with daily
inspection, see Operator's manual, chapter 6
Inspection and maintenance.
Errors that must be repaired by trained personnel.

Any of the machine's functions that do not work
fully.
Critical errors.
Errors that may jeopardise the machine or safety,
such as low oil pressure or an overload. Stop the
machine and repair the error.
Read the operator's manual.

Field c: Affected function
Symbol Function Symbol Function Symbol Function

Engine Fuel level AdBlue level
Combifilter Exhaust temperature Air filter for air intake

combustion air
Coolant level engine Oil level engine Preheater
Transmission Oil temperature torque Lock-up, torque

converter converter
Diff lock Oil pressure Oil level transmission

transmission
Oil temperature Driveline/Axle Tyre pressure

transmission
Brakes Power-assisted brake Parking brake system

system
Oil temperature brake Steering Suspension

system
Load handling Control levers Lift/lower
Lift/lower Extension Side shift
Side shift Spreading (positioning) Spreading (positioning)
Rotation Tilt Tilt lock
Tilt Levelling Levelling lock
Levelling Contact Locked twistlocks

Unlocked twistlocks Container attachment Contact side lift

attachment
Contact top lift Support jacks Control system

attachment
Boom angle Extension Scale
Overload/OLS Height limit Overload/OLS
Frame, body, cab and Hour meter Seat

accessories
Reversible operator\qs Air conditioning ECH, ECC

seat
Fresh air filter Pause heater Recirculation
Washer fluid Wiper Wiper, slow intermittent
Wiper, fast intermittent Revolving or flashing Lighting

beacon
Horn Heater rear Vertically adjustable

window/rear view cab
mirrors
Tiltable cab Length displacement Central lubrication

cab
Hydraulic oil filter Hydraulic oil Battery capacity

temperature
CAN bus CAN bus drive-train

Field d: Error code number
Field d: Error code number

The control system gives error codes from the machine's sub-systems:
1 2 3 Unit number (AAA)
10:23
The first part of the error code indicates the unit that generated the
ACTI VE ERRORS error. The following units can generate error codes:
AAA/ BCCCC- DD E
Unit number Unit
0
1–99 Units in the RedCAN system
100 Engine
0
111 Transmission ZF
210 Exhaust system
015233
0
Component type (B)

Example illustration error codes A letter before the numbers in the component number indicates the
1. Unit number (AAA) component in question. There is no component type (B) for error codes
2. Component number (SPN) (BCCCC-DD) from the engine and transmission.
3. Type of error (FMI) (E) The following component types can be identified:
Prefix Description
A Control panel Drive-train/Wiper
B Converter from non-electric to electric signals or vice versa. Example: inductive sensor.
C Capacitor
D Binary element, delay unit, memory. Example: control unit.
E White light. Example: work lighting.
F Protective device. Example: fuse.
G Alternator, power supply device. Example: battery.
H Signal device. Example: horn, brake lights.
K Relay, contactor. Example: power relay ignition key lock.
M Engine. Example: electric motor.
P Measuring instrument, testing equipment. Example: hour meter.
Q Battery disconnector
R Resistor. Example: potentiometer.
S Electric switch for control circuit, selector. Example: switch.
V Diode
W Antenna
X Outlet/socket, connecting device. Example: connection terminal.
Y Electrically controlled mechanical device. Example: solenoid valve, hydraulic valve.
Component (CCCC)
The numbers are a unique number (SPN) to locate the faulty
component.

Component location (DD)

In cases where multiple components have the same component
number, two letters or the serial number 1-9 are added to make the
error code unique. The letters often specify a location on the machine.
There is no component location (DD) for error codes from the engine
and transmission.
The following placements are used:
Letters Location
LE Left
RI Right
UP Upper
LO Lower
FR Front
LF Left front
RF Right front
RE Rear
LR Left rear
RR Right rear
Type of error (EE)

The FMI code indicates the type of error.
Tabell Specifications FMI
FMI Description SAE-text

0 Too high value. Data valid, but higher than normal operating range.
1 Value too low. Data valid, but lower than normal operating range.
2 Incorrect data. Intermittent or incorrect data.
3 Electrical problem. Abnormally high voltage or short-circuit to higher voltage.
4 Electrical problem. Abnormally low voltage or short-circuit to lower voltage.
5 Electrical problem. Abnormally low current or open circuit.
6 Electrical problem. Abnormally high current or short-circuit to ground.
7 Mechanical problem. Incorrect response from mechanical system.
8 Mechanical problem or electrical Abnormal frequency.
problem.
9 Communication error. Abnormal update rate.
10 Mechanical problem or electrical Abnormally wide variations.
problem.
11 Unknown malfunction. Non-identifiable malfunction.
12 Component error. Incorrect unit or component.
13 Incorrect calibration. Values outside calibration values.
14 Unknown malfunction. Special instructions.
15 Too high value. Data valid, but higher than normal operating range. The least serious
level.
16 Too high value. Data valid, but higher than normal operating range. Moderately
severe level.
17 Value too low. Data valid, but below normal operating range: The least serious level.

FMI Description SAE-text

18 Value too low. Data valid, but below normal operating range: Moderately severe
level.
19 Communication error. Received network data in error.
20 Data too high. Data valid, but higher than normal value.
21 Data too low. Data valid, but lower than normal value.
22-30 Reserved for SAE assignment.
31 FMI is not available or the condition that Not available or condition exists.
is identified by the SPN exists.
32 Electrical problem. Abnormally high resistance or short-circuit to higher voltage.
33 Electrical problem. Abnormally low resistance or short-circuit to lower voltage.
34 Time exceeded. Time exceeded.
35 Communication error. CAN bus error.
36 Communication error. Drive routine error.
37 Communication error. Overflow.
38 Communication error. Error passive state.
39 Communication error. Baudrate.
40 Communication error. Control unit lost (stops sending messages) after start-up.
41 Communication error. Control unit missing during start-up.
42 Communication error. CAN bus segment after control unit is incorrect. Normal side.
43 Communication error. CAN bus segment after control unit is incorrect. RedCAN side.
44 Communication error. Control unit incorrectly positioned RedCAN circuit.
45 Communication error. Checksum error in the control unit.
Field e: Number of error codes

Specifies the number of menu pages with active error codes in Active
errors and the number of menu pages with inactive error codes in Error
history.
Field f: Number of errors on each error code level

Specifies the number of active error codes on each error code level.
Field g: Date and time

Specifies the date and time when the error code was confirmed.
Reading out error code
NOTE
In the event of an error code, perform the actions recommended
in the error code table to identify the fault.
Error codes are stored as active and inactive. Active errors are
shown in the error code menu.
Always use error code menus for reading error codes, otherwise
there is a risk of missing error codes.
1 Turn the ignition key lock to position I.

WARNING
Risk of machine damage.
In the event of error codes of level "WARNING" and
"STOP", serious machine damage may result if the
engine is started.
Do not start the engine until the cause of the error
code has been identified or repaired.
10:23
2 Select the menu for ACTIVE ERRORS or ERROR HISTORY with
CUSTOMER SETTI NGS or and confirm with .
0
014978
10:23
ACTI VE ERRORS e
f
0 d
0 a b c
015229
10:23
3 The error code list is shown on the display. Error code is shown on
ERROR HI STORY e the display where the field d shows the error code number together
f with field e that shows the number of errors.
1 Navigate the error code list with the function keys and . Leave
0 a d c
g the error code list by pressing the function key .
2 11 1 / 5 160 - / 3
0 20 11 - 09 - 19 1 0: 2 3 NOTE
3 0/ 0- / 0 If the error code is not in the error code list, this may be due to
00 00 - 00 - 00 0 0: 0 0 the following:
015230
0
– conditions for error detection are no longer valid, e.g. control
lever has been released or the engine turned off.
Inactive error codes are shown in Error history – loose contact.
Error codes disappear from the list when the cause has been
remedied.
4 Note error code number (field d) to avoid forgetting.
5 Use the error code tables to find more information about the error
code.
6 After the remedial action, check that no active error codes remain
for the function in question.

1 Engine – Engine D:11
1 Engine
Error codes engine, general
When contacting engine supplier, use the supplier code.
• Display indicates error code as shown in the machine, in
accordance with SAE J1939 in SPN/FMI.
• The supplier code indicates the error code in accordance with the
engine manufacturer's specification.
For specification of the FMI codes, see Tabell Specifications FMI, page
D:8.
Error codes engine (engine alternative

Volvo TAD1360VE)
Error codes engine (engine alternative Volvo TAD1360VE)
Display Sup- Description Limitation Action Connec- Diagnos-

plier tions and tic menu
code compo-
nents
91/9 PID91/9 Signal from - Check error codes for - 1.1 Con-
accelerator pedal, accelerator pedal in the trols & Instr
communication machine. 1/XX DI-
error. AGNOSE,
page 8:28
94/1 PID94/1 Sensor fuel No limitation. Check the fuel level. - -
pressure, low fuel Open all fuel taps and
pressure. check for leakage.
Check whether pressure
can be built up with the
hand pump. Measure
the fuel pressure.
Replace all fuel filters
(pre- and fine filter).
Check that no fuel hose
is pinched or kinked.
Remove and clean the
pressure reducing valve
on the fuel transfer pump.
94/3 PID94/3 Sensor fuel No limitation. Check the cable harness D7940/B:16 -
pressure, between control unit and D7940/B:18
abnormally component.
high voltage or Check the sensor.
short-circuit to
higher voltage.
94/5 PID94/5 Sensor fuel No limitation. Check the cable harness D7940/B:16 -
pressure, between control unit and D7940/B:17
abnormally low component.
power or open Check the sensor.
circuit.
94/7 PID94/7 Sensor fuel - - - -
pressure,
mechanical
defect.

D:12 1 Engine – Engine

code compo-
nents
97/0 PID97/0 Water in fuel. No limitation. Drain water separator. - -
Check the switch for the
water in the fuel.
Check the cable harness
between control unit and
component.
97/3 PID97/3 Sensor water in No limitation. Check the cable harness D7940/B:8 -
fuel, abnormally between control unit and D7940/B:10
high voltage or component.
short-circuit to
higher voltage.
97/4 PID97/4 Sensor water in No limitation. Check the cable harness D7940/B:8 -
fuel, abnormally between control unit and D7940/B:10
low voltage or component.
short-circuit to
lower voltage.
98/1 PID98/1 Low oil level Warning indication. Check the oil level in the - 1.8 Lu-
engine. engine. brication
Check that there is no oil 2/XX DI-
leakage. AGNOSE,
page 8:30
Check the sensor.
98/3 PID98/3 Oil level No limitation. Check the cable harness D7940/B:3 1.8 Lu-
sensor engine, between control unit and D7940/B:4 brication
abnormally component. 2/XX DI-
high voltage or Check the sensor. AGNOSE,
short-circuit to page 8:30
higher voltage.
98/4 PID98/4 Oil level sensor No limitation. Check the cable harness D7940/B:3 1.8 Lu-
engine, normally between control unit and D7940/B:4 brication
low voltage or component. 2/XX DI-
short-circuit to Check the sensor. AGNOSE,
lower voltage. page 8:30
98/5 PID98/5 Oil level No limitation. Check the cable harness D7940/B:3 1.8 Lu-
sensor engine, between control unit and D7940/B:4 brication
abnormally low component. 2/XX DI-
power or open Check the sensor. AGNOSE,
circuit. page 8:30
100/1 PID100/ Low oil pressure Reduced engine Check the engine oil - 1.8 Lu-
1 in the engine. power or engine level and oil quality. brication
shutdown. Change the engine oil 1/XX DI-
and oil filter. AGNOSE,
page 8:30
Check that there is no
leakage.
Check the sensor.
100/3 PID100/ Sensor oil No limitation. Check the cable harness D7940/B:11 1.8 Lu-
3 pressure, between control unit and brication
higher voltage.


code compo-
nents
100/5 PID100/ Sensor oil No limitation. Check the cable harness D7940/A:7 1.8 Lu-
5 pressure, between control unit and D7940/A:11 brication
power or open D7940/B:11 AGNOSE,
Check the sensor.
circuit. page 8:30
100/18 PID100/ Sensor oil Reduced engine Check the engine oil - 1.8 Lu-
18 pressure, too low power or engine level and oil quality. brication
value. shutdown. Change the engine oil 1/XX DI-
and oil filter. AGNOSE,
page 8:30
Check that there is no
leakage.
Check the sensor.
105/0 PID105/ Too high booster Reduced engine Check that the engine - 1.6 Intake
0 temperature. power. temperature is normal. Exhaust
Check the coolant level. 3/XX DI-
AGNOSE,
Clean the intercooler and page 8:29
radiator.
Check the sensor.
105/4 PID105/ Sensor booster No limitation. Check the cable harness D7940/A:47 1.6 Intake
4 temperature, between control unit and Exhaust
low voltage or Check the sensor. AGNOSE,
lower voltage.
105/5 PID105/ Sensor booster No limitation. Check the cable harness D7940/A:47 1.6 Intake
5 temperature, between control unit and Exhaust
higher voltage.
105/16 PID105/ Sensor booster Reduced engine Check that the engine - 1.6 Intake
16 temperature, too power. temperature is normal. Exhaust
high value. Check the coolant level. 3/XX DI-
AGNOSE,
Clean the intercooler and page 8:29
radiator.
Check the sensor.
106/0 PID106/ High booster Reduced engine Check the Wastegate - 1.6 Intake
0 pressure. power. valve function. Exhaust
Check the sensor. 3/XX DI-
AGNOSE,
Check that the page 8:29
compressor unit in the
turbo is correct according
to engine specification.
106/3 PID106/ Sensor booster The engine jerks Check the cable harness D7940/A:11 1.6 Intake
3 pressure, more than normal between control unit and Exhaust
abnormally during acceleration component. 3/XX DI-
high voltage or or increased load. Check the sensor. AGNOSE,
higher voltage.


code compo-
nents
106/5 PID106/ Sensor booster The engine jerks Check the cable harness D7940/A:7 1.6 Intake
5 pressure, more than normal between control unit and D7940A:22 Exhaust
abnormally low during acceleration component. 3/XX DI-
power or open or increased load. Check the sensor. AGNOSE,
circuit. page 8:29
106/16 PID106/ Sensor booster - - - 1.6 Intake
16 pressure, too high Exhaust
value. 3/XX DI-
AGNOSE,
page 8:29
107/0 PID107/ Low air pressure. No limitation. Change the air filter. - -
0
107/3 PID107/ Sensor air No limitation. Check the cable harness D7940/A:15 -
3 pressure, between control unit and D7940/A:29
high voltage or Check the sensor.
short-circuit to
higher voltage.
4 pressure, between control unit and D7940A:29
low voltage or
short-circuit to
lower voltage.
107/5 PID107/ Sensor air No limitation. Check the cable harness D7940A:15 -
circuit.
108/2 PID108/ Sensor air No limitation. Check the cable harness - -
2 pressure, between control unit and
intermittent or component.
incorrect data. Replace the engine
control unit (EMS 2).
high voltage or Replace the engine
short-circuit to control unit (EMS 2).
higher voltage.
low voltage or Replace the engine
short-circuit to control unit (EMS 2).
lower voltage.


code compo-
nents
110/0 PID110/ High coolant Reduced engine Check the coolant level. - -
0 temperature. power. Check that radiator is
clean.
Check drive belts'
adjustment.
Check the impeller on
the coolant pump.
Check if there is air in
coolant system.
If the coolant level is low,
pressure test the cooling
system to find leakage.
Check the pressure valve
in the coolant tank.
Check or replace the
coolant thermostat.
Check the sensor for the
coolant temperature.
Clean the coolant
system.
110/4 PID110/ Sensor coolant No limitation. Check the cable harness D7940/B:18 -
4 temperature, between control unit and
low voltage or Check the sensor.
short-circuit to
lower voltage.
5 temperature, between control unit and D7940/B:27
circuit.
110/16 PID110/ Sensor coolant Reduced engine Check the coolant level. - -
16 temperature, too power. Check that radiator is
high value. clean.
Check drive belts'
adjustment.
Check the impeller on
the coolant pump.
Check if there is air in
coolant system.
Check or replace the
coolant thermostat.
coolant temperature.
Clean the coolant
system.


code compo-
nents
111/1 PID111/ Low coolant level. Reduced engine Check the coolant level; - -
1 power. fill if necessary.
Bleed the coolant
system.
Check the wiring to the
sensor.
Check the sensor.
3 level, abnormally between control unit and
short-circuit to
higher voltage.
5 level, abnormally between control unit and
low power or open component.
circuit.
153/0 PID153/ Too high The engine is Check whether - -
0 crankcase switched off. crankcase ventilation
ventilation is clogged. Clean the
pressure. crankcase ventilation
system.
Check the cable harness
component.
crankcase pressure.
Measure the crankcase
pressure.
Check for wear or
damage to the cylinder
liner, piston or piston
rings.
153/3 PID153/ Sensor crankcase No limitation. Check the cable harness D7940/B:18 -
3 ventilation between control unit and D7940/B:28
pressure, component.
abnormally Check the sensor.
high voltage or
short-circuit to
higher voltage.
153/5 PID153/ Sensor crankcase No limitation. Check the cable harness D7940/B:17 -
5 ventilation between control unit and D7940/B:28
pressure, component.
abnormally low Check the sensor.
power or open
circuit.


code compo-
nents
158/1 PID158/ Low battery The engine may be Check the battery cables. - -
1 voltage, CIU, line difficult to start. Check/charge the
short circuited to batteries.
ground, defective
alternator or Check alternator and
battery. alternator belt.
158/3 PID158/ Low battery No limitation. Check the system - -

3 voltage, CIU, voltage from the control
abnormally high unit.
voltage or short
circuit to higher
voltage.
158/4 PID158/ Low battery No limitation. Check the system - -
4 voltage, CIU, voltage from the control
abnormally low unit.
voltage or short
circuit to lower
voltage.
175/0 PID175/ High engine oil Reduced engine Check the oil level in the - 1.8 Lu-
0 temperature. power. engine. brication
Check the coolant level 1/XX DI-
and engine temperature. AGNOSE,
page 8:30
Check that no leakage
occurs.
Check the sensor.
Clean the oil cooling
system and check the
overflow valve for the oil
cooler.
4 temperature, between control unit and brication
low voltage or Check the sensor. AGNOSE,
lower voltage.
5 pressure, between control unit and D7940/B:10 brication
power or open Check the contact AGNOSE,
circuit. pressure in the sleeve page 8:30
31 in engine connector
A and the sleeve 10 in
engine connector B.
Check the sensor.


code compo-
nents
175/16 PID175/ Sensor oil Reduced engine Check the oil level in the - 1.8 Lu-
16 temperature, too power. engine. brication
high value. Check the coolant level 1/XX DI-
and engine temperature. AGNOSE,
page 8:30
Check that no leakage
occurs.
Check the sensor.
Clean the oil cooling
system and check the
overflow valve for the oil
cooler.
190/16 PID190/ Engine speed too No limitation. Ease off throttle or select - -
16 high value. higher gear.
Investigate the cause
of the high speed when
the engine has been
stopped.
354/3 PID354/ Relative humidity, Hygrometer shows Check the cable harness D7940/A:23 -
3 abnormally 50%. between control unit and D7940/A:7
short-circuit to Check the sensor.
higher voltage.
354/5 PID354/ Relative humidity, Hygrometer shows Check the cable harness D7940/A:23 -
5 abnormally low 50%. between control unit and D7940/A:7
power or open component.
circuit. Check the sensor.
442/4 PPID27 Humidity Temperature shown Check the cable harness D7940/A:23 -
1/4 temperature, as 20 °C. between control unit and D7940/A:7
short-circuit to
lower voltage.
442/4 PPID27 Humidity - - - -
2/4 compensation for
air temperature,
abnormally low
voltage or short
circuit at a lower
voltage.
442/5 PPID27 Humidity Temperature shown Check the cable harness - -
1/5 temperature, as 20 °C. between control unit and
circuit.
442/5 PPID27 Humidity - - - -
2/5 compensation for
air temperature,
abnormally low
power or open
circuit.


code compo-
nents
608/9 PPID13 Signal from The engine is Check error codes for - -
2/9 accelerator pedal, running at idle. If the accelerator pedal in the
abnormal update accelerator pedal is machine.
rate. first released and
then pressed again,
the engine may be
forced to run with
the help of the idle
switch.
608/9 PPID98/ Motor synchroni- No limitation. Check the - -
9 sation, acknowl- communication cables to
edgement, abnor- the DCU/CIU.
mal update rate. Check the power
cable between the
motor control unit and
DCU/CIU.
Make sure the DCU/CIU
are programmed for the
correct engine type.
608 SID250 J1708 No limitation. Check all data links D7940A:33 -
communication between DCU/CIU and D7940/A:34
bus, defect. EMS 2.
Check that sleeves 22
and 37 in the connector
for CIU are undamaged.
620/3 SID232/ +5 V voltage feed No limitation. Check voltage feed to the D7940/A:7 -
3 sensor engine, sensors that triggered
abnormally high the error codes.
voltage or short Check the sensor cables.
circuit to the
higher voltage. Check the sensors.
620/4 SID232/ +5 V voltage feed No limitation. Check voltage feed to the D7940/A:7 -
abnormally low the error codes.
circuit to the lower
voltage. Check the sensors.
626/3 PID45/3 Sensor inlet Preheater relay Check the cable harness - -
air heater, never activated, between control unit and
abnormally starting problems in component.
high voltage or cold weather.
short-circuit to White smoke with
higher voltage. cold-start.
626/4 PID45/4 Sensor inlet air Preheater relay Check the cable harness - -
temperature, does not close by, between control unit and
abnormally preheater fuse will component.
low voltage or trip.
short-circuit to Inlet air is hot.
lower voltage.


code compo-
nents
626/5 PID45/5 Sensor inlet Preheater relay Check the cable harness - -
air heater, never activated, between control unit and
abnormally low starting problems in component.
power or open cold weather. Check the contact
circuit. White smoke with pressure in sleeve 25
cold-start. and in sleeve 7 in the
engine connector B.
628/2 SID240/ Memory error in The engine does not Reprogram the control - -
2 engine control, start. unit.
irregular signal. Replace the control unit.
628/12 SID240/ Memory error in - - - -
12 engine control,
defective unit or
component.
629/8 SID254/ Engine control No limitation. Search for short-circuit - -
8 unit, internal fault. in the feeder cables
to the CIU throttle
potentiometer
Reprogram the control
unit that has triggered
the error code.
629/12 SID254/ Control unit No limitation. Search for short-circuit - -
12 engine, defective in the feeder cables
unit or component. to the CIU throttle
potentiometer
Reprogram the control
unit that has triggered
the error code.
630/2 SID253/ Electrical The engine does not Reprogram the control - -
2 fault engine start. unit.
(EEPROM), Replace the control unit
intermittent or if the fault persists.
incorrect data.
defective unit or if the fault persists.
component.
Special if the fault persists.
instructions.
636/2 SID21/2 Sensor rotation The engine takes Check the cable harness D7940/A:45 -
speed camshaft, longer to start than between control unit and D7940/A:46
irregular signal. normal. component.
Check the sensor and its
connection.
636/3 SID21/3 Sensor camshaft The engine takes Check the cable harness D7940/A:45 -
speed, abnormally longer to start than between control unit and D7940A:46
high voltage or normal. component.
short-circuit to Check the sensor and its
higher voltage. installation.


code compo-
nents
636/8 SID21/8 Sensor speed, The engine takes Check the cable harness D7940/A:45 -
camshaft, longer to start than between control unit and D7940/A:46
abnormal normal. component.
frequency. Check sensor
installation.
Try to locate the source
of the disturbance.
Check and clean the
sensor.
637/2 SID22/2 Sensor rotation The engine takes Check the cable harness - 1.9 Con-
speed flywheel, longer to start than between control unit and trol System
no signal. normal. component. 1/XX DI-
Check the sensor and its AGNOSE,
connection. page 8:30
637/3 SID22/3 Sensor flywheel Engine runs Check the cable harness D7940/A:37 1.9 Con-
speed, abnormally unevenly with between control unit and D7940/A:38 trol System
high voltage or increased risk component. 1/XX DI-
short-circuit to of high fuel Check the sensor and its AGNOSE,
higher voltage. consumption and installation. page 8:30
smoking.
637/8 SID22/8 Sensor speed, The engine takes Check the cable harness D7940/A:37 1.9 Con-
flywheel, longer to start than between control unit and D7940/A:38 trol System
abnormal normal. component. 1/XX DI-
frequency. Check sensor AGNOSE,
installation. Try to page 8:30
locate the source of the
disturbance.
Check and clean the
flywheel sensor.
639/2 SID231/ Communication Engine switched off: Check all data links D7940/B:51 -
2 error control unit engine cannot be between DCU/CIU and D7940/B:55
engine (J1939). started. EMS2.
Engine running: the Check that connections
engine can only be 11 and 12 in the
stopped by using connector in the CIU
the emergency stop. are not damaged.
Instrument and
warning lamps stop
working.
639/9 PSID20 Communication No communication Check all data links D7940/B:51 -
1/9 error control unit with the engine between DCU/CIU and D7940/B:55
engine (J1939). control unit. EMS2.
Open circuit or short
circuit between DCU/CIU
and EMS2, via the
engine's connector.
647/3 SID33/3 Cooling fan - - D7940/A:7 -
control abnormally D7940/A:35
high voltage or
short-circuit to D7940/A:39
higher voltage. D7940/B:49
D7940/B:60


code compo-
nents
647/4 SID33/4 Cooling - - D7940/A:7 -
fan control, D7940/A:35
abnormally
low voltage or D7940/A:39
short-circuit to D7940/B:49
lower voltage.
D7940/B:60
647/5 SID33/5 Cooling - - D7940/A:7 -
fan control, D7940/A:35
abnormally low
power or open D7940/A:39
circuit. D7940/B:49
D7940/B:60
651/3 SID1/3 Injector cylinder Engine only runs Check the cable harness D7940/A:12 -
1, abnormally on 5 cylinders, between control unit and D7940/A:16
high voltage or sounds rough and component.
short-circuit to has reduced power. D7940/A:20
higher voltage. D7940/A:24
D7940/A:28
D7940/A:32
D7940/A:36
D7940/A:40
D7940/A:44
D7940/A:48
D7940/A:52
D7940/A:56
low voltage or sounds rough and component.
lower voltage. D7940/A:62
1, abnormally low on 5 cylinders, between control unit and D7940/A:16
power or open sounds rough and component.
circuit. has reduced power. D7940/A:20
Check the contact
pressure in all sleeves D7940/A:24
for injection units in the D7940/A:28
motor connector A.
D7940/A:32
D7940/A:36
D7940/A:40
D7940/A:44
D7940/A:48
D7940/A:52
D7940/A:56
D7940/A:59
D7940/A:60
D7940/A:61
D7940/A:62


code compo-
nents
651/12 SID1/12 Injector cylinder 1, Engine only runs Check the cable harness - -
defective. on 5 cylinders, between control unit and
sounds rough and component.
has reduced power. Check the contact
pressure in all sleeves
for injection units in the
motor connector A.
injector.
D7940/A:28
D7940/A:32
D7940/A:36
D7940/A:40
D7940/A:44
D7940/A:48
D7940/A:52
D7940/A:56
Check the contact
motor connector A.
D7940/A:32
D7940/A:36
D7940/A:40
D7940/A:44
D7940/A:48
D7940/A:52
D7940/A:56
D7940/A:59
D7940/A:60
D7940/A:61
D7940/A:62


code compo-
nents
motor connector A.
injector.
D7940/A:28
D7940/A:32
D7940/A:36
D7940/A:40
D7940/A:44
D7940/A:48
D7940/A:52
D7940/A:56
Check the contact
motor connector A.
D7940/A:32
D7940/A:36
D7940/A:40
D7940/A:44
D7940/A:48
D7940/A:52
D7940/A:56
D7940/A:59
D7940/A:60
D7940/A:61
D7940/A:62


code compo-
nents
motor connector A.
injector.
D7940/A:28
D7940/A:32
D7940/A:36
D7940/A:40
D7940/A:44
D7940/A:48
D7940/A:52
D7940/A:56
Check the contact
motor connector A.
D7940/A:32
D7940/A:36
D7940/A:40
D7940/A:44
D7940/A:48
D7940/A:52
D7940/A:56
D7940/A:59
D7940/A:60
D7940/A:61
D7940/A:62


code compo-
nents
motor connector A.
injector.
D7940/A:28
D7940/A:32
D7940/A:36
D7940/A:40
D7940/A:44
D7940/A:48
D7940/A:52
D7940/A:56
Check the contact
motor connector A.
D7940/A:32
D7940/A:36
D7940/A:40
D7940/A:44
D7940/A:48
D7940/A:52
D7940/A:56
D7940/A:59
D7940/A:60
D7940/A:61
D7940/A:62


code compo-
nents
motor connector A.
injector.
D7940/A:28
D7940/A:32
D7940/A:36
D7940/A:40
D7940/A:44
D7940/A:48
D7940/A:52
D7940/A:56
Check the contact
motor connector A.
D7940/A:32
D7940/A:36
D7940/A:40
D7940/A:44
D7940/A:48
D7940/A:52
D7940/A:56
D7940/A:59
D7940/A:60
D7940/A:61
D7940/A:62


code compo-
nents
motor connector A.
injector.
677/0 PPID3/0 Starter relay on - - - -
the starter motor,
too high value.
677/3 PPID3/3 Starter relay on The engine does not Check the connection D7940/B:29 -
the starter motor, start. and function of the
abnormally high Engine starts ignition key lock.
voltage or short immediately when Check the cable harness
circuit to higher ignition is turned on. between control unit and
voltage. component.
Check the start button on
DCU.
677/4 PPID3/4 Starter relay on The engine does not Check the ignition cable. D7940/B:29 -
the starter motor, start. Check the connection
abnormally low Engine starts and function of the
voltage or short immediately when ignition key lock.
circuit to lower ignition is turned on.
voltage. Check the cable harness
component.
677/5 PPID3/5 Starter relay on The engine does not Check the ignition cable. D7940/B:29 -
the starter motor, start. Check the starter relay
abnormally low Engine starts on the starter motor.
power or open immediately when
circuit. ignition is turned on.
677/10 PPID3/1 Starter relay on - - - -
0 the starter motor,
abnormally large
fluctuations.
729/3 SID70/3 Sensor Fuse for short circuit Check the cable harness - -
preheating, in cable trips. between control unit and
high voltage or Check the function of the
short-circuit to relay.
higher voltage.
Check the heating coil.
729/4 SID70/4 Sensor Preheating cannot Check the function of the D7940/B:7 -
preheating, be activated, relay.
abnormally starting problems Check the cable harness
low voltage or in cold weather. between control unit and
short-circuit to component.
lower voltage.


code compo-
nents
729/5 SID70/5 Sensor Preheating cannot Check the preheater D7940B:7 -
preheating, be activated, fuse.
abnormally low starting problems Check the cable harness
power or open in cold weather. between control unit and
circuit. component.
Check the heating coil.
858/3 PSID82/ AdBlue external No limitation. Check the cable harness - -
3 filter heater, cable between control unit and
short circuited to component.
voltage. Check the component.
4 filter heater, between control unit and
low voltage or Check the component.
short-circuit to
lower voltage.
5 filter heater, cable between control unit and
open circuit or component.
short circuited to Check the component.
ground.
859/3 PSID10 AdBlue external No limitation. Check the cable harness - -
7/3 filter heater, cable between control unit and
7/4 filter heater, between control unit and
low voltage or Check the component.
short-circuit to
lower voltage.
7/5 filter heater, cable between control unit and
short circuited to Check the component.
ground.
970/4 PPID6/4 Sensor ignition off The engine can only Check the stop signal D7940/A:27 -
(stop request), be turned off with cable between the
abnormally the emergency stop. engine control unit and
low voltage or CIU/DCU.
short-circuit to
lower voltage.
975/3 SID26/3 Fan speed, - - - -
abnormally
high voltage or
short-circuit to
higher voltage.
1080/3 SID211/ +5V voltage feed No limitation. Check voltage feed to the D7940/B:17 -
abnormally high the error codes.
circuit to the
higher voltage. Check the sensors.


code compo-
nents
1080/4 SID211/ +5V voltage feed No limitation. Check voltage feed to the D7940B:17 -
abnormally low the error codes.
circuit to the lower
voltage. Check the sensors.
1136/0 PPID55/ ECU-temperature, No limitation. Check if the ambient - -

0 control unit too temperature is high.
hot. Check the control
unit's installation. The
recommended ambient
temperature is 50 °C.
Change the control unit.
1136/4 PPID55/ ECU temperature, No limitation. Change the control unit. - -
4 abnormally
low voltage or
short-circuit to
lower voltage.
1136/5 PPID55/ ECU temperature, No limitation. Change the control unit. - -
5 abnormally low
power or open
circuit.
1184/0 PID173/ High exhaust Reduced engine Make sure the exhaust - -
0 temperature. power. pipe has not been
damaged and that there
are no restrictions.
Check the sensor.
Check the exhaust
system's back pressure.
1184/4 PID173/ Sensor exhaust No limitation. Check the cable harness D7940/B:44 -
4 temperature, between control unit and
short-circuit to
lower voltage.
1184/5 PID173/ Sensor exhaust No limitation. Check the cable harness D7940/B:18 -
5 temperature, between control unit and D7940/B:44
power or open Check the contact
circuit. pressure in sleeves
18 and 44 in the engine
connector B.
Check the sensor.
1184/16 PID173/ Sensor exhaust - - - -
16 temperature, too
high value.
1188/3 SID32/3 Wastegate drive No limitation. Check the cable harness D7940/B:38 -
circuit, abnormally between control unit and
short-circuit to Replace the component.
higher voltage.


code compo-
nents
short-circuit to Replace the component.
lower voltage.
circuit. Check the contact
pressure in sleeves 38 in
the engine connector B.
Replace the component.
1231/2 PSID23 CAN2 J1939 No AdBlue additive. Check the cable harness - -
2/2 communication between control unit and
link, intermittent or component.
incorrect data. Check the component.
1231/2 PSID24 CAN3 No AdBlue additive. Check the cable harness - -
8/2 communication between control unit and
link, intermittent or component.
incorrect data. Check the component.
1231/9 PSID22 CAN-frames No AdBlue additive. Check the cable harness - -
9/9 from UDS/ACM, between control unit and
timeout. component.
Check the component.
1675/0 PPID3/0 Starter motor - Check the cable harness - -
output power between control unit and
(Penta), data component.
valid, but above Check the component.
normal operating
range.
(Penta), component.
abnormally Check the component.
high voltage or
short-circuit to
higher voltage.
(Penta), component.
abnormally Check the component.
low voltage or
short-circuit to
lower voltage.
(Penta), component.
abnormally low Check the component.
power or open
circuit.


code compo-
nents
0 output power between control unit and
(Penta), component.
mechanical Check the component.
problem or
electrical problem.
1761/1 PPID27 After-treatment Temperature shows Fill AdBlue. - -
8/1 reagent, low level, 20 °C. Check sensor.
limited cooling
capacity.
1761/3 PPID27 After-treatment Temperature shows Fill AdBlue. - -
8/3 reagent, level 20 °C. Check sensor.
SCH.
1761/5 PPID27 After-treatment - - - -
8/5 reagent, level,
abnormally low
power or open
circuit.
8/11 reagent, level,
unknown error.
8/18 reagent, level, too
low value.
2061/8 PSID77/ AdBlue ECU No limitation. Check the system - -
8 EEPROM, voltage.
abnormal Check fuses for EATS.
frequency.
2061/8 PPID27 After-treatment Warning indication Fill AdBlue. - -
3/14 reagent, pressure, and reduced engine Check AdBlue filter.
heating defect. power.
Check AdBlue hoses.
Check the wiring and
connections.
12 EEPROM, voltage.
defective unit or Check fuses for EATS.
component.
2061/13 PPID27 After-treatment No limitation. - - -
8/13 reagent, level,
values outside
calibration values.
2061/14 PPID38 AdBlue ECU- SCR-system does Check the system - -
5/14 voltage, internal not start. voltage.
supply, critical Check fuses for EATS.
error.


code compo-
nents
2791/3 PPID19/ Internal EGR IEGR cannot be Check the cable harness D7940/B:30 -
3 status, abnormally activated. between control unit and
high voltage or In the event of component.
short circuit to failure on the
higher voltage. IEGR function,
2791/4 PPID19/ Internal EGR the proportion of D7940/B:30 -
4 status, abnormally nitrogen oxides in
high voltage or exhaust emissions
short circuit to becomes high and
higher voltage. over-revving of the
turbocharger is
2791/5 PPID19/ Internal EGR- possible. Check the cable harness D7940/B:30 -
5 status, abnormally between control unit and D7940/B:57
circuit. D7940/B:60
Check the contact
pressure in sleeves
30, 57 and 60 in the
engine connector B.
Check the coil on IEGR.
2791/7 PPID19/ Internal EGR- Check the operation of - -
7 status, incorrect the solenoid valve on
response from IEGR.
mechanical Check the engine's oil
system. pressure.
2988/3 PPID33 Thermostat, No limitation. Check the cable harness D7940B:34 -
2/3 abnormally between control unit and
short-circuit to Check the cold start
higher voltage. valve.
2988/4 PPID33 Thermostat, No limitation. Check the cable harness D7940/B:34 -
2/4 abnormally between control unit and
short-circuit to Check the cold start
lower voltage. valve.
2988/5 PPID33 Thermostat, No limitation. Check the cable harness D7940/B:34 -
2/5 abnormally low between control unit and
power or open component.
circuit. Check the contact
pressure in sleeves 34 in
the engine connector B.
Check the cold start
valve.
3031/0 PPID27 After-treatment No AdBlue added. Check the wiring and - -
4/0 reagent, tank connections.
temperature, too
high temperature.
temperature, too
low temperature.


code compo-
nents
temperature,
cable short
circuited to
ground.
temperature, open
circuit.
3051/11 PSID90 SCR-system - - - -
performance, no
identifiable error.
3226/2 PPID27 NOx-sensor Reduced engine Check the cable harness - -
0/2 exhaust outlet, power. between control unit and
short circuited component.
cable, intermittent Check the sensor.
or incorrect data.
Check fuse.
3226/7 PPID27 NOx-sensor Reduced engine Check the cable harness - -
0/7 exhaust outlet, power. between control unit and
mechanical component.
problem. Check the sensor.
Check fuse.
3241/4 PPID38 Exhaust No limitation. Check the cable harness - -
6/4 temperature between control unit and
sensor #1, component.
abnormally Check the sensor.
low voltage or
short-circuit to
lower voltage.
3241/5 PPID38 Exhaust No limitation. Check the cable harness - -
6/5 temperature between control unit and
sensor #1, cable component.
open circuit or Check the sensor.
short circuited to
ground.
3361/3 PSID89/ AdBlue metering No AdBlue added. Check the wiring and - -
3 valve, short circuit connections.
to battery.
4 valve, short circuit connections.
to ground.
5 valve, open circuit. connections.
7 valve, valve or connections.
hose clogged.
10 valve, valve connections.
jammed.


code compo-
nents
14 valve, frozen too connections.
many times.
3363/3 PSID75/ AdBlue tank No limitation. Check the cable harness - -
3 heating valve, between control unit and
intermittent or component.
incorrect data. Check the sensor.
short-circuit to
lower voltage.
cable open circuit component.
or short circuited Check the sensor.
to ground.
3464/3 PSID7/3 Actuator motor - Check error codes for - 1.1 Con-
accelerator accelerator pedal in the trols & Instr
control, machine. 1/XX DI-
abnormally AGNOSE,
high voltage or page 8:28
short-circuit to
higher voltage.
abnormally AGNOSE,
low voltage or page 8:28
short-circuit to
lower voltage.
abnormally low AGNOSE,
power or open page 8:28
circuit.
2 accelerator accelerator pedal in the trols & Instr
control, defective machine. 1/XX DI-
unit or component. AGNOSE,
page 8:28
3 EEPROM. ECU voltage.
internal feed high. Check fuses for EATS.
4 EEPROM. ECU voltage.
internal feed low. Check fuses for EATS.


code compo-
nents
values outside power.
calibration values. Check AdBlue hoses.
connections.
3522/16 PSID91/ AdBlue, No limitation. Check for leakage in the - -
16 consumption, too SCR-system.
high value.
3522/18 PSID91/ AdBlue, No limitation. Check for leakage in the - -
18 consumption, too SCR-system.
low value.
leakage. power.
Check AdBlue hoses.
connections.
cable short power.
circuited to Check AdBlue hoses.
ground. Check the wiring and
connections.
open circuit. power.
Check AdBlue hoses.
connections.
accumulated power.
error. Check AdBlue hoses.
connections.
3/9 reagent, and reduced engine Check AdBlue filter.
communication power.
error. Check AdBlue hoses.
connections.
3/10 reagent, and reduced engine Check AdBlue filter.
mechanical power.
problem or Check AdBlue hoses.
electrical problem. Check the wiring and
connections.
values outside power.
calibration values. Check AdBlue hoses.
connections.


code compo-
nents
4337/0 PPID27 Reagent filter No AdBlue added. Check the wiring and - -
5/0 temperature, too connections.
high temperature.
5/1 temperature, too connections.
low temperature,
electrical heating
not possible.
5/2 temperature, connections.
out of operating
range.
5/4 temperature, connections.
cable short
circuited to
ground.
5/5 temperature, open connections.
circuit.
4354/3 PSID10 AdBlue ECU hose No limitation. Check the cable harness - -
3/3 heater 1, cable between control unit and
voltage. Check component.
4354/4 PSID10 AdBlue ECU No limitation. Check the cable harness - -
3/4 hose heater between control unit and
1, abnormally component.
low voltage or Check component.
short-circuit to
lower voltage.
short circuited to Check component.
ground.
4354/14 PSID10 AdBlue ECU hose No limitation. No limitation. - -
3/14 heater 1, special
instructions.
4355/3 PSID84/ AdBlue ECU hose No limitation. Check the cable harness - -
3 heater 2, cable between control unit and
4355/4 PSID84/ AdBlue ECU No limitation. Check the cable harness - -
4 hose heater between control unit and
short-circuit to
lower voltage.
4355/5 PSID84/ AdBlue ECU hose No limitation. Check the cable harness - -
5 heater 2, cable between control unit and
ground.


code compo-
nents
4355/14 PSID84/ AdBlue ECU hose No limitation. No limitation. - -
14 heater 2, special
instructions.
short-circuit to
lower voltage.
ground.
4356/14 PSID10 AdBlue ECU hose No limitation. - - -
2/14 heater 3, special
instructions.
short-circuit to
lower voltage.
ground.
4374/0 PSID87/ AdBlue pump No AdBlue added. Check the wiring and - -
0 motor speed, too connections.
high-speed.
1 motor speed, too connections.
low-speed.
10 motor speed, no connections.
signal from pump.
4376/3 PSID10 AdBlue directional No limitation. Check the wiring and - -
5/3 control valve, connections.
short circuit to
battery.
short circuit to
ground.


code compo-
nents
open circuit.
mechanical
problem.
4811/1 PPID8/1 Oil pressure piston - - - -
cooling, too low
value.
cooling, incorrect
data.
4811/3 PPID8/3 Oil pressure - - - -
piston cooling,
abnormally
high voltage or
short-circuit to
higher voltage.
4811/5 PPID8/5 Oil pressure - - - -
piston cooling,
abnormally low
power or open
circuit.
8 cooling, too low
value.
5246/0 PSID46/ Inducing level, Warning indication Check the cable harness - -
0 Inducing level 3, 4 and reduced engine between control unit and
or 5. power. component.
Check the sensor.
5246/15 PSID46/ Inducing level, Warning indication Check the cable harness - -
15 Inducing level 1 or and reduced engine between control unit and
2. power. component.
Check the sensor.
5246/16 PSID46/ Inducing level, too - - - -
16 high value.
5394/17 PSID90/ SCR-system Warning indication, Check AdBlue quality. - -
17 performance, error message on
metering error. display and reduced
engine power.
520192/ PPID8/1 Low oil pressure Reduced engine Check piston cooling - -
1 piston cooling, power. pressure again.
engine has Error code Replace the monitor for
reduced deactivated at piston cooling pressure if
performance. engine speed below the measurement shows
1000 rpm. that the piston cooling
pressure is correct.


code compo-
nents
520192/ PPID8/3 Sensor oil No limitation. Check the cable harness - -
3 pressure between control unit and
piston cooling, component.
abnormally
high voltage or
short-circuit to
higher voltage.
520194 PPID4 Starter motor input The engine does not Check the connection - -
sensor. start. and function of the
Engine starts ignition key lock.
immediately when Check the cable harness
ignition is turned on. between control unit and
component.
520195/ PPID6/4 Sensor ignition off The engine can only Check the stop signal - -
4 (stop request), be turned off with cable between the
abnormally the emergency stop. engine control unit A27
low voltage or and CIU/DCU.
short-circuit to
lower voltage.
520195/ PPID6/5 Sensor ignition Engine cannot be Check the connections - -
5 off (stop request), shut down. and cables are not
abnormally low damaged.
power or open
circuit.
520195/ PPID6/1 Sensor ignition off - - - -
18 8 (stop request), too
low value.
520233/ PSID85/ AdBlue ECU No limitation. Check the cable harness - -
3 3 main relay, cable between control unit and
voltage. Check the sensor.
520223/ PSID85/ AdBlue ECU main No limitation. Check the cable harness - -
4 4 relay, abnormally between control unit and
lower voltage.
520223/ PSID85/ AdBlue ECU No limitation. Check the cable harness - -
5 5 main relay, cable between control unit and
short circuited to Check the sensor.
ground.
520223/ PSID85/ AdBlue ECU main No limitation. Check the cable harness - -
6 6 relay, abnormally between control unit and
high current or component.
ground.

Error codes engine (engine alternative

Cummins QSM11)
Error codes Cummins QSM11
Code J1587 Description Limitation Action Connec- Diagnos-

tions and tic menu
compo-
nents
84/2 PID084/2 Electrical error, speed Engine speed Check the cable harness - -
sensor, invalid data. limited to maximum between control unit and
speed without component.
gear. Check the sensor.
84/10 PID084/1 Electrical error, Engine speed Check the cable harness - -
0 speed sensor, limited to maximum between control unit and
signal manipulation speed without component.
detected. gear. Check the sensor.
91/3 PID091/3 Electrical error, The engine does Check the cable harness - -
accelerator pedal, not respond to between control unit and
cable short circuit to throttle application. component.
ground. Check the component.
frequency too low. throttle application. component.
frequency too high. throttle application. component.
91/19 SID091/2 Communication error Engine only Use diagnostic menu to - -
with Control unit KFU running at idle. find incorrect segment.
(D7971), electrical
error, accelerator
pedal.
97/3 PID097/3 Electrical error, No limitation. Check the cable harness D7940/Se- -
water-in-fuel sensor, between control unit and nsor:09
cable short circuit to component.
water-in-fuel sensor, between control unit and nsor:09
97/15 PID097/1 Water in fuel. Risk of white Drain water from the fuel - -
5 exhaust smoke filter.
and reduced
engine output.
100/1 PID100/1 Low engine oil Engine output is Check the oil level in - 1.8 Lu-
pressure. reduced gradually. the engine, top up if brication
The engine is necessary. 1/XX DI-
turned off after AGNOSE,
30 seconds. page 8:30


tions and tic menu
compo-
nents
100/2 PID100/2 Sensor, oil pressure, No warning for Check the sensor. D7940/Se- 1.8 Lu-
data error. low engine oil nsor:44 brication
pressure. 1/XX DI-
AGNOSE,
page 8:30
100/3 PID100/3 Sensor oil pressure No warning for Check the cable harness D7940/Se- 1.8 Lu-
cable, short circuit to low engine oil between control unit and nsor:44 brication
voltage. pressure. component. 1/XX DI-
Check the sensor. AGNOSE,
page 8:30
100/4 PID100/4 Sensor oil pressure, No warning for Check the cable harness D7940/Bla- 1.8 Lu-
open circuit or short low engine oil between control unit and ck:14 brication
circuit to ground. pressure. component. 1/XX DI-
Check the sensor. AGNOSE,
page 8:30
100/18 PID100/1 Low engine oil No limitation. Check the oil level in the - 1.8 Lu-
pressure. engine; fill if necessary. brication
Check the sensor. 1/XX DI-
AGNOSE,
page 8:30
102/2 PID102/2 Sensor boost Reduced engine Check the cable harness D7940/Se- 1.6 Intake
pressure indicates power. between control unit and nsor:39 Exhaust
high boost pressure, component. 3/XX DI-
but other engine Check the sensor. AGNOSE,
data indicates that page 8:29
pressure should be
normal.
102/3 PID102/3 Sensor, boost Reduced engine Check the cable harness D7940/Se- 1.6 Intake
pressure, cable power. between control unit and nsor:39 Exhaust
short-circuited to component. 3/XX DI-
voltage. Check the sensor. AGNOSE,
page 8:29
102/4 PID102/4 Sensor boost Reduced engine Check cable harness D7940/Bla- 1.6 Intake
pressure, cable short power. between control unit and ck:3 Exhaust
circuit to ground or component. 3/XX DI-
open circuit. Check the boost pressure AGNOSE,
sensor. page 8:29
103/16 PID103/0 Overspeed Reduced engine Check the component. - -

protection, turbo. power.
105/0 PID105/0 Intake air too warm. Engine output is Check the coolant level - 1.6 Intake
reduced gradually. in the engine; fill if Exhaust
The engine is necessary. 3/XX DI-
turned off after Check that the charge air AGNOSE,
30 seconds. cooler is clean, clean if page 8:29
necessary.
Check that the fan belts
are intact. Check the
intake air temperature
sensor.


tions and tic menu
compo-
nents
105/3 PID105/3 Sensor charge-air Risk of white Check cable harness D794/0Se- 1.6 Intake
temperature, cable exhaust smoke. between control unit and nsor:38 Exhaust
short-circuited to No warning of component. 3/XX DI-
voltage or open high coolant Check that the charge-air AGNOSE,
circuit. temperature. temperature sensor is page 8:29
correctly installed and
connected.
Check the charge-air
temperature sensor.
105/4 PID105/4 Sensor charge-air Risk of white Check the cable harness D7940/Se- 1.6 Intake
temperature, cable exhaust smoke. between control unit and nsor:38 Exhaust
short circuit to ground No warning of component. 3/XX DI-
or open circuit. high coolant Check that the sensor AGNOSE,
temperature. is correctly installed and page 8:29
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 the cable harness D7940/Se- -
pressure sensor, power. between control unit and nsor:06
voltage. Check the sensor.
108/4 PID108/4 Electrical error, air Reduced engine Check the cable harness D7940/Se- -
pressure sensor, power. between control unit and nsor:06
ground. Check the sensor.
110/0 PID110/0 High coolant Engine output is Check the coolant level. - -
temperature. reduced gradually. Check that radiator is
The engine is clean.
turned off after
30 seconds. Check if there is air in
coolant system.
Check the cap on the
expansion tank.
Check the sensor.
Check the thermostat.
110/3 PID110/3 Sensor coolant No display Check the cable harness D7940/Se- -
temperature, cable of engine between control unit and nsor:02
short-circuited to temperature. component.
voltage or open
circuit.
110/4 PID110/4 Sensor coolant No display Check the cable harness D7940/Se- -
temperature, cable of engine between control unit and nsor:02
short circuit to temperature. component.
ground. Check that the sensor is
connected correctly.
Check the sensor.


tions and tic menu
compo-
nents
111/1 PID111/1 Low coolant level. Engine output is Check the coolant level; - -
reduced gradually. fill if necessary.
The engine is Check the sensor.
turned off after
30 seconds.
111/2 PID111/2 Electrical error, No warning for low Check the cable harness D7940/Se- -
sensor coolant level, coolant level. between control unit and nsor:09
data error. component.
Check the sensor.
166/2 PID116/2 Output imbalance Rough idle. Check fuel quality. The - -
between cylinders. error code could be
generated if the fuel
system has been opened,
allowing air to enter the
system. Troubleshoot the
engine.
167/1 PID167/1 Low battery voltage. Warning active Check batteries and D7940/OE- -
until voltage is alternator. M:7, 8, 17,
correct. 18, 28
167/16 PID167/0 Low battery voltage. Warning active Check fuses. Check D7940/OE- 1.9 Con-
until voltage is batteries and alternator. M:7, 8, 17, trol System
correct. 18, 28 2/XX DI-
AGNOSE,
page 8:31
167/18 PID167/1 High battery voltage. Warning active Check batteries and D7940/OE- 1.9 Con-
until voltage is alternator. M:7, 8, 17, trol System
correct. The 18, 28 2/XX DI-
engine runs at AGNOSE,
increased idle in page 8:31
order to increase
voltage.
168/16 PID168/0 High voltage feed to No limitation. Check fuses. Check D7940/OE- 1.9 Con-
control unit. batteries and alternator. M:7, 8, 17, trol System
18, 28 2/XX DI-
AGNOSE,
page 8:31
168/18 PID168/1 Low voltage feed to Rough idle. Check fuses. Check D7940/OE- 1.9 Con-
control unit. batteries and alternator. M:7, 8, 17, trol System
18, 28 2/XX DI-
AGNOSE,
page 8:31
175/0 PID175/0 High engine oil Engine output is Check the coolant and oil - 1.8 Lu-
temperature. reduced gradually. level in the engine, top up brication
The engine is if necessary. 1/XX DI-
turned off after Check that the oil cooler is AGNOSE,
30 seconds. clean, clean if necessary. page 8:30
Check that the fan belts
are intact.
Check the sensor.


tions and tic menu
compo-
nents
175/3 PID175/3 Sensor, oil No display Check the cable harness D7940/Se- 1.8 Lu-
temperature, cable of engine oil between control unit and nsor:42 brication
short-circuited to temperature. component. 1/XX DI-
voltage or open Check that the sensor is AGNOSE,
circuit. connected correctly. page 8:30
175/4 PID175/4 Sensor oil No display Check the cable harness D7940/Se- 1.8 Lu-
temperature, cable of engine oil between control unit and nsor:42 brication
short circuit to temperature. component. 1/XX DI-
ground. Check the sensor. AGNOSE,
page 8:30
188/4 SID032/4 Electrical error, Reduced engine Check the cable harness D7940/Ac-
wastegate solenoid power. between control unit and tuator:24
valve 1 short circuit component.
to ground. Check the solenoid valve.
190/0 PID190/0 Engine speed too Fuel supply Ease off the throttle or - -
high. restricted until select higher gear.
engine speed is
below permitted
value.
190/2 PID190/2 Electrical error, The engine stops Check the cable harness D7940/Se- -
sensor rotation and cannot be between control unit and nsor:47, 50
speed/ignition mode; restarted. component.
no signal from any Check the sensor.
sensors.
0 sensor rotation between control unit and nsor:47, 50
speed/ignition mode, component.
one of two signals Check the sensor.
missing.
191/16 PID191/0 Speed limitation Speed is reduced. Decrease throttle - -
activated. application.
191/18 PID191/1 Speed warning for Engine only Increase throttle - -
low speed. running at idle. application.
251/2 PID251/2 Internal error engine - - - -
control unit.
441/3 PID441/3 Extra temperature No warning for Check the cable harness D7940/Se-
sensor, short circuit high temperature, between control unit and nsor:12
to ground. Control unit, component.
engine (D7940). Check the sensor.
441/4 PID441/4 Extra temperature No warning for Check the cable harness D7940/Se-
sensor, short circuit high temperature, between control unit and nsor:12
to voltage. Control unit, component.
engine (D7940). Check the sensor.
558/2 SID230/2 Electrical error, No limitation. Check cable between D7940/OE- -
sensor accelerator control unit and M:03, 13
pedal, idle switch, component.
data error. Check component.


tions and tic menu
compo-
nents
558/4 SID230/4 Electrical error, The engine does Check cable between D7940/OE- -
sensor accelerator not respond to control unit and M:03, 13
pedal, idle switch, throttle application. component.
cable short circuit to Check component.
ground.
558/13 SID230/1 Electrical error, Engine only Check cable between D7940/OE- -
3 sensor accelerator running at idle. control unit and M:13
pedal, idle switch, component.
calibration error. Check component.
608/2 SID250/2 Communication error No limitation. Check the control unit. D7940/O-
with Control unit, EM:26, 27,
engine (D7940). 36, 37, 46
608/9 SID250/9 Communication error No limitation. Check the control unit. D7940/O-
with Control unit, EM:26, 27,
engine (D7940). 36, 37, 46
620/3 SID232/3 Electrical error, Reduced engine Check the cable harness D7940/S- -
1080/3 reference voltage power. No warning between control unit and ensor:18,
to sensor short circuit for low oil pressure component. 25, 45
to voltage. or low coolant Check the control unit.
level.
620/4 SID232/4 Electrical error, Reduced engine Check the cable harness D7940/S- -
1081/4 reference voltage power. No warning between control unit and ensor:18,
to sensor short circuit for low oil pressure component. 25, 45
to ground. or low coolant Check the component.
level.
626/11 SID237/1 Electrical error to Preheating not Check the cable harness D7940Ac- -
1 control of relay working. Risk of between control unit and tuator:34
preheating. white smoke. component.
627/2 SID251/2 Voltage feed Reduced engine Check fuses. D7940/OE- -
to control unit power. Engine Check batteries and M:7, 8, 17,
disappears without difficult to start or alternator. 18, 28
ignition off. dies.
629/12 SID254/1 Internal error Control The engine does Check the control unit. - -
2 unit, engine (D7940). not start.
629/12 SID254/1 Internal error Control No limitation. Check the control unit. - -
2 unit, engine (D7940).
630/2 SID253/2 Software error Reduced engine Reprogram the software - -
Control unit, engine power. Engine in Control unit, engine
(D7940). difficult to start or (D7940).
dies.
632/3 SID017/3 Electrical error, fuel No limitation. Check the cable harness D7940Ac- -
cut-off solenoid valve, between control unit and tuator:33
voltage. Check the solenoid valve.
632/4 SID017/4 Electrical error, fuel The engine is Check the cable harness D7940/Ac- -
cut-off solenoid valve, switched off. between control unit and tuator:33
ground. Check the solenoid valve.


tions and tic menu
compo-
nents
639/2 SID231/2 Communication error Functions via CAN Use diagnostic menu to - -
with Control unit, bus not working. find incorrect segment.
engine (D7940).
engine (D7940).
engine (D7940),
timeout error.
3 with Control unit, bus not working. find incorrect segment.
engine (D7940),
configuration error.
644/2 SID030/2 Electrical error, The engine is Check the cable harness - -
accelerator pedal, switched off. between control unit and
signal not within valid component.
interval. Check the component.
647/4 SID033/4 Electrical error, fan Cooling fan runs Check the cable harness D7940/Ac- -
connection, cable constantly. between control unit and tuator:10,
short circuit to component. Actuator:9
651/5 SID001/5 Electrical error, Engine only runs Check the cable harness D7940/Ac- -
injector cylinder 1, on 5 cylinders, between control unit and tuator:10,
open circuit on cable. sounds rough component. Actuator:9
and has reduced Check the injector.
power.
cable short circuit to sounds rough component. Actuator:9
ground. and has reduced Check the injector.
power.
injector cylinder 2, on 5 cylinders, between control unit and tuator:7, 8
open circuit on cable. sounds rough component.
power.
cable short circuit to sounds rough component.
power.
power.
653/6 SID003/6 Electrical error, Engine only runs Check cable between D7940/Ac- -
injector cylinder 3, on 5 cylinders, control unit and tuator:6, 16
ground. and has reduced Check component.
power.


tions and tic menu
compo-
nents
open circuit on cable. sounds rough component. 36
power.
cable short circuit to sounds rough component. 36
power.
power.
ground. and has reduced Check component.
power.
and has reduced Check component.
power.
power.
702/3 SID040/3 Electrical error, No limitation. Check the cable harness D7940/Ac- -
PID154/3 auxiliary output 2, between control unit and tuator:14
703/3 SID051/3 Electrical error, No limitation. Check the cable harness D7940/Ac- -
auxiliary output 2, between control unit and tuator:45
974/3 SID029/3 Electrical error, extra The engine does Check the cable harness D7940/OE- -
accelerator pedal, not respond to between control unit and M:21
974/4 SID029/4 Electrical error, extra The engine does Check the cable harness D7940/OE- -
accelerator pedal, not respond to between control unit and M:21
974/19 SID029/2 Communication error The engine does Use diagnostic menu to - -
with Control unit KFU not respond to find incorrect segment.
(D7971), electrical throttle application.
error, accelerator
pedal.


tions and tic menu
compo-
nents
1043/3 PID221/3 Electrical error, Engine only Check the cable harness D7940/OE- -
accelerator pedal running at idle. between control unit and M:48
reference voltage, component.
cable short circuit to Check the component.
voltage.
1043/4 PID221/4 Electrical error, Engine only Check the cable harness D7940/OE- -
accelerator pedal running at idle. between control unit and M:48
reference voltage, component.
cable short circuit to Check the component.
ground.
1072/11 SID070/1 Electrical error, Engine brake Check the cable harness D7940/Ac- -
1 solenoid valve engine 1 cannot be between control unit and tuator:44
brake 2. activated. component.
Check the solenoid valve.
1073/11 SID029/1 Electrical error, Engine brake Check the cable harness D7940/Ac- -
1 solenoid valve engine 2 cannot be between control unit and tuator:44
brake 2. activated. component.
Check the solenoid valve.
1079/3 SID232/3 Electrical error, Reduced engine Check the cable harness D7940/Se- -
reference voltage power. between control unit and nsor:17, 37
to sensor short circuit component.
to voltage. Check the sensor.
1079/4 SID232/4 Electrical error, Reduced engine Check the cable harness D7940/Se- -
reference voltage power. between control unit and nsor:17, 37
to sensor short circuit component.
to ground. Check the sensor.
1188/3 SID032/3 Electrical error, Reduced engine Check the cable harness D7940/Ac- -
solenoid valve power. between control unit and tuator:24
wastegate 1 short component.
circuit to voltage. Check the solenoid valve.
solenoid valve power. between control unit and tuator:23
wastegate 2 short component.
circuit to voltage. Check the solenoid valve.
wastegate solenoid power. between control unit and tuator:23
valve 2 short circuit component.
to ground. Check the solenoid valve.
1265/4 SID085/4 Electrical error, No limitation. Check the cable harness - -
oil-burn solenoid between control unit and
valve, cable short component.
circuit to ground. Check the solenoid valve.
1319/2 PID102/2 Electrical error, boost Reduced engine Check the cable harness D7940/Se- -
pressure sensor. power. between control unit and nsor:9
component.
Check the sensor.
1380/1 PID017/1 Low oil level engine. No limitation. Check the oil level in - -
the engine, top up if
necessary.


tions and tic menu
compo-
nents
1383/31 SID151/1 Engine turned off No limitation. Turn off the engine with - -
1 other than with start the start key.
key, causing load.
1384/31 SID029/1 Engine turned off No limitation. Turn off the engine with - -
4 other than with start the start key.
key, causing load.
1387/3 PID223/3 Electrical error, extra No protection Check the cable harness D7940/Se- -
pressure sensor, for pressure between control unit and nsor:19
cable short circuit to (customer-specific component.
voltage. option). Check the sensor.
1387/4 PID223/4 Electrical error, extra No protection Check the cable harness D7940/Se- -
pressure sensor, for pressure between control unit and nsor:19
cable short circuit to (customer-specific component.
ground. option). Check the sensor.
1484/31 SID216/1 Error codes in other No limitation. Check error codes for - -
1 control units. other control units on the
machine, in particular
Control unit KFU
(D7971) and Control unit,
transmission (D7930).

2 Transmission – Transmission D:51
2 Transmission
Error codes transmission
In the event of serious faults in the transmission the control unit
uses four conditions with reduced functionality in order to protect the
transmission from damage. These are:
• "Substitute clutch control".
In this mode the operator can use the machine as usual. However,
gear shifting and change of direction is not under the control of
normal modulation. The control unit uses the default values for
the modulation of the clutches.
• "Limp home".
In this mode, the operator can use one of the transmission gears
in each direction, and in some cases only in one direction. To
continue to drive in the event of a fault with the "Limp home"
restriction, the machine must be stopped to a standstill and the gear
selector moved to neutral before the gear can be selected again.
• "Transmission shut down".
In this mode, the transmission is permanently in neutral as the
solenoid valves for the clutches and parts of the power supply to
the transmission are shut off. Park the machine and switch off
the engine.
• "TCU shut down".
In this mode, the transmission is permanently in neutral as all
solenoid valves and all power supplies to the transmission are shut
off. Park the machine and switch off the engine.
D:8.
Error codes transmission ZF 5WG261
Connec-
Display tions and Diagnos-
Description Limitation Action
(SPN/F- Code ZF code compo- tic menu
MI) (dec) (hex) nents
5110/3 37 25 The transistor has No limitation. Check the cable D7930- 2.8 Control
been tripped due harness between 2/39 - A3/8 System
to short circuit to control unit and 3/XX DI-
voltage or open component. AGNOSE,
circuit in the circuit Check the sensor. page 8:36
for Sensor, oil The sensor is
temperature sump. mounted inside
the transmission.
511074 38 26 The transistor has No limitation. Check the cable D7930- 2.8 Control
been tripped due harness between 2/39 - A3/8 System
to short circuit to control unit and 3/XX DI-
ground in the circuit component. AGNOSE,
for Sensor, oil Check the sensor. page 8:36
temperature sump, The sensor is
transmission. mounted inside
the transmission.

D:52 2 Transmission – Transmission
Connec-
been tripped due harness between 2/49 - System
to short circuit control unit and B7660/1 3/XX DI-
to voltage or component. AGNOSE,
open circuit in the Check the sensor. page 8:36
circuit for Sensor,
oil temperature
transmission
(B7660).
been tripped due harness between 2/49 - System
to short circuit control unit and B7660/1 3/XX DI-
to ground in the component. AGNOSE,
circuit for Sensor, Check the sensor. page 8:36
oil temperature
transmission
(B7660).
5140/3 49 31 The transistor has Hard shifting Check the cable D7930- -
been tripped due (Substitute harness between 2/19 -
to short circuit to clutch control). control unit and B7530/1
voltage or open component.
circuit in the circuit Check the sensor.
for Sensor, engine
speed (B7530).
Voltage over 7.0 V.
ground in the circuit component.
for Sensor, engine Check the sensor.
speed (B7530).
Voltage below 0.45
V.
5140/12 51 33 Logical error Hard shifting Check the cable D7930- -
Sensor engine (Substitute harness between 2/19 -
speed (B7530). clutch control). control unit and B7530/1
Sudden loss of component.
speed signal. Check that the
sensor is connected
correctly.
Check that the
sensor is installed
correctly.
Check the sensor.
voltage or open If any of the component.
circuit in the circuit error codes Check the sensor.
for Sensor, turbine 52-54 are
speed (B7510). set at the
Voltage over 7.0 V. same time, the
transmission is
locked in neutral
(Shut-down).

Connec-
ground in the circuit If any of the component.
for Sensor, turbine error codes Check the sensor.
speed (B7510). 52-54 are
Voltage below 0.45 set at the
V. same time, the
transmission is
locked in neutral
(Shut-down).
Sensor turbine (Substitute harness between 2/41 -
Sudden loss of If any of the component.
speed signal. error codes Check that the
52-54 are sensor is connected
set at the correctly.
same time, the Check that the
transmission is sensor is installed
locked in neutral correctly.
(Shut-down).
Check the sensor.
voltage or open component.
circuit in the circuit Check the sensor.
for Sensor, drum
speed (B7520).
Voltage over 7.0 V.
ground in the circuit component.
for Sensor, drum Check the sensor.
speed (B7520).
Voltage below 0.45
V.
Sensor drum (Substitute harness between 2/42 -
Sudden loss of component.
speed signal. Check that the
sensor is connected
correctly.
Check that the
sensor is installed
correctly.
Check the sensor.

Connec-
5170/3 58 3A The transistor has Hard shifting Check the cable D7930- -
voltage or open If any of the component.
circuit in the circuit error codes Check the sensor.
for Sensor, output 58-60 are
shaft (B7580). set at the
Voltage over 12.5 same time, the
V. transmission is
locked in neutral
(Shutdown).
5170/4 59 3B The transistor has Hard shifting Check the cable D7930- -
ground in the circuit If any of the component.
for Sensor, output error codes Check the sensor.
shaft (B7580). 58-60 are
Voltage below 1.0 set at the
V. same time, the
transmission
is locked in
neutral.
5170/12 60 3C Logical error Hard shifting Check the cable D7930- -
Sensor speed (Substitute harness between 2/62 -
output shaft clutch control). control unit and B7580/2
(B7580). If any of the component.
Sudden loss of error codes Check that the
speed signal. 58-60 are sensor is connected
set at the correctly.
same time, the Check that the
transmission sensor is installed
is locked in correctly.
neutral.
Check the sensor.
5180/2 62 3E Logical error Hard shifting Check that the D7930- -
Sensor speed (Substitute sensor is installed 2/62 -
output shaft clutch control). correctly. B7580/2
(B7580). If any of the Check the sensor.
Speed signal is 0, error codes
in spite of the other 58-60 are
sensor indicating set at the
that it should be same time, the
higher. transmission
shifts to neutral
(Limp home).
5260/9 84 54 Incorrect CAN - Check CAN bus - -
message from drive-train with
Control unit KID diagnostic menus.
(D7950). Check Control unit,
KID (D7950).
5270/9 85 55 Incorrect CAN If joystick Check CAN bus - -
message from control is drive-train with
Control unit KFU activated, the diagnostic menus.
(D7971). transmission Check Control unit
switches to KFU (D7971)
neutral.

Connec-
5280/9 86 56 Incorrect CAN Hard shifting Check CAN bus - -
message from (Substitute drive-train with
Control unit engine clutch control). diagnostic menus.
(D7940). Check Control unit,
engine (7940).
5310/2 89 59 Logical error AEB - Check the software - -
request at the in Control unit
same time as transmission
parking brake (D7930).
request via the
CAN bus.
5390/2 97 61 Incorrect AEB - Check CAN bus - -
request via the drive-train with
CAN bus. diagnostic menus.
Check the control
unit's connections.
Check Control
unit, transmission
(D7930).
5480/3 113 71 The transistor has The Check the cable D7930- -
been tripped due transmission is harness between 2/32 - A3/3
to short circuit locked in neutral control unit and
to voltage in position. component.
the circuit to the In the event Check the cable
Solenoid valve of errors harness in the
clutch K1. on several transmission.
clutches: Check the solenoid
Transmission valve.
locked in neutral
(Shut-down).
to short circuit to locked in neutral control unit and
ground in the circuit position. component.
to the Solenoid In the event Check the cable
valve clutch K1. of errors harness in the
on several transmission.
Transmission valve.
locked in neutral
(Shut-down).
been tripped due transmission harness between 2/32 - A3/3
to open circuit in shifts to neutral control unit and
the circuit to the (Limp-home). component.
Solenoid valve In the event Check the cable
clutch K1. of errors harness in the
Transmission valve.
locked in neutral
(Shut-down).

Connec-
to short circuit locked in neutral control unit and
to voltage in position. component.
Transmission valve.
locked in neutral
(Shut-down).
to short circuit to shifts to neutral control unit and
ground in the circuit (Limp-home). component.
Transmission valve.
locked in neutral
(Shut-down).
Transmission valve.
locked in neutral
(Shut-down).
to short circuit shifts to neutral control unit and
to voltage in (Limp-home). component.
Transmission valve.
locked in neutral
(Shut-down).
Transmission valve.
locked in neutral
(Shut-down).

Connec-
Transmission valve.
locked in neutral
(Shut-down).
Transmission valve.
locked in neutral
(Shut-down).
Transmission valve.
locked in neutral
(Shut-down).
Transmission valve.
locked in neutral
(Shut-down).
5520/3 132 84 The transistor has The Check the cable D7930-2/9 -
been tripped due transmission harness between - A3/5
clutch KV. on several transmission.
Transmission valve.
locked in neutral
(Shut-down).

Connec-
valve clutch KV. of errors harness in the
Transmission valve.
locked in neutral
(Shut-down).
clutch KV. of errors harness in the
Transmission valve.
locked in neutral
(Shut-down).
clutch KR. on several transmission.
Transmission valve.
locked in neutral
(Shut-down).
valve clutch KR. of errors harness in the
Transmission valve.
locked in neutral
(Shut-down).
clutch KR. of errors harness in the
Transmission valve.
locked in neutral
(Shut-down).

Connec-
5660/2 177 B1 Clutch K1 slips. The Check the supply - -
The difference transmission oil pressure to the
between the input shifts to neutral clutch.
and output shaft (Limp-home). Check the main oil
speed is too high In the event pressure.
when the clutch is of errors Check the speed
locked. on several sensors.
clutches:
Transmission
locked in neutral
(Shut-down).
clutches:
Transmission
locked in neutral
(Shut-down).
clutches:
Transmission
locked in neutral
(Shut-down).
clutches:
Transmission
locked in neutral
(Shut-down).
5680/2 181 B5 Clutch KV slips. The Check the supply - -
clutches:
Transmission
locked in neutral
(Shut-down).

Connec-
5685/2 182 B6 Clutch KR slips. The Check the supply - -
clutches:
Transmission
locked in neutral
(Shut-down).
5700/0 183 B7 Transmission oil No limitation. Check the oil level. D7930- 2.8 Control
temperature sump Check transmission 2/39 - A3/8 System
too high. oil cooler. 3/XX DI-
Temperature above AGNOSE,
Check the sensor. page 8:36
100 °C.
5730/0 186 BA The transistor has No limitation. Change oil filter. D7930- 2.8 Control
been tripped due Check the cable 2/17 - System
to short circuit harness between B2710/1 3/XX DI-
to voltage or control unit and AGNOSE,
open circuit in the component. page 8:36
circuit for Sensor,
transmission oil Check the sensor.
filter (B2710).
5745/15 188 BC Speed limitation - - - -
exceeded.
5755/15 194 C2 Torque limit input - - - -
shaft too high.
5760/0 195 C3 Transmission No limitation. Check the oil level. D7930- 2.8 Control
oil temperature Check transmission 2/49 - System
Torque converter oil cooler. B7660/1 3/XX DI-
too high. AGNOSE,
Check the sensor. page 8:36
Temperature above
120 °C.
5810/3 209 D1 The transistor has - Check the cable D7930- -
been tripped due harness between 2/46 -
to short circuit control unit and B7660,
to voltage in the component. D7930-
circuit for the power Check the 2/46 -
supply to sensors. component. S2710,
Voltage over 6 V. D7930-
2/46 - A3
5810/4 210 D2 The transistor has - Check the cable D7930- -
been tripped due harness between 2/46 -
to short circuit control unit and B7660,
to ground in the component. D7930-
circuit for the power Check the 2/46 -
supply to sensors. component. S2710,
Voltage below 4 V. D7930-
2/46 - A3

Connec-
5820/4 211 D3 Low battery Transmission Check alternator, D7930- -
voltage. locked in neutral battery, and 2/23, 68
Voltage below 18 (Shut-down). cable harness - F58-1/5:1
V. between battery D7930-
and alternator. 2/45 -
F58-2/5:1
5820/3 212 D4 High battery Transmission Check alternator D7930- -

voltage. locked in neutral and battery. 2/23, 68
Voltage over 32.5 (Shut-down). If auxiliary start - F58-1/5:1
V. equipment is D7930-
connected, 2/45 -
disconnect it. F58-2/5:1
5830/2 213 D5 The transistor has Transmission Check the cable D793/12 -
been tripped due locked in neutral harness between -A3/7
to short circuit to (Shut-down). control unit and D793/13 -
voltage or open solenoid valve. A3/7
circuit in the circuit Check the control
for power supply unit.
for solenoid valves
VPS 1. Check the solenoid
valve.
5840/2 214 D6 The transistor has Transmission Check the cable D7930-2/8 -
been tripped due locked in neutral harness between -
to short circuit to (Shut-down). control unit and D7930-
voltage or open solenoid valve. 2/53 -
circuit in the circuit Check the control
for power supply unit.
for solenoid valves
VPS 2. Check the solenoid
valve.
5860/3 227 E3 The transistor has - Check the cable - -
been tripped due harness between
to short circuit to the control unit and
voltage on the display.
CAN-bus to the Check the display.
display.
5860/4 228 E4 The transistor has - Check the cable - -

been tripped due harness between
to short circuit the control unit and
to ground to the display.
CAN-bus to the Check the display.
display.

Connec-
5270/9 229 E5 Incorrect CAN The Check the cable - -
message from the transmission harness between
display. shifts to neutral the control unit and
(Limp-home). display.
Check the display.
5880/2 230 E6 Incorrect CAN The - - -
message for transmission
identification. shifts to neutral
(Limp-home).
5890/2 241 F1 Memory error Transmission Replace the control - -

Control unit, locked in neutral unit.
transmission (Shut-down).
(D7930).
5900/13 242 F2 Incorrect Transmission Reprogram Control - -
configuration locked in neutral unit, transmission
Control unit (Shut-down). (D7930).
transmission
(D7930).
5910/13 243 F3 Program error Transmission Replace Control - -
Control unit, locked in neutral unit, transmission
transmission (Shut-down). (D7930).
(D7930).
5930/7 245 F5 Connection error Transmission Check the - -
during calibration. locked in neutral transmission
(Shut-down). after incorrect
connections.
5930/13 246 F6 Calibration data No limitation. Calibrate the - -
incorrect. transmission; see
Transmission,
calibration, page
2:17.

8 Control system – Control system D:63
8 Control system
Error codes machine
D:8.
Node specifies which control unit generated the error.
Tabell Node, explanation
Node Control unit

1 KCU (D7901)
2 KFU (D7971)
3 KFU-2 (D7972)
6 KAU-2 (D7912)
7 KAU (D7911)
11 KPU (D7902)
12 KID (D7950)
Error codes machine
Connec-
tions
Lo- and Diag-
P 708 14 1, Operating - Connect the - - -
11, times do not Kalmar Service
12 correspond tool and Repair
to reference or contact
Control Cargotec
unit KFU support.
(D7971).
H 1037 6 11 2 Indicator Light not Check the H1037 - Control
light working. cable harness D7902/C- lever, de-
Levelling between control 4:2 scription,
lock (H1037) unit control page 7:6
in switch on lever.
control lever.
S 1310 7 11 Travel Selection Check cabling S1310 2.1 Con- Travel di-
direction of gear or between the trols & In- rection
selector activation control unit and str 1/XX selec-
(S1310), of parking the component DIAG- tor and
logical error brake not with diagnostic NOSE, parking
working. menu. page brake,
Check the 8:33 descrip-
travel direction tion,
selector. page 2:9

D:64 8 Control system – Control system
Error codes machine
Connec-
tions
Lo- and Diag-
B 2460 2 1 Pressure Cooling Check the drive B2460 9.4 Cli- Pressure
switch function belt for the D7901/C- mate switch,
(B2460) for for air compressor for 1:1 System descrip-
low or high conditioning air conditioning. 6/XX tion,
pressure in unit not Check that DIAG- page
refrigerant working. compressor for NOSE, 9:42
circuit. air conditioning page
is activated. 8:60
Check cabling
between the
control unit and
the component
with diagnostic
menu.
Pressure
test the air
conditioning
unit.
K 3150 6 1 Relay Starter motor Check cabling K3150 11.7 I/O Ignition
ignition not working. between the D7901/C- D7901 voltage
(K3150), control unit and 2:11 KCU (15), de-
short circuit the component 1-48/XX scription,
to ground. with diagnostic DIAG- page
menu. NOSE, 11:17
Check the page
component. 8:95
K 3600 6 2 Only engine The engine Check the K3600/86 1.11 Start Starter
alternative does not cable harness D7971/C- & Stop motor,
Cummins start. between control 1:43 1/XX descrip-
QSM11 unit and DIAG- tion (en-
Starter relay component. NOSE, gine al-
engine page ternative
(K3600) 8:32 Cummins
short circuit QSM11),
to ground. page
1:36
E 4000 5 2 LE Low beam Low beam Check bulb. E4000-LE 9.6 Light- Control
left (E4000), left not Check cabling D7971/C- ing Sys valve cab
open circuit. working. between the 2:1 3/XX move-
control unit and DIAG- ment, de-
the component NOSE, scription,
with diagnostic page page
menu. 8:67 9:96
E 4000 6 2 LE Low beam Low beam Check cabling E4000-LE 9.6 Light- Control
left (E4000) left not between the D7971/C- ing Sys valve cab
short circuit working. control unit and 2:1 3/XX move-
to ground. the component DIAG- ment, de-
with diagnostic NOSE, scription,
menu. page page
8:67 9:96

Error codes machine
Connec-
tions
Lo- and Diag-
E 4000 5 2 RI Low beam Low beam Check bulb. E4000-RI 9.6 Light- Control
right right not Check cabling D7971C2: ing Sys valve cab
(E4000), working. between the 3 3/XX move-
open circuit. control unit and DIAG- ment, de-
menu. 8:67 9:96
E 4000 6 2 RI Low beam Low beam Check bulb. E4000-RI 9.6 Light- Control
right right not Check cabling D7971C2: ing Sys valve cab
(E4000), working. between the 3 3/XX move-
short circuit control unit and DIAG- ment, de-
to ground. the component NOSE, scription,
menu. 8:67 9:96
E 4020 5 2 LE High beam High beam Check bulb. E4020-LE 9.6 Light- Control
left (E4020), left not Check cabling D7971/C- ing Sys valve cab
open circuit. working. between the 2:2 2/XX move-
control unit and DIAG- ment, de-
menu. 8:66 9:96
E 4020 6 2 LE High beam High beam Check cabling E4020-LE 9.6 Light- Control
left (E4020), left not between the D7971/C- ing Sys valve cab
short circuit working. control unit and 2:2 2/XX move-
to ground. the component DIAG- ment, de-
menu. page page
8:66 9:96
E 4020 5 2 RI High High beam Check bulb. E4020-RI 9.6 Light- Control
beam right right not Check cabling D7971/C- ing Sys valve cab
(E4020), working. between the 2:4 2/XX move-
menu. 8:66 9:96
E 4020 6 2 RI High High beam Check cabling E4020-RI 9.6 Light- Control
beam right right not between the D7971/C- ing Sys valve cab
(E4020), working. control unit and 2:4 2/XX move-
short circuit the component DIAG- ment, de-
to ground. with diagnostic NOSE, scription,
menu. page page
8:66 9:96
E 4041 5 2 1 Extra Extra Check bulb. E4041 9.6 Light- Control
working working Check cabling D7971/C- ing Sys valve cab
lights frame lights frame between the 2:5 16/XX move-
left (E4041- left not control unit and DIAG- ment, de-
LE-A) working. the component NOSE, scription,
(E4041-LE- with diagnostic page page
B), open menu. 8:70 9:96
circuit.

Error codes machine
Connec-
tions
Lo- and Diag-
E 4041 6 2 1 Extra Extra Check cabling E4041 9.6 Light- Control
working working between the D7971/C- ing Sys valve cab
lights frame lights frame control unit and 2:5 16/XX move-
left (E4041- left not the component DIAG- ment, de-
LE-A) working. with diagnostic NOSE, scription,
(E4041-LE- menu. page page
B), short 8:70 9:96
circuit to
ground.
right (E4041- right not control unit and DIAG- ment, de-
RI-A) working. the component NOSE, scription,
(E4041-RI with diagnostic page page
B), open menu. 8:70 9:96
circuit.
RI-A) working. the component NOSE, scription,
(E4041-RI- with diagnostic page page
B), short menu. 8:70 9:96
circuit to
ground.
E 4042 5 1 LE Working Working Check bulb. E4042-LE 9.6 Light- Control
lights cab left lights left not Check cabling D7901/C- ing Sys valve cab
(E4042-LE), working. between the 2:22 11/XX move-
menu. 8:69 9:96
E 4042 6 1 LE Working Working Check cabling E4042-LE 9.6 Light- Control

lights cab left lights left not between the D7901/C- ing Sys valve cab
(E4042-LE), working. control unit and 2:22 11/XX move-
menu. page page
8:69 9:96
E 4042 5 1 RI Working Working Check bulb. E4042-RI 9.6 Light- Control
lights right lights right Check cabling D7901/C- ing Sys valve cab
(E4042-RI) not working. between the 2:23 11/XX move-
menu. 8:69 9:96
E 4042 6 1 RI Working Working Check cabling E4042-RI 9.6 Light- Control

lights right lights right between the D7901/C- ing Sys valve cab
(E4042-RI), not working. control unit and 2:23 11/XX move-
menu. page page
8:69 9:96

Error codes machine
Connec-
tions
Lo- and Diag-
lights boom lights boom Check cabling D7971/C- ing Sys valve cab
left (E4043- left not between the 2:36 14/XX move-
LE), open working. control unit and DIAG- ment, de-
circuit. the component NOSE, scription,
menu. 8:70 9:96

lights boom lights boom between the D7971/C- ing Sys valve cab
left (E4043- left not control unit and 2:36 14/XX move-
LE), short working. the component DIAG- ment, de-
circuit to with diagnostic NOSE, scription,
ground. menu. page page
8:70 9:96
lights boom lights boom Check cabling D7971/C- ing Sys valve cab
right (E4043- right not between the 2:36 14/XX move-
RI) open working. control unit and DIAG- ment, de-
circuit. the component NOSE, scription,
menu. 8:70 9:96
E 4043 6 2 RI Working Working Check cabling E4043-RI 9.6 Light- Control

lights boom lights boom between the D7971/C- ing Sys valve cab
right (E4043- right not control unit and 2:36 14/XX move-
RI), short working. the component DIAG- ment, de-
8:70 9:96
lights lights Check cabling D7911/C2 ing Sys valve cab
attachment attachment between the :5 21/XX move-
left (E4044- left not control unit and DIAG- ment, de-
LE), open working. the component NOSE, scription,
circuit. with diagnostic page page
menu. 8:72 9:96

lights lights between the D7911/C2 ing Sys valve cab
attachment attachment control unit and :5 21/XX move-
left (E4044- left not the component DIAG- ment, de-
LE), short working. with diagnostic NOSE, scription,
circuit to menu. page page
ground. 8:72 9:96
lights lights Check cabling D7911/C2 ing Sys valve cab
attachment attachment between the :6 21/XX move-
RI), open working. the component NOSE, scription,
menu. 8:72 9:96

Error codes machine
Connec-
tions
Lo- and Diag-
E 4044 6 7 Ri Working Working Check cabling E4044-RI 9.6 Light- Control
lights lights between the D7911/C2 ing Sys valve cab
attachment attachment control unit and :6 21/XX move-
right (E4044- right not the component DIAG- ment, de-
RI), short working. with diagnostic NOSE, scription,
ground. 8:72 9:96
E 4044 5 7 LE-B Working Working Check bulb. E4044- 9.6 Light- Control
lights lights Check cabling LE-B ing Sys valve cab
attachment attachment between the D7911/C2 22/XX move-
left (E4044- left not control unit and :3 DIAG- ment, de-
LE), open working. the component NOSE, scription,
menu. 8:72 9:96
E 4044 6 7 LE-B Working Working Check cabling E4044- 9.6 Light- Control
lights lights between the LE-B ing Sys valve cab
attachment attachment control unit and D7911/C2 22/XX move-
left (E4044- left not the component :3 DIAG- ment, de-
LE), short working. with diagnostic NOSE, scription,
ground. 8:72 9:96
E 4044 5 7 RI-B Working Working Check bulb. E4044- 9.6 Light- Control
lights lights Check cabling RI-B ing Sys valve cab
attachment attachment between the D7911/C2 22/XX move-
right (E4044- right not control unit and :4 DIAG- ment, de-
RI), open working. the component NOSE, scription,
menu. 8:72 9:96
E 4044 6 7 RI-B Working Working Check cabling E4044- 9.6 Light- Control
lights lights between the RI-B ing Sys valve cab
attachment attachment control unit and D7911/C2 22/XX move-
right (E4044- right not the component :4 DIAG- ment, de-
RI), short working. with diagnostic NOSE, scription,
ground. 8:72 9:96
H 4110 6 2 Brake lights Brake lights Check cabling H4110 9.6 Light- Control
(H4110-RI) not working. between the D7971/C- ing Sys valve cab
and (H4110- control unit and 1:13 5/XX move-
LE), short the component DIAG- ment, de-
Check the lamp. 8:67 9:96
H 4120 6 2 1 Rear lights Tail lights not Check cabling H4120 9.6 Light- Control
(H4120-LE) working. between the D7971/C- ing Sys valve cab
and (H4120- control unit and 1:19 4/XX move-
RI) the component DIAG- ment, de-
menu. page page

Error codes machine
Connec-
tions
Lo- and Diag-
H 4160 6 2 Position Running Check cabling H4160-FL 9.6 Light- Control
lights lights not between the H416 ing Sys valve cab
(H4160-FL, working. control unit and 0-FR 9/XX move-
H4160-FR, the component DIAG- ment, de-
H4160-RL, with diagnostic H416 NOSE, scription,
H4160-RR), menu. 0-RL page page
short circuit Check the lamp. H416 8:68 9:96
to ground. 0-RR
D7971/C-
1:16
H 4220 6 2 LE Direction Left direction Check cabling H4220-FL 9.6 Light- Control
indicators left indicator not between the H422 ing Sys valve cab
(H4220-FL) working. control unit and 0-RL 7/XX move-
and (H4220- the component DIAG- ment, de-
RL) with diagnostic D7971/C- NOSE, scription,
menu. 1:20 page page
H 4220 6 2 RI Direction Right Check cabling H422 9.6 Light- Control

indicators direction between the 0-FR ing Sys valve cab
right (H4220- indicator not control unit and H422 8/XX move-
FR) and working. the component 0-RR DIAG- ment, de-
(H4220-RR) with diagnostic NOSE, scription,
menu. D7971/C- page page
1:26 8:68 9:96
Check the lamp.
H 4281 6 2 Revolving Revolving Check cabling H4281 9.7 Sig- Control
beacon beacon on between the D7971/C- nalling valve cab
on boom boom not control unit and 1:45 Sys 3/XX move-
(H4281), working. the component DIAG- ment, de-
short circuit with diagnostic NOSE, scription,
to ground. menu. page page
Check the bulb 8:73 9:96
holder.
E 4340 6 1 Interior Interior Check cabling E4340 9.6 Light- Control
lighting lighting in between the D7901/C- ing Sys valve cab
(E4340), cab not control unit and 2:30 19/XX move-
short circuit working. the component DIAG- ment, de-
menu. page page
Check bulb. 8:71 9:96
H 5001 6 7 Indicator Indicator Check cabling H5001 - Control

light light not between the D7911/C1 valve cab
overheight working. control unit and :20 move-
legs up the component ment, de-
(H5001) (on with diagnostic scription,
inner boom), menu. page
short circuit Check the lamp. 9:96
to ground.

Error codes machine
Connec-
tions
Lo- and Diag-
H 5620 6 7 Indicator Indicator Check cabling H5620 7.9 Load Control
light light not between the D7911/C1 Carrier valve cab
unlocked working. control unit and :12 9/XX move-
twistlocks the component DIAG- ment, de-
(H5620) (on with diagnostic NOSE, scription,
inner boom), menu. page page
short circuit Check the lamp. 8:51 9:96
to ground.
H 5620 6 1 2 Indicator Indicator Check cabling H5620-2 7.9 Load Control
light light not between the D7901/C- Carrier valve cab
unlocked working. control unit and 2:1 13/XX move-
twistlocks the component DIAG- ment, de-
(H5620-2) with diagnostic NOSE, scription,
(on roof menu. page page
panel in cab), Check the light 8:52 9:96
short circuit panel.
to ground.
light locked light not between the D7901/C- Carrier valve cab
twistlocks working. control unit and 2:2 12/XX move-
(H5630-2) the component DIAG- ment, de-
(on roof with diagnostic NOSE, scription,
panel in cab), menu. page page
short circuit Check the light 8:52 9:96
to ground. panel.
light locked light not between the D7911/C1 Carrier valve cab
twistlocks working. control unit and :13 8/XX move-
(H5630) (on the component DIAG- ment, de-
inner boom), with diagnostic NOSE, scription,
short circuit menu. page page
to ground. Check the lamp. 8:51 9:96

light contact light not between the D7901/C- Carrier valve cab
(H5640-2) working. control unit and 2:3 14/XX move-
(on roof the component DIAG- ment, de-
panel in cab), with diagnostic NOSE, scription,
to ground. Check the light 8:52 9:96
panel.
light contact light not between the D7911/C1 Carrier valve cab
(H5640) (on working. control unit and :16 8/XX move-
inner boom), the component DIAG- ment, de-

Error codes machine
Connec-
tions
Lo- and Diag-
H 5991 6 1 0 Fasten Indicator Check cabling H5991 9.3 Seat Control
seat belt light not between the D7901/C- 1/XX valve cab
indicator light working. control unit and 2:7 DIAG- move-
(H5991), the component NOSE, ment, de-
short circuit with diagnostic page scription,
to ground. menu. 8:58 page
Check the 9:96
component.
H 5992 6 1 Mini- Indicator Check cabling H5992 5.2 Control
wheel/joy- light not between the D7901/C- Power valve cab
stick con- working. control unit and 2:33 Assisted move-
trol, indicator the component 4/XX ment, de-
light (on/off) with diagnostic DIAG- scription,
(H5992), menu. NOSE, page
short circuit Check the page 9:96
to ground. component. 8:39
H 5993 6 11 3 Indicator Indicator Check the H5993 11.8 I/O Control

light tilt lock light not cable harness D7902/C- D7902 valve cab
(H5993) in working. between control 4:3 KPU move-
the switch on unit control 1–41/XX ment, de-
the control lever. DIAG- scription,
lever, short Check the NOSE, page
circuit to control lever. page 9:96
ground 8:95
Y 6003 5 2 Solenoid Attachment Check cabling Y6003 10.4 Control
valve functions between the D7971/C- Pumps valve cab
engagement not working control unit and 1:15 1/XX move-
of hydraulics or are very the component DIAG- ment, de-
top lift slow. with diagnostic NOSE, scription,
(Y6003), menu. page page
open circuit. Check the 8:78 9:96
component.
Y 6003 6 2 Solenoid Attachment Check cabling Y6003 10.4 Control
valve functions between the D7971/C- Pumps valve cab
engagement not working control unit and 1:15 1/XX move-
of hydraulics or are very the component DIAG- ment, de-
top lift slow. with diagnostic NOSE, scription,
(Y6003), menu. page page
short circuit Check the 8:78 9:96
to ground. component.
Y 6004 5 2 Solenoid Lower not Check cabling Y6004 7.2 Lifting Control
valve, lower working. between the D7971/C- Lower- valve cab
(Y6004), control unit and 1:28 ing 7/XX move-
open circuit. the component DIAG- ment, de-
menu. page page
Check the 8:42 9:96
component.

Error codes machine
Connec-
tions
Lo- and Diag-
Y 6004 6 2 Solenoid Lower not Check cabling Y6004 7.2 Lifting Control
valve lower working. between the D7971/C- Lower- valve cab
menu. page page
Check the 8:42 9:96
component.
Y 6005 5 2 Solenoid Lift not Check cabling Y6005 7.2 Lifting Control
valve, lift working. between the D7971/C- Lower- valve cab
open circuit the component DIAG- ment, de-
menu. page page
Check the 8:41 9:96
component.
Y 6005 6 2 Solenoid Lift not Check cabling Y6005 7.2 Lifting Control
valve lift working. between the D7971/C- Lower- valve cab
menu. page page
Check the 8:41 9:96
component.
Y 6006 5 2 Solenoid Boom out not Check cabling Y6006 7.2 Ex- Control
valve, boom working. between the D7971/C- tension valve cab
out (Y6006), control unit and 1:33 1/XX move-
menu. page page
Check the 8:43 9:96
component.
Y 6006 6 2 Solenoid Boom out not Check cabling Y6006 7.2 Ex- Control
valve boom working. between the D7971/C- tension valve cab
out (Y6006), control unit and 1:33 1/XX move-
menu. page page
Check the 8:43 9:96
component.
Y 6007 5 2 Solenoid Boom in not Check cabling Y6007 7.3 Ex- Control
valve, boom working. between the D7971/C- tension valve cab
in (Y6007), control unit and 1:29 2/XX move-
menu. page page
Check the 8:43 9:96
component.

Error codes machine
Connec-
tions
Lo- and Diag-
Y 6007 6 2 Solenoid Boom in not Check cabling Y6007 7.3 Ex- Control
valve boom working. between the D7971/C- tension valve cab
in (Y6007), control unit and 1:29 2/XX move-
menu. page page
Check the 8:43 9:96
component.
Y 6008 5 7 Solenoid Rotation Check cabling Y6008 7.6 Rota- Control
valve clockwise between the D7911/C1 tion 1/XX valve cab
rotation not working. control unit and :27 DIAG- move-
clockwise the component NOSE, ment, de-
(Y6008), with diagnostic page scription,
open circuit menu. 8:46 page
Check the 9:96
component.
Y 6008 6 7 Solenoid Rotation Check cabling Y6008 7.6 Rota- Control
valve clockwise between the D7911/C1 tion 1/XX valve cab
rotation not working. control unit and :27 DIAG- move-
clockwise the component NOSE, ment, de-
short circuit menu. 8:46 page
to ground. Check the 9:96
component.
Y 6009 5 7 Solenoid Rotation an- Check cabling Y6009 7.6 Rota- Control
valve ro- ticlockwise between the D7911/C1 tion 2/XX valve cab
tation an- not working. control unit and :28 DIAG- move-
ticlockwise the component NOSE, ment, de-
open circuit menu. 8:47 page
Check the 9:96
component.
Y 6009 6 7 Solenoid Rotation an- Check cabling Y6009 7.6 Rota- Control
valve ro- ticlockwise between the D7911/C1 tion 2/XX valve cab
tation an- not working. control unit and :28 DIAG- move-
ticlockwise the component NOSE, ment, de-
short circuit menu. 8:47 page
to ground. Check the 9:96
component.
Y 6010 5 7 Solenoid Tilt out not Check cabling Y6010 7.7 Tilt Control
valve, tilt working between the D7911/C1 4/XX valve cab
out (Y6010), control unit and :37 DIAG- move-
open circuit the component NOSE, ment, de-
with diagnostic page scription,
menu. 8:47 page
Check the 9:96
component.

Error codes machine
Connec-
tions
Lo- and Diag-
Y 6010 6 7 Solenoid Tilt out not Check cabling Y6010 7.7 Tilt Control
valve tilt working between the D7911/C1 4/XX valve cab
out (Y6010), control unit and :37 DIAG- move-
short circuit the component NOSE, ment, de-
to ground. with diagnostic page scription,
menu. 8:47 page
Check the 9:96
component.
Y 6011 5 7 Solenoid Tilt in not Check cabling Y6011 7.7 Tilt Control
valve, tilt working between the D7911/C1 5/XX valve cab
in (Y6011), control unit and :36 DIAG- move-
open circuit. the component NOSE, ment, de-
with diagnostic page scription,
menu. 8:48 page
Check the 9:96
component.
Y 6011 6 7 Solenoid Tilt in not Check cabling Y6011 7.7 Tilt Control
valve tilt working between the D7911/C1 5/XX valve cab
in (Y6010), control unit and :36 DIAG- move-
short circuit the component NOSE, ment, de-
to ground. with diagnostic page scription,
menu. 8:48 page
Check the 9:96
component.
Y 6012 5 7 1 Solenoid Tilt damping Check cabling Y6012-1 7.7 Tilt Control
valve tilt lock not working, between the D7911/C1 6/XX valve cab
1 (Y6012-1), tilt locked. control unit and :23 DIAG- move-
open circuit. Machine the component NOSE, ment, de-
speed limited with diagnostic page scription,
to 5 km/h. menu. 8:48 page
Check the 9:96
component.
short circuit Machine the component NOSE, ment, de-
to ground. speed limited with diagnostic page scription,
Check the 9:96
component.
open circuit. Machine the component NOSE, ment, de-
speed limited with diagnostic page scription,
Check the 9:96
component.

Error codes machine
Connec-
tions
Lo- and Diag-
short circuit Machine the component NOSE, ment, de-
to ground. speed limited with diagnostic page scription,
Check the 9:96
component.
Y 6016 5 2 Solenoid Hydraulic Check cabling Y6016 9.10 Cab Control
valve cab cab between the D7971/C- suspen- valve cab
movement movement control unit and 1:41 sion 2/XX move-
up/forward only moves the component DIAG- ment, de-
(Y6016), in one with diagnostic NOSE, scription,
open circuit. direction. menu. page page
Check the 8:76 9:96
component.
up/forward only moves the component DIAG- ment, de-
(Y6016), in one with diagnostic NOSE, scription,
short circuit direction. menu. page page
to ground. Check the 8:76 9:96
component.
lower/back- only moves the component DIAG- ment, de-
ward in one with diagnostic NOSE, scription,
(Y6017), direction. menu. page page
open circuit. Check the 8:76 9:96
component.
lower/back- only moves the component DIAG- ment, de-
ward in one with diagnostic NOSE, scription,
(Y6017), direction. menu. page page
short circuit Check the 8:76 9:96
to ground. component.
Y 6018 5 7 Solenoid Spreading Check cabling Y6018 7.5 Attach-
valve, not working. between the D7971/C- Spread- ment
spreading control unit and 1:29 ing 10/XX control
out (Y6018), the component DIAG- valve, de-
open circuit with diagnostic NOSE, scription,
menu. page page
Check the 8:45 7:44
component.

Error codes machine
Connec-
tions
Lo- and Diag-
valve not working. between the D7971/C- Spread- ment
out (Y6018), the component DIAG- valve, de-
Check the 8:45 7:44
component.
valve, not working. between the D7971/C- Spread- ment
in (Y6019), the component DIAG- valve, de-
open circuit. with diagnostic NOSE, scription,
menu. page page
Check the 8:46 7:44
component.
valve not working. between the D7971/C- Spread- ment
in (Y6019), the component DIAG- valve, de-
Check the 8:46 7:44
component.
Y 6020 5 7 Solenoid Side shift not Check cabling Y6020 7.4 Side Attach-
valve, side working. between the D7971/C- Shift ment
shift left control unit and 1:34 3/XX control
(Y6020), the component DIAG- valve, de-
open circuit with diagnostic NOSE, scription,
menu. page page
Check the 8:44 7:44
component.
valve side working. between the D7971/C- Shift ment
shift left control unit and 1:34 3/XX control
Check the 8:44 7:44
component.
valve, side working. between the D7971/C- Shift ment
shift right control unit and 1:38 4/XX control
menu. page page
Check the 8:44 7:44
component.

Error codes machine
Connec-
tions
Lo- and Diag-
valve side working. between the D7971/C- Shift ment
shift right control unit and 1:38 4/XX control
Check the 8:44 7:44
component.
Y 6034 5 7 1 Solenoid Levelling Check cabling Y6034-1 7.8 Lev- Levelling
valve locked, between the D7911/C1 elling cylinders'
levelling lock levelling not control unit and :21 5/XX valve
1 (Y6034-1), working. the component DIAG- block, de-
open circuit. Machine with diagnostic NOSE, scription,
speed limited menu. page page
to 5 km/h. Check the 8:49 7:100
component.
short circuit Machine with diagnostic NOSE, scription,
to ground. speed limited menu. page page
component.
open circuit. Machine with diagnostic NOSE, scription,
speed limited menu. page page
component.
short circuit Machine with diagnostic NOSE, scription,
to ground. speed limited menu. page page
component.
Y 6035 5 7 Solenoid Levelling not Check cabling Y6035 7.8 Lev- Attach-
valve lev- working. between the D7911/C1 elling ment
elling anti- control unit and :40 4/XX control
clockwise the component DIAG- valve, de-
(Y6035), with diagnostic NOSE, scription,
open circuit. menu. page page
Check the 8:49 7:99
component.

Error codes machine
Connec-
tions
Lo- and Diag-
valve lev- working. between the D7911/C1 elling ment
elling anti- control unit and :40 4/XX control
component.
valve working. between the D7911/C1 elling ment
levelling control unit and :41 3/XX control
Check the 8:48 7:99
component.
valve working. between the D7911/C1 elling ment
levelling control unit and :41 3/XX control
component.
Y 6039 5 7 Solenoid Twistlocks Check cabling Y6039 7.9 Load Attach-
valve, lock not working. between the D7911/C1 Carrier ment
twistlocks control unit and :15 7/XX control
menu. page page
Check the 8:51 7:106
component.
valve lock not working. between the D7911/C1 Carrier ment
component.
valve, open not working. between the D7911/C1 Carrier ment
menu. page page
component.

Error codes machine
Connec-
tions
Lo- and Diag-
valve open not working. between the D7911/C1 Carrier ment
component.
Y 6045 5 2 LE Solenoid Lower not Check cabling Y6045 7.2 Lifting Valve
valve working. between the D7971/C- Lower- block
blocking control unit and 1:36 ing 8/XX lift cylin-
lower left the component DIAG- der, de-
(Y6045-LE), with diagnostic NOSE, scription,
Check the 8:42 7:20
component.
Y 6045 6 2 LE Solenoid Lower not Check cabling Y6045 7.2 Lifting Valve
lower left the component DIAG- der, de-
component.
Y 6045 5 2 RI Solenoid Lower not Check cabling Y6045 7.2 Lifting Valve
lower right the component DIAG- der, de-
(Y6045-RI), with diagnostic NOSE, scription,
Check the 8:42 7:20
component.
Y 6045 6 2 RI Solenoid Lower not Check cabling Y6045 7.2 Lifting Valve
lower right the component DIAG- der, de-
component.
Y 6050 5 2 Solenoid Boom in not Check cabling Y6050 7.3 Ex- Valve
valve working. between the D7971/C- tension block ex-
blocking control unit and 1:35 3/XX tension
extension the component DIAG- cylin-
(Y6050), with diagnostic NOSE, der, de-
open circuit menu. page scription,
Check the 8:43 page
component. 7:34

Error codes machine
Connec-
tions
Lo- and Diag-
Y 6050 6 2 Solenoid Boom in not Check cabling Y6050 7.3 Ex- Valve
valve working. between the D7971/C- tension block ex-
blocking control unit and 1:35 3/XX tension
extension the component DIAG- cylin-
(Y6050), with diagnostic NOSE, der, de-
short circuit menu. page scription,
to ground. Check the 8:43 page
component. 7:34
Y 6051 5 2 1 Solenoid Regener- Check cabling Y6051-1 7.3 Ex- Valve

valve ation, ex- between the D7971/C- tension block ex-
regeneration tension not control unit and 1:34 4/XX tension
extension working. the component DIAG- cylin-
(Y6051-1), with diagnostic NOSE, der, de-
open circuit. menu. page scription,
Check the 8:44 page
component. 7:34
Y 6051 6 2 1 Solenoid Regener- Check cabling Y6051-1 7.3 Ex- Valve

valve ation, ex- between the D7971/C- tension block ex-
regeneration tension not control unit and 1:34 4/XX tension
extension working. the component DIAG- cylin-
(Y6051-1), with diagnostic NOSE, der, de-
component. 7:34
Y 6051 5 2 LE Solenoid Regenera- Check cabling Y6051-LE 7.2 Lifting Valve

valve tion, lift not between the D7971/C- Lower- block
regeneration working. control unit and 1:11 ing 9/XX lift cylin-
lift left the component DIAG- der, de-
Check the 8:42 7:20
component.
Y 6051 6 2 LE Solenoid Regenera- Check cabling Y6051-LE 7.2 Lifting Valve
lift left the component DIAG- der, de-
component.
Y 6051 5 2 RI Solenoid Regenera- Check cabling Y6051-RI 7.2 Lifting Valve
lift right the component DIAG- der, de-
open circuit menu. page page
Check the 8:42 7:20
component.

Error codes machine
Connec-
tions
Lo- and Diag-
Y 6051 6 2 RI Solenoid Regenera- Check cabling Y6051-RI 7.2 Lifting Valve
lift right the component DIAG- der, de-
component.
Y 6093 5 2 Solenoid Disengage- Check cabling Y6093 7.3 Ex- Solenoid
valve pump ment of hy- between the D7971/C- tension valve
unloading draulic oil control unit and 1:14 5/XX pump
boom in pump 2 not the component DIAG- unload-
(Y6093), working. with diagnostic NOSE, ing, de-
open circuit. menu. page scription,
Check the 8:44 page
component. 10.4 10:25
Pumps
2/XX
DIAG-
NOSE,
page
8:78
Y 6093 6 2 Solenoid Disengage- Check cabling Y6093 7.3 Ex- Solenoid
valve pump ment of hy- between the D7971/C- tension valve
unloading draulic oil control unit and 1:14 5/XX pump
boom in pump 2 not the component DIAG- unload-
(Y6093), working. with diagnostic NOSE, ing, de-
component. 10.4 10:25
Pumps
2/XX
DIAG-
NOSE,
page
8:78
Y 6120 6 1 2 Damper Recirculation Check cabling Y6120 9.4 Cli- Fresh
motor damper for between the D7901/C- mate air/recir-
recirculation ventilation control unit and 2:28 System culation
air not working. the component 11/XX damper,
conditioning with diagnostic DIAG- descrip-
unit (Y6120), menu. NOSE, tion,
short circuit page page
to ground. 8:61 9:30
Y 6120 6 2 2 Damper Recirculation Check cabling Y6120 9.4 Cli- Fresh
motor, damper for between the D7901/C- mate air/recir-
recirculation ventilation control unit and 2:29 System culation
air not working. the component 12/XX damper,
conditioning with diagnostic DIAG- descrip-
unit (Y6120), menu. NOSE, tion,
short circuit page page
to ground. 8:62 9:30

Error codes machine
Connec-
tions
Lo- and Diag-
Y 6150 6 2 1 Voltage feed Joystick Check cabling Y6150/4 5.2 Control
to electronic control or between the D7971/C- Power valve
steering mini-wheel control unit and 1:48 Assisted steer-
module not working. the component 5/XX ing, de-
(Y6150) with diagnostic DIAG- scription,
for joystick menu. NOSE, page
control/mini- Check the page 5:23
wheel, short component. 8:39
circuit to
ground.
Y 6150 6 2 2 Electronic Joystick Check cabling Y6150/1 5.2 Control
steering control or between the D7971/C- Power valve
module mini-wheel control unit and 1:50 Assisted steer-
(Y6150) not working. the component 5/XX ing, de-
for joystick with diagnostic DIAG- scription,
control/mini- menu. NOSE, page
wheel, short Check the page 5:23
circuit to component. 8:39
ground.
Y 6150 2 2 3 Electronic Joystick Check the Y6150/2 5.2 Control
control control or steering valve. D7971/C- Power valve
module mini-wheel Check control 2:23 Assisted steer-
(Y6150) not working. valve steering. 6/XX ing, de-
for joystick DIAG- scription,
control/mini- Check cabling NOSE, page
wheel, between the page 5:23
oversteer. control unit and 8:40
the component
This error with diagnostic
code may be menu.
generated
if the valve
slide is
pressurised
in the wrong
way, for
example
by turning
the steering
wheel when
joystick
control or
mini wheel
is activated.
Y 6420 5 2 Solenoid Parking Check cabling Y6420 4.5 Park Solenoid
valve parking brake cannot between the D7971/C- Brake valve
brake be released. control unit and 1:17 Sys 3/XX parking
(Y6420), the component DIAG- brake,
open circuit. with diagnostic NOSE, descrip-
menu. page tion,
Check the 8:37 page
component. 4:37

Error codes machine
Connec-
tions
Lo- and Diag-
Y 6420 6 2 Solenoid Parking Check cabling Y6420 4.5 Park Solenoid
valve parking brake cannot between the D7971/C- Brake valve
brake be released. control unit and 1:17 Sys 3/XX parking
(Y6420), the component DIAG- brake,
short circuit with diagnostic NOSE, descrip-
to ground. menu. page tion,
Check the 8:37 page
component. 4:37
Y 6450 5 2 Magnetic Air Check cabling Y6450 9.4 Cli- Com-

coupling, conditioning between the D7971/C- mate pressor
cooling not working. control unit and 2:34 System air con-
compressor the component 13/XX dition-
(Y6450), with diagnostic DIAG- ing, de-
open circuit. menu. NOSE, scription,
Check the page page
component. 8:62 9:38
Y 6450 6 2 Magnetic Air Check cabling Y6450 9.4 Cli- Com-

coupling, conditioning between the D7971/C- mate pressor
cooling not working. control unit and 2:34 System air con-
compressor the component 13/XX dition-
(Y6450), with diagnostic DIAG- ing, de-
short circuit menu. NOSE, scription,
to ground. Check the page page
M 6502 7 1 Wiper rear Rear window Check cabling M6502/3 9.5 Wiper
window, wiper not between the D7901/C- Wiper & motor
position working. control unit and 1:12 Washer rear, de-
signal the component Sys 5/XX scription,
(M6502), the with diagnostic DIAG- page
wiper does menu. NOSE, 9:55
not move. Check the page
motor. 8:65
window wiper not between the D7901/C- Wiper & motor
(M6502), working. control unit and 2:17 Washer rear, de-
open circuit. the component Sys 5/XX scription,
with diagnostic DIAG- page
menu. NOSE, 9:55
Check the page
component. 8:65
window wiper not between the D7901/C- Wiper & motor
(M6502), working. control unit and 2:17 Washer rear, de-
short circuit the component Sys 5/XX scription,
menu. NOSE, 9:55
Check the page
component. 8:65

Error codes machine
Connec-
tions
Lo- and Diag-
M 6503 7 1 Combined Combined Check cabling M6503/3 9.5 Wiper
wiper wiper front between the D7901/C- Wiper & motor,
windscreen windscreen control unit and 1:13 Washer front and
and roof and roof the component Sys 2/XX roof, de-
window, window not with diagnostic DIAG- scription,
position working. menu. NOSE, page
signal Check the page 9:57
(M6503) component. 8:64

window window not with diagnostic DIAG- scription,
(M6503), working. menu. NOSE, page
open circuit. Check the page 9:57
component. 8:64

window window not with diagnostic DIAG- scription,
(M6503), working. menu. NOSE, page
short circuit Check the page 9:57
M 6512 5 1 Motor, Rear window Check cabling M6512 9.5 Washer

washer fluid, washer not between the D7901/C- Wiper & mo-
rear window working. control unit and 2:16 Washer tor and
(M6512), the component Sys 6/XX reser-
open circuit. with diagnostic DIAG- voir, de-
menu. NOSE, scription,
Check the page page
M 6512 6 1 Motor, Rear window Check cabling M6512 9.5 Washer

washer fluid, washer not between the D7901/C- Wiper & mo-
rear window working. control unit and 2:16 Washer tor and
(M6512), the component Sys 6/XX reser-
short circuit with diagnostic DIAG- voir, de-
to ground. menu. NOSE, scription,
Check the page page
M 6513 5 1 Motor, Windscreen Check cabling M6513 9.5 Washer

washer fluid, washer, between the D7901/C- Wiper & mo-
combined combined control unit and 2:15 Washer tor and
wiper front the component Sys 3/XX reser-
windscreen windscreen with diagnostic DIAG- voir, de-
and roof and roof menu. NOSE, scription,
window window not Check the page page
(M6513), working. component. 8:65 9:54
open circuit.

Error codes machine
Connec-
tions
Lo- and Diag-
M 6513 6 1 Motor, Windscreen Check cabling M6513 9.5 Washer
washer fluid, washer, between the D7901/C- Wiper & mo-
combined combined control unit and 2:15 Washer tor and
wiper front the component Sys 3/XX reser-
windscreen windscreen with diagnostic DIAG- voir, de-
and roof and roof menu. NOSE, scription,
window window not Check the page page
(M6513), working. component. 8:65 9:54
short circuit
to ground.
M 6570 5 1 Cab fan Cab fan not Check cabling M6570 9.4 Cli- Cab fan,
(M6570), working. between the D7901/C- mate descrip-
open circuit. control unit and 2:37 System tion,
the component 9/XX page
with diagnostic DIAG- 9:31
menu. NOSE,
Check the page
component. 8:61
M 6570 6 1 Cab fan Cab fan not Check cabling M6570 9.4 Cli- Cab fan,
(M6570), working. between the D7901/C- mate descrip-
short circuit control unit and 2:37 System tion,
to ground. the component 9/XX page
menu. NOSE,
Check the page
component. 8:61
M 6670 6, 5 1 Circulation Pause Check cabling M6670 9.4 Cli- Pause

pump, pause heater not between the D7901/C- mate heater,
heater working. control unit and 2:14 System descrip-
(M6670), the component 20/XX tion,
open circuit. with diagnostic DIAG- page
menu. NOSE, 9:50
Check the page
component. 8:64
M 6670 6 1 Circulation Pause Check cabling M6670 9.4 Cli- Pause

pump pause heater not between the D7901/C- mate heater,
heater working. control unit and 2:14 System descrip-
(M6670), the component 20/XX tion,
short circuit with diagnostic DIAG- page
to ground. menu. NOSE, 9:50
Check the page
component. 8:64
M 6680 5 2 Cooling fan Cooling of Check cabling M6680 10.6 Oil Cooling
(M6680) hydraulic oil between the D7971/C- Temp/Cl- fan, de-
(hydraulic not working. control unit and 2:35 ean 2/XX scription,
system), the component DIAG- page
open circuit. with diagnostic NOSE, 10:33
menu. page
Check the 8:79
component.

Error codes machine
Connec-
tions
Lo- and Diag-
M 6680 6 2 Cooling fan Cooling of Check cabling M6680 10.6 Oil Cooling
(M6680) hydraulic oil between the D7971/C- Temp/Cl- fan, de-
(hydraulic not working. control unit and 2:35 ean 2/XX scription,
system), the component DIAG- page
short circuit with diagnostic NOSE, 10:33
to ground. menu. page
Check the 8:79
component.
Y 6720 3 1 Air Air Check cabling Y6720/9 9.4 Cli- Air dis-
distribution distribution between the D7901/C- mate tribu-
valve in cab cannot control unit and 1:28 System tor, de-
(Y6720) be adjusted. the component 8/XX scription,
position with diagnostic DIAG- page
signal, menu. NOSE, 9:46
high signal Check the page
voltage. component. 8:61
Y 6720 4 1 Air Air Check cabling Y6720/9 9.4 Cli- Air dis-
(Y6720) be adjusted. the component 8/XX scription,
position with diagnostic DIAG- page
signal, menu. NOSE, 9:46
low signal Check the page
Y 6720 5 1 1 Air Air Check cabling Y6720/6 9.4 Cli- Air dis-
(Y6720), be adjusted. the component 16/XX scription,
menu. NOSE 9:46
Check the , page
component. 8:63
to ground. menu. NOSE 9:46
Check the , page
component. 8:63
menu. NOSE, 9:46
Check the page
component. 8:63

Error codes machine
Connec-
tions
Lo- and Diag-
Check the page
component. 8:63
Y 6730 3 1 Heating Cab heat Check cabling Y6730/9 9.4 Cli- Water
valve cannot be between the D7901/C- mate valve, de-
(Y6730) adjusted. control unit and 1:29 System scription,
position the component 7/XX page
signal, with diagnostic DIAG- 9:36
high signal menu. NOSE,
voltage. Check the page
component. 8:60
Y 6730 4 1 Heating Cab heat Check cabling Y6730/9 9.4 Cli- Water
(Y6730) adjusted. control unit and 1:29 System scription,
position the component 7/XX page
signal, with diagnostic DIAG- 9:36
low signal menu. NOSE,
component. 8:60
Y 6730 5 1 1 Heating Cab heat Check cabling Y6730/6 9.4 Cli- Water
(Y6730), adjusted. control unit and 2:26 System scription,
open circuit. the component 15/XX page
menu. NOSE,
Check the page
component. 8:62
short circuit the component 15/XX page
to ground. with diagnostic DIAG- 9:36
menu. NOSE,
Check the page
component. 8:62
open circuit. the component 14/XX page
menu. NOSE,
Check the page
component. 8:62

Error codes machine
Connec-
tions
Lo- and Diag-
short circuit the component 14/XX page
to ground. with diagnostic DIAG- 9:36
menu. NOSE,
Check the page
component. 8:62
M 6740 6, 5 2 Cooling fan Cooling Check cabling M6740 4.8 Oil Cooling
(M6740) of brake between the D7971/C- Temp/Cl- fan, de-
(brake system not control unit and 2:37 ean 2/XX scription,
system), working. the component DIAG- page
open circuit. If the with diagnostic NOSE, 4:50
temperature menu. page
becomes too Check the 8:38
high then component.
machine
speed is
limited, and
wear on
the brakes
increases.
M 6740 6 2 Cooling fan Cooling Check cabling M6740 4.8 Oil Cooling
(M6740) of brake between the D7971/C- Temp/Cl- fan, de-
(brake system not control unit and 2:37 ean 2/XX scription,
system), working. the component DIAG- page
short circuit If the with diagnostic NOSE, 4:50
to ground. temperature menu. page
becomes too Check the 8:38
high then component.
machine
speed is
limited, and
wear on
the brakes
increases.
B 6900 3 11 1 Accelerator Engine Check cabling B6900/2 1.1 Con- Accel-
pedal speed limited between the D7902/C- trols & In- erator
(B6900) to idle. control unit and 8:5 str 1/XX pedal de-
signal A, the component DIAG- scription,
high voltage with diagnostic NOSE, page
signal. menu. page 1:22
Check the 8:28
component.
signal A, the component DIAG- scription,
low voltage with diagnostic NOSE, page
Check the 8:28
component.

Error codes machine
Connec-
tions
Lo- and Diag-
signal B, the component DIAG- scription,
high voltage with diagnostic NOSE, page
Check the 8:28
component.
signal B, the component DIAG- scription,
low voltage with diagnostic NOSE, page
Check the 8:28
component.
M 6930 5 2 1 Pump central Central Check cabling M6930 9.14 Central
lubrication lubrication between the D7971/C- Cen- lubrica-
(M6930), not working. control unit and 1:46 tral Lubr tion, de-
open circuit. the component 2/XX scription,
with diagnostic DIAG- page
menu. NOSE, 9:116
Check the page
component. 8:77
M 6930 6 2 1 Pump central Central Check cabling M6930 9.14 Central

lubrication lubrication between the D7971/C- Cen- lubrica-
(M6930), not working. control unit and 1:46 tral Lubr tion, de-
short circuit the component 2/XX scription,
menu. NOSE, 9:116
Check the page
component. 8:77
M 6930 5 7 Pump central Central Check cabling M6930 9.14 Central

lubrication lubrication between the D7911/C1 Cen- lubrica-
attachment not working. control unit and :46 tral Lubr tion, de-
(M6930), the component 3/XX scription,
menu. NOSE, 9:116
Check the page
component. 8:77
M 6930 6 7 Pump central Central Check cabling M6930 9.14 Central

lubrication lubrication between the D7911/C1 Cen- lubrica-
attachment not working. control unit and :46 tral Lubr tion, de-
(M6930), the component 3/XX scription,
Check the page
component. 8:77

Error codes machine
Connec-
tions
Lo- and Diag-
B 6941 3 11 Motor, Movement of Check cabling B6941/9 - Instru-
right-hand dashboard between the D7902/C- ment
dashboard panel not control unit and 2:3 and con-
panel for- working. the component trol pan-
ward/back- with diagnostic els, de-
ward position menu. scription,
signal, high Check the page
signal volt- component. 9:102
age.
panel for- working. the component trol pan-
ward/back- with diagnostic els, de-
ward posi- menu. scription,
tion signal, Check the page
low signal component. 9:102
voltage.
B 6941 7 11 Motor, Movement of Check that B6941/9 - Instru-
right-hand dashboard nothing is D7902/C- ment
dashboard panel not blocking the 2:3 and con-
panel for- working. movement of trol pan-
ward/back- the dashboard els, de-
ward posi- panel. scription,
tion signal, Check the page
mechanical motor. 9:102
fault.
M 6941 6 11 1 Motor, Movement of Check cabling M6941/5 9.1 Con- Instru-
right-hand dashboard between the D7902/C- trols & In- ment
dashboard panel not control unit and 2:7 str 5/XX and con-
panel for- working. the component DIAG- trol pan-
ward/back- with diagnostic NOSE, els, de-
ward menu. page scription,
(M6941), Check the 8:57 page
short circuit component. 9:102
to ground.
panel for- working. the component DIAG- trol pan-
ward/back- with diagnostic NOSE, els, de-
ward menu. page scription,
(M6941), Check the 8:57 page
short circuit component. 9:102
to ground.
panel working. the component trol pan-
up/down with diagnostic els, de-
position menu. scription,
signal, Check the page
high signal component. 9:102
voltage.

Error codes machine
Connec-
tions
Lo- and Diag-
panel working. the component trol pan-
up/down with diagnostic els, de-
position menu. scription,
low signal component. 9:102
voltage.
B 6942 7 11 Motor, Movement of Check that B6942/9 - Instru-
right-hand dashboard nothing is D7902/C- ment
dashboard panel not blocking the 2:4 and con-
panel working. movement of trol pan-
up/down the dashboard els, de-
position panel. scription,
mechanical motor. 9:102
fault.
panel working. the component DIAG- trol pan-
up/down with diagnostic NOSE, els, de-
(M6942), menu. page scription,
short circuit Check the 8:58 page

panel working. the component DIAG- trol pan-
up/down with diagnostic NOSE, els, de-
(M6942), menu. page scription,
short circuit Check the 8:58 page
B 6943 3 11 Motor, Movement Check cabling B6942/9 - Instru-

steering of steering between the D7902/C- ment
panel panel not control unit and 1:9 and con-
up/down working. the component trol pan-
position with diagnostic els, de-
signal, menu. scription,
high signal Check the page
B 6943 4 11 Motor, Movement Check cabling B6942/9 - Instru-

steering of steering between the D7902/C- ment
panel panel not control unit and 1:9 and con-
up/down working. the component trol pan-
position with diagnostic els, de-
signal, menu. scription,
low signal Check the page

Error codes machine
Connec-
tions
Lo- and Diag-
B 6943 7 11 Motor, Movement Check that B6942/9 - Instru-
steering of steering nothing is D7902/C- ment
panel panel not blocking the 1:9 and con-
up/down working. movement of trol pan-
position the dashboard els, de-
signal, panel. scription,
mechanical Check the page
fault. motor. 9:102
M 6943 6 11 1 Motor, Movement Check cabling M6943/5 9.1 Con- Instru-

steering of steering between the D7902/C- trols & In- ment
panel panel not control unit and 2:5 str 3/XX and con-
up/down working. the component DIAG- trol pan-
(M6943), with diagnostic NOSE, els, de-
component. 9:102
M 6943 6 11 2 Motor, Movement Check cabling M6943/6 9.1 Con- Instru-

steering of steering between the D7902/C- trols & In- ment
panel panel not control unit and 2:6 str 3/XX and con-
up/down working. the component DIAG- trol pan-
(M6943), with diagnostic NOSE, els, de-
component. 9:102
B 7226 3 2 1 Sensor, Load sensor Check the B7226- 8.2 Mon- Sensor
hydraulic and overload cable harness 1/4 itoring hydraulic
pressure system not between the D7971/C- 17/XX pressure
lift cylinder, working. control unit and 2:10 DIAG- lift cylin-
piston Lift and the sensor using NOSE, der, de-
side, left extension the diagnostic page scription,
(B7226-1), blocked. menu. 8:55 page
high signal Check the 8.2 Mon- 8:16
voltage. sensor. itoring
18/XX
DIAG-
NOSE,
page
8:55
piston side, Lift and the sensor using NOSE, der, de-
left (B7226- extension the diagnostic page scription,
1), low signal blocked. menu. 8:55 page
voltage. Check the 8.2 Mon- 8:16
sensor. itoring
18/XX
DIAG-
NOSE,
page
8:55

Error codes machine
Connec-
tions
Lo- and Diag-
piston Lift and the sensor using NOSE, der, de-
side, right extension the diagnostic page scription,
(B7226-2), blocked. menu. 8:55 page
high signal Check the 8.2 Mon- 8:16
voltage. sensor. itoring
18/XX
DIAG-
NOSE,
page
8:55
piston side, Lift and the sensor using NOSE, der, de-
right (B7226- extension the diagnostic page scription,
2), low signal blocked. menu. 8:55 page
sensor. itoring
18/XX
DIAG-
NOSE,
page
8:55
rod side, left Lift and the sensor using NOSE, der, de-
(B7226-3), extension the diagnostic page scription,
high signal blocked. menu. 8:55 page
sensor. itoring
18/XX
DIAG-
NOSE,
page
8:55
rod side, left Lift and the sensor using NOSE, der, de-
low signal blocked. menu. 8:55 page
sensor. itoring
18/XX
DIAG-
NOSE,
page
8:55

Error codes machine
Connec-
tions
Lo- and Diag-
pressure lift system not between the D7971/C- 17/XX pressure
cylinder, rod working. control unit and 2:14 DIAG- lift cylin-
side, right Lift and the sensor using NOSE, der, de-
high signal blocked. menu. 8:55 page
sensor. itoring
18/XX
DIAG-
NOSE,
page
8:55
pressure lift system not between the D7971/C- 17/XX pressure
cylinder, rod working. control unit and 2:14 DIAG- lift cylin-
side, right Lift and the sensor using NOSE, der, de-
low signal blocked. menu. 8:55 page
sensor. itoring
18/XX
DIAG-
NOSE,
page
8:55
B 7230 3 7 Sensor Damping in Check the B7230 -
damping vicinity of the cable harness D7911/C2
attachment container not between the :12
(B7230), working control unit and
high signal the sensor using
voltage. the diagnostic
menu.
Check the
sensor.
B 7230 4 7 Sensor Damping in Check the B7230 -
damping vicinity of the cable harness D7911/C2
attachment container not between the :12
(B7230), working control unit and
low signal the sensor using
voltage. the diagnostic
menu.
Check the
sensor.

Error codes machine
Connec-
tions
Lo- and Diag-
B 7241 3 2 Sensor Load sensor Check the B7241 8.2 Mon- Sensor
boom angle and overload cable harness D7971/C- itoring boom an-
(B7241), system not between the 2:15 16/XX gle, de-
high signal working. control unit and DIAG- scription,
voltage. Lift and the sensor using NOSE, page
extension the diagnostic page 8:18
blocked. menu. 8:54
Regenera- Check the
tion lift and sensor.
end position
damping not
working.
B 7241 4 2 Sensor Load sensor Check the B7241 8.2 Mon- Sensor
boom angle and overload cable harness D7971/C- itoring boom an-
(B7241), system not between the 2:15 16/XX gle, de-
low signal working. control unit and DIAG- scription,
voltage. Lift and the sensor using NOSE, page
extension the diagnostic page 8:18
blocked. menu. 8:54
Regenera- Check the
tion lift and sensor.
end position
damping not
working.
B 7252 3 11 Sensor, Searchlight Make sure there B7252 8.1 Con- Cab
ambient and function are no objects D7902/C- trols & In- overview,
brightness light in or dirt in front of 6:20 str 1/XX page 9:5
(B7252), silicone the sensor in the DIAG-
high signal panels driveline panel. NOSE,
voltage. can give page
incorrect 8:53
brightness.
B 7252 4 11 Sensor, Searchlight Make sure there B7252 8.1 Con- Cab
ambient and function are no objects D7902/C- trols & In- overview,
brightness light in or dirt in front of 6:20 str 1/XX page 9:5
(B7252), silicone the sensor in the DIAG-
low signal panels driveline panel. NOSE,
voltage. can give page
incorrect 8:53
brightness.
high signal (empty or control unit and DIAG- scription,
menu. 8:28
Check the
sensor.

Error codes machine
Connec-
tions
Lo- and Diag-
low signal (empty or control unit and DIAG- scription,
menu. 8:28
Check the
sensor.
B 7681 3 2 Sensor Brake lights Check the B7681 4.3 Brake
brake and declutch cable harness D7971/C- Power pres-
pressure not working. between the 2:7 Assisted sure sen-
(B7681), control unit and 3/XX sor, de-
high signal the sensor using DIAG- scription,
voltage. the diagnostic NOSE, page
menu. page 4:31
Check the 8:36
sensor.
B 7681 4 2 Sensor Brake lights Check the B7681 4.3 Brake
brake and declutch cable harness D7971/C- Power pres-
pressure not working. between the 2:7 Assisted sure sen-
low signal the sensor using DIAG- scription,
voltage. the diagnostic NOSE, page
menu. page 4:31
Check the 8:36
sensor.
B 7683 3 2 Sensor Indicator Check the B7683 4.3 Accu-
accumulator light parking cable harness D7971/C- Power mula-
pressure brake and between the 2:8 Assisted tor pres-
(B7683), warning for control unit and 3/XX sure sen-
high signal low brake the sensor using DIAG- sor, de-
voltage. pressure not the diagnostic NOSE, scription,
switching off. menu. page page
Gear cannot Check the 8:36 4:28
be engaged sensor.
because the
signal for
released
parking
brake is not
working.

Error codes machine
Connec-
tions
Lo- and Diag-
B 7683 4 2 Sensor Indicator Check the B7683 4.3 Accu-
accumulator light parking cable harness D7971/C- Power mula-
pressure brake and between the 2:8 Assisted tor pres-
(B7683), warning for control unit and 3/XX sure sen-
low signal low brake the sensor using DIAG- sor, de-
voltage. pressure not the diagnostic NOSE, scription,
switching off. menu. page page
Gear cannot Check the 8:36 4:28
be engaged sensor.
because the
signal for
released
parking
brake is not
working.
B 7686 3 2 Sensor Load sensor Check the B7683 8.2 Mon- Sensor,
boom length and overload cable harness D7971/C- itoring boom
(B7686), system not between the 2:16 16/XX length,
high signal working. control unit and DIAG- descrip-
voltage. Lift and the sensor using NOSE, tion,
extension the diagnostic page page
blocked. menu. 8:54 8:19
Regenera- Check the
tion exten- sensor.
sion and
end position
damping not
working.
B 7686 4 2 Sensor Load sensor Check the B7683 8.2 Mon- Sensor,
boom length and overload cable harness D7971/C- itoring boom
(B7686), system not between the 2:16 16/XX length,
low signal working. control unit and DIAG- descrip-
voltage. Lift and the sensor using NOSE, tion,
extension the diagnostic page page
blocked. menu. 8:54 8:19
Regenera- Check the
tion exten- sensor.
sion and
end position
damping not
working.
B 7720 0 2 High Machine Check the B7720 4.8 Oil Sensor,
temperature speed is function of the D7971/C- Temp/Cl- oil tem-
oil, brake limited. cooling fan. 2:29 ean 1/XX perature
system. Check that the DIAG- brake
radiator is not NOSE, system,
clogged. page descrip-
8:38 tion,
Check the oil page
level in the brake 4:52
system's tank.

Error codes machine
Connec-
tions
Lo- and Diag-
B 7720 32 2 Sensor Display of Check the B7720 4.8 Oil Sensor,
temperature brake oil cable harness D7971/C- Temp/Cl- oil tem-
oil brake temperature between the 2:29 ean 1/XX perature
system not working, control unit and DIAG- brake
(B7720), warning for the sensor using NOSE, system,
high high brake oil the diagnostic page descrip-
resistance or temperature menu. 8:38 tion,
open circuit. not working. Check the page
Machine sensor. 4:52
speed is
limited.
B 7720 33 2 Sensor Display of Check the B7720 4.8 Oil Sensor,
temperature brake oil cable harness D7971/C- Temp/Cl- oil tem-
oil brake temperature between the 2:29 ean 1/XX perature
system not working, control unit and DIAG- brake
(B7720), low warning for the sensor using NOSE, system,
resistance or high brake oil the diagnostic page descrip-
short circuit. temperature menu. 8:38 tion,
not working. Check the page
Machine sensor. 4:52
speed is
limited.
B 7740 32 1 Sensor Air Check the B7740 9.4 Cli- Ambient
ambient conditioning cable harness D7901/C- mate tempera-
temperature not working. between the 1:36 System ture sen-
high the sensor using DIAG- scription,
resistance or the diagnostic NOSE, page
open circuit. menu. page 9:49
Check the 8:59
sensor. 9.4 Cli-
mate
System
5/XX
DIAG-
NOSE,
page
8:60
B 7740 33 1 Sensor Air Check the B7740 9.4 Cli- Ambient
ambient conditioning cable harness D7901/C- mate tempera-
(B7740), low control unit and 4/XX sor, de-
resistance or the sensor using DIAG- scription,
short circuit. the diagnostic NOSE, page
menu. page 9:49
Check the 8:59
sensor. 9.4 Cli-
mate
System
5/XX
DIAG-
NOSE,
page
8:60

Error codes machine
Connec-
tions
Lo- and Diag-
B 7751 32 1 Sensor Air Check the B7751 9.4 Cli- Interior
inside conditioning cable harness D7901/C- mate tempera-
Check the 8:59
sensor. 9.4 Cli-
mate
System
5/XX
DIAG-
NOSE,
page
8:60
B 7751 33 1 Sensor Air Check the B7751 9.4 Cli- Interior
inside conditioning cable harness D7901/C- mate tempera-
menu. page 9:49
Check the 8:59
sensor. 9.4 Cli-
mate
System
5/XX
DIAG-
NOSE,
page
8:60
B 7752 32 1 Sensor fan Air Check cabling B7751 9.4 Cli- Fan tem-
temperature conditioning between the D7901/C- mate pera-
(B7752), not working. control unit and 1:34 System ture sen-
high the component 4/XX sor, de-
resistance or with diagnostic DIAG- scription,
open circuit. menu. NOSE, page
Check the page 9:48
sensor. 8:59
9.4 Cli-
mate
System
5/XX
DIAG-
NOSE,
page
8:60

Error codes machine
Connec-
tions
Lo- and Diag-
B 7752 33 1 Sensor fan Air Check the B7751 9.4 Cli- Fan tem-
temperature conditioning cable harness D7901/C- mate pera-
(B7752), low not working. between the 1:34 System ture sen-
resistance or control unit and 4/XX sor, de-
short circuit. the sensor using DIAG- scription,
the diagnostic NOSE, page
menu. page 9:48
Check the 8:59
sensor. 9.4 Cli-
mate
System
5/XX
DIAG-
NOSE,
page
8:60
B 7753 32 1 Sensor Air Check the B7753 9.4 Cli- Temper-
temperature conditioning cable harness D7901/C- mate ature de-
display not working. between the 1:35 System icing sen-
Check the 8:59
sensor. 9.4 Cli-
mate
System
5/XX
DIAG-
NOSE,
page
8:60
B 7753 33 1 Sensor Air Check the B7753 9.4 Cli- Temper-
temperature conditioning cable harness D7901/C- mate ature de-
display not working. between the 1:35 System icing sen-
menu. page 9:44
Check the 8:59
sensor. 9.4 Cli-
mate
System
5/XX
DIAG-
NOSE,
page
8:60
B 7760 32 2 Sensor Check the B7760 10.6 Oil Sensor,
temperature cable harness D7971/C- Temp/Cl- hydraulic
hydraulic between the 2:25 ean 1/XX oil tem-
oil (B7760), control unit and DIAG- pera-
high the sensor using NOSE, ture, de-
resistance or the diagnostic page scription,
open circuit. menu. 8:79 page
Check the 10:33
sensor.

Error codes machine
Connec-
tions
Lo- and Diag-
B 7760 33 2 Sensor Check the B7760 10.6 Oil Sensor,
temperature cable harness D7971/C- Temp/Cl- hydraulic
hydraulic oil between the 2:25 ean 1/XX oil tem-
(B7760), low control unit and DIAG- pera-
resistance or the sensor using NOSE, ture, de-
short circuit. the diagnostic page scription,
menu. 8:79 page
Check the 10:33
sensor.
D 7901 31 12 Cab control Functions Check the cable D7901/C- 11.6 11.6.2
unit (D7901) in cab not harness to the 1:3 Commu- Redun-
missing. working. control unit. D7901/C- nication dant
Troubleshoot 1:4 1/XX, CAN bus,
the CAN page page
D7901/C- 8:92 11:48
bus with the 1:6
diagnostic 11.6
menu. D7901/C- Commu-
1:7 nication
2/XX,
D 7902 31 12 KPU control Controls in Check the cable D7902/C- 11.6.2
page
unit (D7902) the right harness to the 1:3 Redun-
8:92
missing. dashboard control unit. D7902/C- dant
panel or 11.6 CAN bus,
Troubleshoot 1:4
steering Commu- page
the CAN D7902/C-
panel not nication 11:48
bus with the 1:5
working. 3/XX,
diagnostic
D7902/C- page
menu.
1:6 8:93
11.6
D 7911 31 12 Control unit Controls in Check the cable D7911/C1 Commu- 11.6.2
KAU (D7911) the right harness to the :3 nication Redun-
missing. dashboard control unit. D7911/C1 4/XX, dant
panel or Troubleshoot :4 page CAN bus,
steering the CAN 8:93 page
panel not D7911/C1 11:48
bus with the :6 11.6
working. diagnostic
D7911/C1 Commu-
menu. nication
:7
5/XX,
page
8:93
11.6
Commu-
nication
6/XX,
page
8:93
11.6
Commu-
nication
7/XX,
page
8:94

Error codes machine
Connec-
tions
Lo- and Diag-
D 7930 31 2 10 Transmis- Gear Check the cable D7971/C- - 11.6.2
sion control selection not harness to the 1:31 Redun-
unit (D7930) working. control unit. D7971/C- dant
missing. 1:32 CAN bus,
page
11:48
D 7940 31 2 1 Engine Engine Check the cable D7971/C- - 11.6.2
control unit does not harness to the 1:31 Redun-
(D7940) respond to control unit. D7971/C- dant
missing commands 1:32 CAN bus,
from the cab. page
11:48
D 7950 31 12 KID control Display not Check the cable D7950/C- 11.6 11.6.2
unit (D7950) working. harness to the 1:3 Commu- Redun-
missing control unit. D7950/C- nication dant
Troubleshoot 1:4 1/XX, CAN bus,
the CAN page page
D7950/C- 8:92 11:48
bus with the 1:6
diagnostic 11.6
menu. D7950/C- Commu-
1:7 nication
2/XX,
D 7971 31 2 KFU control Numerous Check the cable D7971/C- 11.6.2
page
unit (D7971) functions not harness to the 1:3 Redun-
8:92
missing working, en- control unit. D7971/C- dant
gine, trans- 11.6 CAN bus,
Troubleshoot 1:4
mission, load Commu- page
the CAN D7971/C-
handling, nication 11:48
bus with the 1:6
etc. 3/XX,
diagnostic
D7971/C- page
menu.
1:7 8:93
11.6
Commu-
nication
4/XX,
page
8:93
11.6
Commu-
nication
5/XX,
page
8:93
11.6
Commu-
nication
6/XX,
page
8:93
11.6
Commu-
nication
7/XX,
page
8:94

Error codes machine
Connec-
tions
Lo- and Diag-
E 8020 5 2 Electrically Electrically Check cabling E8020 9.9 Glass Rear
heated rear heated rear between the D7971/C- Wind view mir-
view mirror view mirror control unit and 2:22 Mirr 1/XX ror, de-
(E8020), not working. the component DIAG- scription,
open circuit. with diagnostic NOSE, page
menu. page 9:83
Check the 8:75
component.
E 8020 6, 5 2 Electrically Electrically Check cabling E8020-LE 9.9 Glass Rear
heated rear heated rear between the E8020-RI Wind view mir-
view mirror view mirror control unit and Mirr 1/XX ror, de-
(E8020-LE) not working. the component D7971/C- DIAG- scription,
and (R8020- with diagnostic 2:22 NOSE, page
RI), short menu. page 9:83
circuit to Check the 8:75
ground. component.
R 8070 3 11 1 Control Lift and lower Check cabling S8150/4 7.1 Con- Control
lever lift- not working. between the D7902/C- trols lever, de-
ing/lowering control unit and 3:3 and In- scription,
(S8150-Y), the component str 5/XX page 7:6
high signal with diagnostic DIAG-
voltage. menu. NOSE,
Check the page
component. 8:40
R 8070 4 11 1 Control Lift and lower Check cabling S8150/4 7.1 Con- Control
lever lift- not working. between the D7902/C- trols lever, de-
ing/lowering control unit and 3:3 and In- scription,
(S8150-Y), the component str 5/XX page 7:6
low signal with diagnostic DIAG-
Check the page
component. 8:40
R 8070 3 11 2 Control lever Boom in and Check cabling S8150/3 7.1 Con- Control
boom out/in out as well between the D7902/C- trols lever, de-
(S8150-X), as levelling control unit and 3:4 and In- scription,
high signal not working. the component str 5/XX page 7:6
voltage. with diagnostic DIAG-
menu. NOSE,
Check the page
component. 8:40
R 8070 4 11 2 Control lever Boom in and Check cabling S8150/3 7.1 Con- Control
boom out/in out as well between the D7902/C- trols lever, de-
(S8150-X), as levelling control unit and 3:4 and In- scription,
low signal not working. the component str 5/XX page 7:6
voltage. with diagnostic DIAG-
menu. NOSE,
Check the page
component. 8:40

Error codes machine
Connec-
tions
Lo- and Diag-
R 8070 3 11 3 Control lever Side Check cabling S8150/5 7.1 Con- Control
side shift and shift and between the D7902/C- trols lever, de-
spreading spreading control unit and 3:5 and In- scription,
(S8150- not working. the component str 6/XX page 7:6
Thumb X), with diagnostic DIAG-
high signal menu. NOSE,
component. 8:41
R 8070 4 11 3 Control lever Side Check cabling S8150/5 7.1 Con- Control
side shift and shift and between the D7902/C- trols lever, de-
spreading spreading control unit and 3:5 and In- scription,
(S8150- not working. the component str 6/XX page 7:6
Thumb X), with diagnostic DIAG-
low signal menu. NOSE,
component. 8:41
R 8070 3 11 4 Control lever Rotation Check cabling S8150/6 7.1 Con- Control
rotation and and tilt not between the D7902/C- trols lever, de-
tilt (S8150- working. control unit and 3:6 and In- scription,
Thumb Y), the component str 6/XX page 7:6
high signal with diagnostic DIAG-
Check the page
component. 8:41
R 8070 4 11 4 Control lever Rotation Check cabling S8150/6 7.1 Con- Control
rotation and and tilt not between the D7902/C- trols lever, de-
tilt (S8150- working. control unit and 3:6 and In- scription,
Thumb Y), the component str 6/XX page 7:6
low signal with diagnostic DIAG-
Check the page
component. 8:41
R 8250 3 1 Joystick Joystick Check cabling R8250-1 5.2 Joystick,

(R8250-1), control not between the D7901/C- Power descrip-
high signal working. control unit and 1:37 Assisted tion,
voltage. the component 2/XX page 5:6
with diagnostic DIAG-
menu. NOSE,
Check the page
potentiometer. 8:38
R 8250 4 1 Joystick Joystick Check cabling R8250-1 5.2 Joystick,

(R8250-1), control not between the D7901/C- Power descrip-
low signal working. control unit and 1:37 Assisted tion,
voltage. the component 2/XX page 5:6
with diagnostic DIAG-
menu. NOSE,
Check the page
potentiometer. 8:38

Error codes machine
Connec-
tions
Lo- and Diag-
R 8250 3 1 1 Mini-wheel Mini-wheel Check cabling R8250-1 5.2 Mini-
channel 1 not working. between the D7901/C- Power wheel,
(R8250-1), control unit and 1:37 Assisted descrip-
high signal the component 3/XX tion,
voltage. with diagnostic DIAG- page 5:5
menu. NOSE,
Check the page
potentiometer. 8:39

low signal the component 3/XX tion,
menu. NOSE,
Check the page
potentiometer. 8:39

high signal the component 3/XX tion,
menu. NOSE,
Check the page
potentiometer. 8:39

low signal the component 3/XX tion,
menu. NOSE,
Check the page
potentiometer. 8:39
H 8500 6 1 Horn Horn not Check cabling H8500-1 9.7 Sig- Horn, de-
(H8500), working. between the D7901/C- nalling scription,
short circuit control unit and 2:12 Sys 1/XX page
to ground. the component DIAG- 9:67
with diagnostic NOSE,
menu. page
Check the 8:73
component.
K 8881 6 1 Relay heater Rear window Check cabling K8881 9.9 Glass Rear win-
rear window heater not between the D7901/C- Wind dow, de-
(K8881), working. control unit and 2:6 Mirr 2/XX scription,
short circuit the component DIAG- page
to ground. with diagnostic NOSE, 9:83
menu. page
Check the 8:75
component.

Error codes machine
Connec-
tions
Lo- and Diag-
H 9003 5 7 Buzzer, Buzzer for Check cabling H9003 - Buzzer
automatic automatic between the D7911/C1 auto-
spread spreading control unit and :43 matic
20'-40', open not working. the component spread-
circuit. with diagnostic ing 20'-
menu. 40', de-
Check the scription,
component. page
7:72
H 9003 6 7 Buzzer Buzzer for Check cabling H9003 - Buzzer
automatic automatic between the D7911/C1 auto-
spreading spreading control unit and :43 matic
20'-40', short not working. the component spread-
circuit to with diagnostic ing 20'-
ground. menu. 40', de-
Check the scription,
component. page
7:72
H 9650 6 2 1 Reverse Back-up Check cabling H9650 9.7 Sig- Reverse
alarm alarm not between the D7971/C- nalling alarm,
(H9650) working. control unit and 1p18 Sys 5/XX descrip-
the component DIAG- tion,
with diagnostic NOSE, page
menu. page 9:68
Check the 8:74
component.
10002 14 1 Control Speed Contact - - 11.5.3.1
unit KCU limitation. Cargotec KCU
(D7901), support. control
configuration unit
numbers do (D7901),
not match. page
11:25
unit KFU limitation. Cargotec KFU
wrong unit
configuration (D7971),
number. page
11:31
unit KAU limitation. Cargotec Control
(D7911), support. unit KAU
wrong (D7911),
configuration page
number. 11:38
unit KPU limitation. Cargotec KPU
wrong unit
number. page
11:27

Error codes machine
Connec-
tions
Lo- and Diag-
10002 14 12 Control unit Speed Contact - - 11.5.3.3
KID (D7950), limitation. Cargotec Control
wrong support. unit, KID
number. page
11:29
unit KCU limitation. Cargotec KCU
wrong unit
software (D7901),
version. page
11:25
unit KFU limitation. Cargotec KFU
wrong unit
software (D7971),
version. page
11:31
unit KAU limitation. Cargotec Control
(D7911), support. unit KAU
wrong (D7911),
software page
version. 11:38
unit KPU limitation. Cargotec KPU
wrong unit
software (D7902),
version. page
11:27
10003 14 12 Control unit Speed Contact - - 11.5.3.3
KID (D7950), limitation. Cargotec Control
wrong support. unit, KID
software (D7950),
version. page
11:29
10004 14 1 Control Functions Contact - - 11.5.3.1
unit KCU connected Cargotec KCU
(D7901), to the KCU support. control
set-up file control unit unit
missing. (D7901) not (D7901),
working. page
11:25
unit KFU connected Cargotec KFU
(D7971), to the KFU support. control
working. page
11:31

Error codes machine
Connec-
tions
Lo- and Diag-
unit KAU connected to Cargotec Control
(D7911), Control unit support. unit KAU
set-up file KAU (D7911) (D7911),
missing. not working. page
11:38
unit KPU connected Cargotec KPU
(D7902), to the KPU support. control
working. page
11:27
10004 14 12 Control unit Display not Contact - - 11.5.3.3
KID (D7950), working. Cargotec Control
set-up file support. unit, KID
missing. (D7950),
page
11:29
10005 14 1 1 Control System Contact - - 11.5.3.1
unit KCU error, Cargotec KCU
(D7901), machine not support. control
parameter drivable. unit
file drive- (D7901),
train missing. page
11:25
10005 14 2 1 Control System Contact - - 11.5.3.4
unit KFU error, Cargotec KFU
(D7971), machine not support. control
parameter drivable. unit
train missing. page
11:31
10005 14 2 2 Control Scales, OLS Contact - - 11.5.3.4
unit KFU not working. Cargotec KFU
parameter unit
file load (D7971),
sensor page
missing. 11:31
10005 14 2 3 Control Fuel gauge Contact - - 11.5.3.4
unit KFU may display Cargotec KFU
(D7971), an incorrect support. control
parameter value. unit
file fuel tank (D7971),
missing. page
11:31
10005 14 2 4 Control Central Contact - - 11.5.3.4
unit KFU lubrication Cargotec KFU
(D7971), frame not support. control
parameter working. unit
file central (D7971),
lubrication page
frame 11:31
missing.

Error codes machine
Connec-
tions
Lo- and Diag-
10005 14 2 5 Control Speedome- Contact - - 11.5.3.4
unit KFU ter may Cargotec KFU
(D7971), display an support. control
parameter incorrect unit
file tyres front value. (D7971),
missing. page
11:31
10005 14 2 6 Control Overload Contact - - 11.5.3.4
unit KFU system not Cargotec KFU
(D7971), working, lift- support. control
parameter ing/lowering unit
file overload blocked. (D7971),
system page
missing. 11:31
10005 14 7 4 Control Central Contact - - 11.5.3.4
unit KFU lubrication Cargotec KFU
(D7971), not working. support. control
parameter unit
file central (D7971),
lubrication page
missing. 11:31
10005 14 11 1 Control Machine not Contact - - 11.5.3.2
unit KPU drivable. Cargotec KPU
parameter unit
train missing. page
11:27
10005 14 11 7 Control Control lever Contact - - 11.5.3.2
unit KPU not working. Cargotec KPU
parameter unit
file control (D7902),
lever page
missing. 11:27
10005 14 12 1 Control unit Machine not Contact - - 11.5.3.3
KID (D7905), drivable. Cargotec Control
parameter support. unit, KID
train missing. page
11:29
10101 3 1 Control Functionality Check batteries FA9968- 11.5 Distr Ignition
unit KCU of controls in and alternator. RD:2 of Electr voltage
(D7901), the cab may Check the D7901/C- 1/XX (15),
high battery be affected. cable harness 2:38 DIAG- func-
voltage. between battery NOSE, tion de-
and control unit. page scription,
8:81 page
11:17

Error codes machine
Connec-
tions
Lo- and Diag-
10101 4 1 Control Functionality Check fuse FA9968- 11.5 Distr Ignition
unit KCU of controls in FA9968-RD:2. RD:2 of Electr voltage
(D7901), the cab may Check the D7901/C- 1/XX (15),
low battery be affected. cable harness 2:38 DIAG- func-
voltage. between battery NOSE, tion de-
and control unit. page scription,
8:81 page
Check the 11:17
control unit.
10102 3 1 Control KCU control Check batteries F9954:2 11.5 Distr Ignition
unit KCU unit (D7901) and alternator. D7901/C- of Electr voltage
(D7901), not working. Check the 3:1 1/XX (15),
high ignition cable harness DIAG- func-
voltage. between NOSE, tion de-
electronic box page scription,
frame and 8:81 page
control unit. 11:17
10102 4 1 Control KCU control Check fuse F9954:2 11.5 Distr Ignition
unit KCU unit (D7901) FA9954 2. D7901/C- of Electr voltage
(D7901), not working. Check the 3:1 1/XX (15),
low ignition cable harness DIAG- func-
frame and 8:81 page
control unit. 11:17
10102 3 2 Control KFU control Check batteries F9954- 11.5 Distr Ignition
unit KFU unit (D7971) and alternator. 1:3 of Electr voltage
(D7971), not working. Check the D7971/C- 4/XX (15),
high ignition cable harness 3:1 DIAG- func-
frame and 8:81 page
control unit. 11:17
10102 4 2 Control KFU control Check the F9954- 11.5 Distr Ignition
unit KFU unit (D7971) cable harness 1:3 of Electr voltage
(D7971), not working. between D7971/C- 4/XX (15),
low ignition electronic box 3:1 DIAG- func-
voltage. frame and NOSE, tion de-
control unit. page scription,
8:81 page
11:17
10102 6 2 2 Control Engine Check cable D7940 11.9 I/O Ignition
unit KFU cannot be harness D7971/C- D7971 voltage
(D7971), started. between control 1:49 KFU (15),
ignition unit and engine. 1–75/XX func-
voltage to Check the DIAG- tion de-
Control unit control unit. NOSE, scription,
engine, short page page
circuit to 8:96 11:17
ground.

Error codes machine
Connec-
tions
Lo- and Diag-
10102 3 7 Control Control unit Check batteries F9954- 11.5 Distr Ignition
unit KAU KAU (D7911) and alternator. 1:3 of Electr voltage
(D7911), not working. Check the D7911/C3 13/XX (15),
high ignition cable harness :1 DIAG- func-
frame and 8:84 page
control unit. 11:17
10102 4 7 Control Control unit Check the F9954- 11.5 Distr Ignition
unit KAU KAU (D7911) cable harness 1:3 of Electr voltage
(D7911), not working. between D7911/C3 13/XX (15),
low ignition electronic box :1 DIAG- func-
8:84 page
11:17
10102 3 11 Control KPU control Check batteries F9968- 11.5 Distr Ignition
unit KPU unit (D7902) and alternator. BK:1 of Electr voltage
(D7902), not working. Check the D7902/C- 16/XX (15),
high ignition cable harness 1:1 DIAG- func-
frame and 8:84 page
control unit. 11:17
10102 4 11 Control KPU control Check the F9968- 11.5 Distr Ignition
unit KPU unit (D7902) cable harness BK:1 of Electr voltage
(D7902), not working. between D7902/C- 16/XX (15),
low ignition electronic box 1:1 DIAG- func-
8:84 page
11:17
10102 3 12 Control unit KID control Check batteries F9968- 11.5 Distr Ignition
KID (D7950), unit (D7950) and alternator. BK:1 D79 of Electr voltage
high ignition not working. Check the 50/C1:2 23/XX (15),
voltage. cable harness DIAG- func-
between NOSE, tion de-
frame and 8:86 page
control unit. 11:17
10102 4 12 Control unit KID control Check the F9968- 11.5 Distr Ignition
KID (D7950), unit (D7950) cable harness BK:1 of Electr voltage
low ignition not working. between D7950/C- 23/XX (15),
voltage. electronic box 1:2 DIAG- func-
frame and NOSE, tion de-
8:86 page
11:17

Error codes machine
Connec-
tions
Lo- and Diag-
10103 6 1 Control No control Check the D7901/C- 11.5 Distr Redun-
unit KCU units cable harness 2:35 of Electr dant volt-
(D7901), working. between Control 2/XX age feed
redundant unit KCU DIAG- of con-
voltage feed (D7901) and NOSE, trol units,
from control other units. page func-
units, short 8:81 tion de-
circuit to scription,
ground. page
11:15
10103 3 2 Control KFU control Check batteries D7901/C- 11.5 Distr Redun-
unit KFU unit (D7971) and alternator. 2:35 of Electr dant volt-
(D7971), not working. Check the D7971/C- 4/XX age feed
high voltage cable harness 1:2 DIAG- of con-
redundant between Control NOSE, trol units,
voltage feed. unit KFU page func-
(D7971) and 8:81 tion de-
Control unit KCU scription,
(D7901). page
11:15
10103 4 2 Control KFU control Check the D7901/C- 11.5 Distr Redun-
unit KFU unit (D7971) cable harness 2:35 of Electr dant volt-
(D7971), not working. between Control D7971/C- 4/XX age feed
low voltage unit KFU 1:2 DIAG- of con-
redundant (D7971) and NOSE, trol units,
voltage feed. Control unit KCU page func-
(D7901). 8:81 tion de-
scription,
page
11:15
10103 3 7 Control Control unit Check batteries D7901/C- 11.5 Distr Redun-
unit KAU KAU (D7911) and alternator. 2:35 of Electr dant volt-
(D7911), not working. Check the D7911/C1 13/XX age feed
high voltage cable harness :2 DIAG- of con-
redundant between Control NOSE, trol units,
voltage feed. unit KAU page func-
(D7911) and 8:84 tion de-
Control unit KCU scription,
(D7901). page
11:15
10103 4 7 Control Control unit Check the D7901/C- 11.5 Distr Redun-
unit KAU KAU (D7911) cable harness 2:35 of Electr dant volt-
(D7911), not working. between Control D7911/C1 13/XX age feed
low voltage unit KAU :2 DIAG- of con-
redundant (D7911) and NOSE, trol units,
voltage feed. Control unit KCU page func-
(D7901). 8:84 tion de-
scription,
page
11:15

Error codes machine
Connec-
tions
Lo- and Diag-
10103 4 11 Control KPU control Check the D7901/C- 11.5 Distr Redun-
unit KPU unit (D7902) cable harness 2:35 of Electr dant volt-
(D7902), not working. between KPU D7902/C- 16/XX age feed
low voltage control unit and 1:7 DIAG- of con-
redundant KCU control NOSE, trol units,
voltage feed. unit. page func-
8:84 tion de-
scription,
page
11:15
10103 3 12 Control unit KID control Check batteries D7901/C- 11.5 Distr Redun-
KID (D7950), unit (D7950) and alternator. 2:35 of Electr dant volt-
high voltage not working. Check the D7950/C- 23/XX age feed
redundant cable harness 1:9 DIAG- of con-
voltage feed. between Control NOSE, trol units,
unit KID (D7950) page func-
and Control unit 8:86 tion de-
KCU (D7901). scription,
page
11:15
10103 4 12 Control unit KID control Check the D7901/C- 11.5 Distr Redun-
KID (D7950), unit (D7950) cable harness 2:35 of Electr dant volt-
low voltage not working. between Control D7950/C- 23/XX age feed
redundant unit KID (D7950) 1:9 DIAG- of con-
voltage feed. and Control unit NOSE, trol units,
KCU (D7901). page func-
8:86 tion de-
scription,
page
11:15
10104 3 1 5 V Analogue Check cabling D7901/C- 11.5 Distr 11.5.3.1
Reference controls between the 1:8 of Electr KCU
voltage in cab control unit and A3720- 1/XX control
Control not work- the component 1:4, DIAG- unit
unit KCU ing (mini- with diagnostic R8250- NOSE, (D7901),
(D7901), wheel/steer- menu. 1/RD, Y6 page page
above 5.1 V. ing lever and Check the 720/10, 8:81 11:25
controls for component. Y6730/10
air condition-
ing).
10104 4 1 5 V Analogue Check cabling D7901/C- 11.5 Distr 11.5.3.1
Reference controls between the 1:8 of Electr KCU
voltage in cab control unit and A3720- 1/XX control
Control not work- the component 1:4, DIAG- unit
unit KCU ing (mini- with diagnostic R8250- NOSE, (D7901),
(D7901), wheel/steer- menu. 1/RD, Y6 page page
below 4.9 V. ing lever and Check the 720/10, 8:81 11:25
controls for component. Y6730/10
air condition-
ing).

Error codes machine
Connec-
tions
Lo- and Diag-
10104 3 2 5 V Sensor for Check cabling D7971/C- 11.5 Distr 11.5.3.4
Reference pressure between the 1:8 of Electr KFU
voltage lift cylinder, control unit and B2020/1, 4/XX control
Control boom angle, the component B7228/1 DIAG- unit
unit KFU boom length, with diagnostic B7235- NOSE, (D7971),
(D7971), fuel level, menu. LE/1, page page
above 5.1 V. brake Check B7235- 8:81 11:31
pressure, component. RI/1,
accumulator B7226-
pressure 1/2,
and parking B7226-
brake not 2/2,
working. B7226-
3/2,
B7238/2,
B7245-
LE/1,
B7245-
RI/1.
B7570,
B7681/2,
B7683/2,
10104 4 2 5 V Sensor for Check cabling D7971/C- 11.5 Distr 11.5.3.4
Reference pressure between the 1:8 of Electr KFU
voltage lift cylinder, control unit and B2020/1, 4/XX control
Control boom angle, the component B7228/1 DIAG- unit
unit KFU boom length, with diagnostic B7235- NOSE, (D7971),
(D7971), fuel level, menu. LE/1, page page
below 4.9 V. brake Check B7235- 8:81 11:31
pressure, component. RI/1,
accumulator B7226-
pressure 1/2,
and parking B7226-
brake not 2/2,
working. B7226-
3/2,
B7238/2,
B7245-
LE/1,
B7245-
RI/1.
B7570,
B7681/2,
B7683/2,
10104 3 7 5 V - Check the cable D7911/C1 11.5 Distr 11.5.3.8
Reference harness at the :8 of Electr Control
voltage control unit. 13/XX unit KAU
Control DIAG- (D7911),
unit KAU NOSE, page
(D7911), page 11:38
above 5.1 V. 8:84

Error codes machine
Connec-
tions
Lo- and Diag-
10104 4 7 5 V - Check the cable D7911/C1 11.5 Distr 11.5.3.8
Reference harness at the :8 of Electr Control
voltage control unit. 13/XX unit KAU
Control DIAG- (D7911),
unit KAU NOSE, page
(D7911), page 11:38
below 4.9 V. 8:84
10104 3 11 5 V Steering Check cabling D7902/C- 11.5 Distr 11.5.3.2
Reference panel between the 2:1 of Electr KPU
voltage up/down, control unit and M6941/ 17/XX control
Control right the component 10, M6 DIAG- unit
unit KPU instrument with diagnostic 942/10, NOSE, (D7902),
(D7902), up/down and menu. M6943/10 page page
above 5.1 V. forward/back Check 8:85 11:27
do not work. component.
10104 4 11 5 V Steering Check cabling D7902/C- 11.5 Distr 11.5.3.2
Reference panel between the 2:1 of Electr KPU
voltage up/down, control unit and M6941/ 17/XX control
Control right the component 10, M6 DIAG- unit
unit KPU instrument with diagnostic 942/10, NOSE, (D7902),
(D7902), up/down and menu. M6943/10 page page
below 4.9 V. forward/back Check 8:85 11:27
do not work. component.
10104 3 11 1 5 V Switches Check cabling D7902/C- 11.5 Distr Cab
Reference and controls between the 6:1 of Electr overview,
voltage from on the control unit and A3700/1 18/XX page 9:5
Control steering the component DIAG-
unit KPU panel do not with diagnostic NOSE,
(D7902) work. menu. page
to steering Check 8:85
panel, above component.
5.1 V.
10104 4 11 1 5 V Switches Check cabling D7902/C- 11.5 Distr Cab
Reference and controls between the 6:1, D79 of Electr overview,
voltage from on the control unit and 02/C7:01, 18/XX page 9:5
Control steering the component D7902/C- DIAG-
unit KPU panel do not with diagnostic 9:01 NOSE,
(D7902) work. menu. A3700/1 page
to steering Check 8:85
panel, below component.
4.9 V.
10104 3 11 2 5 V voltage The lighting Check cabling D7902/C- - Cab
feed in the between the 6:18, D79 overview,
background steering control unit and 02/C7:20, page 9:5
lighting panel is too the component D7902/C-
steering strong or with diagnostic 7:22
panel, above does not menu. A3700/1
5.1 V. illuminate. Check
component.

Error codes machine
Connec-
tions
Lo- and Diag-
10104 4 11 2 5 V voltage The lighting Check cabling D7902/C- - Cab
feed in the between the 6:18, D79 overview,
background steering control unit and 02/C7:20, page 9:5
lighting panel the component D7902/C-
steering does not with diagnostic 7:22
panel, below illuminate. menu. A3700/1
4.9 V. Check
component.
10104 3 11 3 5 V voltage The function Check cabling D7902/C- - Cab
feed function lighting in between the 6:19, D79 overview,
lighting the steering control unit and 02/C7:21, page 9:5
steering panel is too the component D7902/C-
panel, above strong or with diagnostic 7:23
5.1 V. does not menu. A3700/1
illuminate. Check
component.
10104 4 11 3 5 V voltage The function Check cabling D7902/C- - Cab
feed function lighting in between the 6:19, D79 overview,
lighting the steering control unit and 02/C7:21, page 9:5
steering panel the component D7902/C-
panel, below does not with diagnostic 7:23
4.9 V. illuminate. menu. A3700/1
Check
component.
10104 3 12 5 V Control Check cabling D7950/C- 11.5 Distr 11.5.3.3
Reference wheel panel between the 1:8 of Electr Control
voltage does not control unit and S1017/2 23/XX unit, KID
Control unit work. the component DIAG- (D7950),
KID (D7950), with diagnostic NOSE, page
below 4.9 V. menu. page 11:29
Check 8:86
component.
10104 4 12 5 V Control Check cabling D7950/C- 11.5 Distr 11.5.3.3
Reference wheel panel between the 1:8 of Electr Control
voltage from does not control unit and S1017/2 23/XX unit, KID
Control unit work. the component DIAG- (D7950),
KID (D7950), with diagnostic NOSE, page
above 5.1 V. menu. page 11:29
Check 8:86
component.
10105 2 2 1 Control unit Lift, lower, Check cabling D7971/C- 11.5 Distr 11.5.3.4
KFU (D7971) boom in and between the 1:10 of Electr KFU
reference boom out not control unit and Y6004/2, 28/XX control
ground working. the component Y6005/2, DIAG- unit
1, loose with diagnostic Y6006/2, NOSE, (D7971),
connection. menu. Y6007/2, page page
Check Y6045- 8:87 11:31
component. LE,
Y6045-RI

Error codes machine
Connec-
tions
Lo- and Diag-
10105 6 2 1 Control unit Lift, lower, Check cabling D7971/C- 11.5 Distr 11.5.3.4
KFU (D7971) boom in and between the 1:10 of Electr KFU
reference boom out not control unit and Y6004/2, 28/XX control
ground 1, working. the component Y6005/2, DIAG- unit
high current. with diagnostic Y6006/2, NOSE, (D7971),
menu. Y6007/2, page page
Check Y6045- 8:87 11:31
component. LE,
Y6045-RI
10105 2 2 2 Control unit Boom in, Check cabling D7971/C- 11.5 Distr 11.5.3.4
KFU (D7971) regeneration between the 1:30 of Electr KFU
reference boom out control unit and Y6051- 29/XX control
ground and cab the component 1/2, DIAG- unit
2, loose movement with diagnostic Y6050/2, NOSE, (D7971),
connection. not working. menu. Y6016/2, page page
Check Y6017/2 8:88 11:31
component.
10105 6 2 2 Control unit Boom in, Check cabling D7971/C- 11.5 Distr 11.5.3.4
KFU (D7971) regeneration between the 1:30 of Electr KFU
reference boom out control unit and Y6051- 29/XX control
ground 2, and cab the component 1/2, DIAG- unit
high current. movement with diagnostic Y6050/2, NOSE, (D7971),
not working. menu. Y6016/2, page page
Check Y6017/2 8:88 11:31
component.
10105 2 7 1 Control unit Side shift, Check cabling D7971/C- 11.5 Distr 11.5.3.8
KAU (D7911) spreading, between the 1:10 of Electr Control
reference rotation, control unit and Y6020/2, 43/XX unit KAU
ground controllable the component Y6012/2, DIAG- (D7911),
1, loose tilt, hydraulic with diagnostic Y6018/2, NOSE, page
connection. levelling, menu. Y6019/2, page 11:38
twistlock not Check Y6008/2, 8:91
working. component. Y6009/2,
Y6010/2,
Y6011/2,
Y6035/2,
Y6036/2,
Y6039/2,
Y6040/2,
10105 6 7 1 Control unit Side shift, Check cabling D7971/C- 11.5 Distr 11.5.3.8
KAU (D7911) spreading, between the 1:10 of Electr Control
reference rotation, control unit and Y6020/2, 43/XX unit KAU
ground 1, controllable the component Y6012/2, DIAG- (D7911),
high current. tilt, hydraulic with diagnostic Y6018/2, NOSE, page
levelling, menu. Y6019/2, page 11:38
twistlock not Check Y6008/2, 8:91
working. component. Y6009/2,
Y6010/2,
Y6011/2,
Y6035/2,
Y6036/2,
Y6039/2,
Y6040/2,

Error codes machine
Connec-
tions
Lo- and Diag-
10105 2 7 2 Control unit - Check cabling D7971/C- 11.5 Distr 11.5.3.8
KAU (D7911) between the 1:30 of Electr Control
reference control unit and Y6061- 44/XX unit KAU
ground the component RR, Y601 DIAG- (D7911),
2, loose with diagnostic 3-RR NOSE, page
connection. menu. page 11:38
Check 8:91
component.
10105 6 7 2 Control unit - Check cabling D7971/C- 11.5 Distr 11.5.3.8
KAU (D7911) between the 1:30 of Electr Control
reference control unit and Y6061- 44/XX unit KAU
ground 2, the component RR, Y601 DIAG- (D7911),
high current. with diagnostic 3-RR NOSE, page
menu. page 11:38
Check 8:91
component.
10105 2 7 3 Control unit The indicator Check cabling D7971/C- - 11.5.3.8
KAU (D7911) lights on the between the 2:35 Control
reference boom are not control unit and H5620- unit KAU
ground working. the component 1/2, (D7911),
3, loose with diagnostic H5630- page
connection. menu. 1/2, 11:38
Check H5640-
component. 1/2,
H5001-
1/2
10105 6 7 3 Control unit The indicator Check cabling D7971/C- - 11.5.3.8
KAU (D7911) lights on the between the 2:35 Control
reference boom are not control unit and H5620- unit KAU
ground 3, working. the component 1/2, (D7911),
high current. with diagnostic H5630- page
menu. 1/2, 11:38
Check H5640-
component. 1/2,
H5001-
1/2
10106 6 1 24 V voltage Mini- Check cabling D7901/C- 11.5 Distr Mini-
feed mini- wheel/joy- between the 2:5 of Electr wheel,
wheel/joystick control control unit and S1130/1, 3/XX descrip-
stick control, do not work. the component S1310- DIAG- tion,
short circuit with diagnostic 3/+, NOSE, page 5:5
to ground. menu. S1992/1, page Joystick,
Check S1470/2. 8:81 descrip-
component. B7250/1, tion,
M6501- page 5:6
LE/53a,
M6501-
RI/53a,
M6502/
53a, M6
503/53a,
B2190/1,
B2460/1

Error codes machine
Connec-
tions
Lo- and Diag-
10106 6 2 1 24 V voltage Central Check cabling D7971/C- 11.5 Distr -
feed sensor lubrication between the 2/32 of Electr
frame, short frame control unit and B7242/ 5/XX
circuit to and start the component BN DIAG-
ground. interlock with diagnostic NOSE,
for engine menu. page
heater not Check 8:82
working. component.
10106 6 2 2 24 V voltage - Check cabling D7971/C- 11.5 Distr -
feed sensor between the 2:33 of Electr
frame, short control unit and - 6/XX
circuit to the component DIAG-
ground. with diagnostic NOSE,
menu. page
Check 8:82
component.
10106 6 7 LE 24 V voltage Twistlocks, Check cabling D7911/2:3 11.5 Distr -
feed sensor spreading between the 2 of Electr
attachment stop and control unit and B7202- 14/XX
left-hand damping the component FL/BN, DIAG-
side, short as well as with diagnostic B7202- NOSE,
circuit to rotation stop menu. RL/BN, page
ground. not working. Check B7204- 8:84
component. LE/BN,
B7205-
LE/BN,
B7225/
BN, B769
0/BN, B77
70/BN
10106 6 7 RI 24 V voltage Twistlocks, Check cabling D7911/2:3 11.5 Distr -
feed sensor spreading between the 3 of Electr
attachment stop and control unit and B7202- 15/XX
right-hand damping the component RR, DIAG-
side, short as well with diagnostic B7202- NOSE,
circuit to as central menu. FR/BN, page
ground. lubrication Check B7204- 8:84
attachment component. RI/BN,
not working. B7205-
RI/BN, B7
242/BN
10106 6 11 24V voltage Control Check cabling D7902/C- 11.5 Distr Control
feed to breaker between the 8:1 of Electr breaker
switch, cannot be control unit and S2500/1 22/XX voltage,
control disengaged. the component DIAG- func-
breaker with diagnostic NOSE, tion de-
(S2500), menu. page scription,
short circuit Check 8:86 page

Error codes machine
Connec-
tions
Lo- and Diag-
10106 6 11 1 24 V voltage Switches Check cabling D7902/C- 11.5 Distr -
feed to and controls between the 3:9 of Electr
switches in the cab not control unit and S1004/3, 19/XX
and controls working. the component S1006F- DIAG-
in the cab, with diagnostic R/1, S1 NOSE,
short circuit menu. 006R/3, page
to ground. Check S1006- 8:85
component. FR/3,
S1008/3,
S1008-
2/3,
S1010/3,
S1010-
2/3, S1
012-2/3,
S1013/3,
S1015/3,
S1014/3,
S1023-
1/3,
S1024/1,
S1031/2,
S1046/3,
S1028/3,
S1029/3,
S1037/3,
S1049/3,
S1310-
2/6,
S1490/1,
S1690/3,
S1750/3,
S1751/3,
S1752/3,
S1990-
1/3,
S1990-
2/3, S1
990-3/3,
S1990-
4/3, S1
990-5/3,
S1990-
6/3, S1
990-7/3,
S2992/3,
S8150/7,
S8070-
1/1, S8
070-2/1,
S8070-
3/1, S8
070-4/1,
S8070-
5/1,

Error codes machine
Connec-
tions
Lo- and Diag-
10106 6 11 2 24V voltage Bypass Check cabling D7902/C- 11.5 Distr -
feed to safety between the 4:1 of Electr
switches system, lock control unit and S1003/3, 20/XX
in the cab, twistlocks, the component S1005/3, DIAG-
short circuit switch off with diagnostic S1047/3 NOSE,
to ground. sounds in menu. page
cab do not Check 8:85
work. component.
10106 6 11 3 24V voltage Mini- Check cabling D7902/C- 11.5 Distr -
feed to wheel/joy- between the 5:1 of Electr
switches stick control, control unit and B7700- 21/XX
and controls travel direc- the component 1/BN, DIAG-
in the cab, tion selector, with diagnostic B7700- NOSE,
short circuit direction in- menu. 2/BN, page
to ground. dicators do Check S1310/1, 8:86
not work. component. S1600/31
, S1600/4
9a
10107 6 11 1 Lighting Lighting Check cabling D7902/C- 8.1 Con- Cab
switch, short switch is not between the 3:10 trols & In- overview,
circuit to working. control unit and S1006R- str 3/XX page 9:5
ground. the component /6, S10 DIAG-
with diagnostic 06FR/6, NOSE,
menu. S1008/6, page
Check S1008- 8:53
component. 2/6,
S1010/6,
S1012/6,
S1013/6,
S1028/6,
S1029/6,
S1031/6,
S1690/6,
S1750/6,
S1751/6,
S1752/6,
S1990-
2/6, S1
990-5/6,
S1990-
6/6, S1
990-7/6,
S2992/6
10201 40 1 Control Functions Use diagnostic - 11.6 11.6.2
unit KCU routed menu to Commu- Redun-
(D7901), has through find incorrect nication dant
lost contact the control segment. 8/XX, CAN bus,
with the CAN unit are not page page
bus after working. 8:94 11:48
start-up.

Error codes machine
Connec-
tions
Lo- and Diag-
unit KCU routed menu to Commu- Redun-
(D7901), the through find incorrect nication dant
control unit the control segment. 7/XX, CAN bus,
could not unit are not page page
be identified working. 8:94 11:48
during
start-up of
the CAN bus.
10201 42 1 Control No limitation. Use diagnostic - 11.6 11.6.2
unit KCU menu to Commu- Redun-
(D7901), find incorrect nication dant
segment segment. 6/XX, CAN bus,
error page page
redundant 8:93 11:48
CAN bus
normal side.
unit KCU menu to Commu- Redun-
error page page
CAN bus
redundant
side.
unit KFU routed menu to Commu- Redun-
start-up.
unit KFU routed menu to Commu- Redun-
during
start-up of
the CAN bus.
unit KFU menu to Commu- Redun-
error page page
CAN bus
normal side.

Error codes machine
Connec-
tions
Lo- and Diag-
unit KFU menu to Commu- Redun-
error page page
CAN bus
redundant
side.
unit KAU routed menu to Commu- Redun-
start-up.
unit KAU routed menu to Commu- Redun-
during
start-up of
the CAN bus.
unit KAU menu to Commu- Redun-
error page page
CAN bus
normal side.
unit KAU menu to Commu- Redun-
error page page
CAN bus
redundant
side.
unit KPU routed menu to Commu- Redun-
start-up.

Error codes machine
Connec-
tions
Lo- and Diag-
unit KPU routed menu to Commu- Redun-
during
start-up of
the CAN bus.
unit KPU menu to Commu- Redun-
error page page
CAN bus
normal side.
unit KPU menu to Commu- Redun-
error page page
CAN bus
redundant
side.
10201 40 12 Control unit Display not Use diagnostic - 11.6 11.6.2
KID (D7950), working. menu to Commu- Redun-
has lost find incorrect nication dant
contact with segment. 8/XX, CAN bus,
the CAN page page
bus after 8:94 11:48
start-up.
the control find incorrect nication dant
unit could not segment. 7/XX, CAN bus,
be identified page page
during 8:94 11:48
start-up of
the CAN bus.
10201 42 12 Control unit No limitation. Use diagnostic - 11.6 11.6.2
KID (D7950), menu to Commu- Redun-
segment find incorrect nication dant
error segment. 6/XX, CAN bus,
redundant page page
CAN bus 8:93 11:48
normal side.
10201 43 12 Control unit No limitation. Use diagnostic - 11.6 11.6.2
KID (D7950), menu to Commu- Redun-
segment find incorrect nication dant
error segment. 6/XX, CAN bus,
redundant page page
CAN bus 8:93 11:48
redundant
side.

Error codes machine
Connec-
tions
Lo- and Diag-
control unit find incorrect nication dant
incorrectly segment. 2/XX, CAN bus,
located on page page
the CAN bus. 8:92 11:48
11.6
Commu-
nication
4/XX,
page
8:93
10202 35 2 CAN bus Gear Check the cable D7971/C1 - 11.6.3
drive-train, selection not harness and :31, D797 CAN bus
open circuit working. termination 1/C1:32 drive-
Engine resistance. D7940, train,
does not If the error D7930 page
respond to persists, contact 11:51
commands Cargotec.
from the cab.
communica- working. termination 1/C1:32 drive-
tion error. Engine resistance. D7940, train,
commands Cargotec.
from the cab.
commands Cargotec.
from the cab.
commands Cargotec.
from the cab.

Error codes machine
Connec-
tions
Lo- and Diag-
10204 35 1 CAN bus 1 Check the cable D7901/C1 - 11.6.2
customer harness and :26, D790 Redun-
equipment, termination 1/C1:27 dant
open circuit resistance. D7950/C1 CAN bus,
Disconnect :12, D795 page
any customer 0/C1:13 11:48
equipment in
order to isolate
the source of the
error.
If the error
persists, contact
Cargotec.
10204 36 1 CAN bus Some Check the cable D7901/C1 - 11.6.2
customer optional harness and :26, D790 Redun-
equipment, functions do termination 1/C1:27 dant
communica- not work. resistance. D7950/C1 CAN bus,
tion error. If the error :12, D795 page
persists, contact 0/C1:13 11:48
Cargotec.
Cargotec.
Cargotec.
10301 2 1 Control Memory Connect the - - 11.5.3.1
unit KCU errors can Kalmar Service KCU
(D7901) disrupt Tool and Repair. control
memory machine If the error unit
error non- operations. persists, replace (D7901),
volatile the control unit. page
memory. 11:25
10301 2 2 Control unit Memory Connect the - - 11.5.3.4
KFU (D7971) errors can Kalmar Service KFU
memory disrupt Tool and Repair. control
error non- machine If the error unit
volatile operations. persists, replace (D7971),
memory. the control unit. page
11:31
KAU (D7911) errors can Kalmar Service KFU
memory disrupt Tool and Repair. control
error non- machine If the error unit
volatile operations. persists, replace (D7971),
memory. the control unit. page
11:31

Error codes machine
Connec-
tions
Lo- and Diag-
10301 2 11 Control Memory Connect the - - 11.5.3.2
unit KPU errors can Kalmar Service KPU
(D7902) disrupt Tool and Repair. control
memory machine If the error unit
error non- operations. persists, replace (D7902),
volatile the control unit. page
memory. 11:27
KID (D7950) errors can Kalmar Service Control
memory disrupt Tool and Repair. unit, KID
error non- machine If the error (D7950),
volatile operations. persists, replace page
memory. the control unit. 11:29
10303 0 1 Control None when Clean dirt and - - 11.5.3.4
unit KCU the error dust from the KFU
(D7901), becomes control unit and control
high active, but its immediate unit
temperature may affect surroundings. (D7971),
circuit board. the lifespan page
of the control 11:31
unit.
unit KFU the error dust from the KFU
unit.
unit KAU the error dust from the KFU
unit.
unit KPU the error dust from the KPU
unit.
10303 0 12 Control unit None when Clean dirt and - - 11.5.3.3
KID (D7950), the error dust from the Control
high becomes control unit and unit, KID
temperature active, but its immediate (D7950),
circuit board. may affect surroundings. page
the lifespan 11:29
of the control
unit.

Error codes machine
Connec-
tions
Lo- and Diag-
10304 2 1 Control Slow Fully - - 11.5.3.1
unit KCU response de-energise KCU
(D7901), on machine the machine control
long functions. by switching unit
processing off the ignition (D7901),
time for and switching page
programs. off the main 11:25
switch. Restart
the machine.
If the error
persists, contact
Cargotec
support.
unit KFU response de-energise KFU
switch. Restart
the machine.
If the error
persists, contact
Cargotec
support.
unit KAU response de-energise KFU
switch. Restart
the machine.
If the error
persists, contact
Cargotec
support.
unit KPU response de-energise KPU
switch. Restart
the machine.
If the error
persists, contact
Cargotec
support.

Error codes machine
Connec-
tions
Lo- and Diag-
10304 2 12 Control unit Slow Fully - - 11.5.3.3
KID (D7950), response de-energise Control
long on machine the machine unit, KID
processing functions. by switching (D7950),
time for off the ignition page
programs. and switching 11:29
off the main
switch. Restart
the machine.
If the error
persists, contact
Cargotec
support.
10305 6 1 Control Fuses can If there are other - - 11.5.3.1
unit KCU blow and error codes, KCU
(D7901), functionality check these first. control
high power can be lost. Check the unit
consump- wiring. (D7901),
tion. page
11:25
unit KFU blow and error codes, KFU
tion. page
11:31
unit KAU blow and error codes, KFU
tion. page
11:31
unit KPU blow and error codes, KPU
tion. page
11:27
10306 3 2 1 Control No limitation, Check the D7971/ 11.5 Distr 11.5.3.4
unit KFU but may supply voltage C1:27, of Electr KFU
(D7971), affect the to the control C1:28, 25/XX control
control control unit's unit, connection C1:29, DIAG- unit
breaker function in C3:1. C1:33, NOSE, (D7971),
voltage the long Check the C1:34, page page
group 1 short term. wiring. C1:35, 8:87 11:31
circuit to C1:36,
voltage. C1:37,
C1:38,
C1:40,
C1:41

Error codes machine
Connec-
tions
Lo- and Diag-
10306 4 2 1 Control Lift, lower Check the D7971/ 11.5 Distr 11.5.3.4
unit KFU extension supply voltage C1:27, of Electr KFU
(D7971), and cab to the control C1:29, 25/XX control
control movement unit, connection C1:33, DIAG- unit
breaker not working. C3:1. C1:34, NOSE, (D7971),
voltage Check the C1:35, page page
group 1 short wiring. C1:36, 8:87 11:31
circuit to C1:37,
ground. C1:38,
C1:40,
C1:41
10306 3 2 2 Control No limitation, Check the D7971/ 11.5 Distr 11.5.3.4
unit KFU but may supply voltage C1:47, of Electr KFU
(D7971), affect the to the control C1:48, 26/XX control
control control unit's unit, connection C1:50 DIAG- unit
breaker function in C3:1. NOSE, (D7971),
voltage the long Check the page page
group 2 short term. wiring. 8:87 11:31
circuit to
voltage.
10306 4 2 2 Control Mini- Check the D7971/ 11.5 Distr 11.5.3.4
unit KFU wheel/joy- supply voltage C1:47, of Electr KFU
(D7971), stick control to the control C1:48, 26/XX control
control do not work. unit, connection C1:50 DIAG- unit
breaker C3:1. NOSE, (D7971),
voltage Check the page page
group 2 short wiring. 8:87 11:31
circuit to
ground.
10306 4 2 3 Control Hydraulic oil Check the C7971/C2 11.5 Distr 11.5.3.4
unit KFU cooler fan supply voltage :35, C2:37 of Electr KFU
(D7971), and braking to the control 27/XX control
control system oil unit, connection DIAG- unit
breaker cooler can C3:1. NOSE, (D7971),
voltage stop working. Check the page page
circuit to
ground.
10306 4 7 1 Control Side shift, Check the D7971/ 11.5 Distr 11.5.3.4
unit KAU spreading, supply voltage C1:27, of Electr KFU
(D7911), rotation, to the control C1:29, 40/XX control
control controllable unit, connection C1:33, DIAG- unit
breaker tilt and C3:1. C1:34, NOSE, (D7971),
voltage hydraulic Check the C1:35, page page
group 1 short levelling not wiring. C1:36, 8:90 11:31
circuit to working. C1:37,
ground. C1:38,
C1:40,
C1:41

Error codes machine
Connec-
tions
Lo- and Diag-
10306 4 7 2 Control Indicator Check the D7911/ 11.5 Distr 11.5.3.4
unit KAU lights boom supply voltage C1:47, of Electr KFU
(D7911), and lowering to the control C1:48, 41/XX control
control of lift jacks unit, connection C1:50 DIAG- unit
breaker right rear not C3:1. NOSE, (D7971),
voltage working. Check the page page
circuit to
ground.
10307 2 1 Control No limitation. Fully - - 11.5.3.1
unit KCU de-energise KCU
(D7901), the machine control
memory by switching unit
error. off the ignition (D7901),
and switching page
off the main 11:25
switch. Restart
the machine.
If the error
persists, contact
Cargotec
support.
unit KFU de-energise KFU
and switching page
off the main 11:31
switch. Restart
the machine.
If the error
persists, contact
Cargotec
support.
and switching page
off the main 11:31
switch. Restart
the machine.
If the error
persists, contact
Cargotec
support.

Error codes machine
Connec-
tions
Lo- and Diag-
and switching page
off the main 11:25
switch. Restart
the machine.
If the error
persists, contact
Cargotec
support.
and switching page
off the main 11:31
switch. Restart
the machine.
If the error
persists, contact
Cargotec
support.
unit KAU de-energise KFU
and switching page
off the main 11:31
switch. Restart
the machine.
If the error
persists, contact
Cargotec
support.
and switching page
off the main 11:25
switch. Restart
the machine.
If the error
persists, contact
Cargotec
support.

Error codes machine
Connec-
tions
Lo- and Diag-
and switching page
off the main 11:31
switch. Restart
the machine.
If the error
persists, contact
Cargotec
support.
unit KAU de-energise KFU
and switching page
off the main 11:31
switch. Restart
the machine.
If the error
persists, contact
Cargotec
support.

D:134

E:1
E Schematics
Contents E Schematics
Schematics......................................................................................................... E:3
Common hydraulics ........................................................................................ E:3
Hydraulic diagrams, compilation ................................................................ E:3
Hydraulic diagram brake system ................................................................ E:4
Hydraulic diagram, basic machine ............................................................. E:6
Hydraulic diagram top lift............................................................................ E:8
Hydraulic diagram top lift, hydraulic levelling ........................................... E:10
Hydraulic diagram top lift, overheight legs ............................................... E:12
Hydraulic diagram cab movement and support jacks............................... E:13
Common electrics ......................................................................................... E:16
Circuit diagrams, subdivision.................................................................... E:16
Circuit diagram, description ..................................................................... E:16
Component designations ......................................................................... E:17
Circuit diagrams, compilation ................................................................... E:17

E:2

E Schematics – Schematics E:3
E Schematics
Common hydraulics
Hydraulic diagrams, compilation
Designation Drawing number
Hydraulic diagram brake system, page E:4 A60531.0100
Hydraulic diagram, basic machine, page E:6 A40740.1100
Hydraulic diagram top lift, page E:8 A60787.0200

Hydraulic diagram top lift, hydraulic levelling, page E:10 A60787.0100
Hydraulic diagram top lift, overheight legs, page E:12 A60787.0300
Hydraulic diagram cab movement and support jacks, page E:13 A60532.0100

E:4 E Schematics – Common hydraulics
Hydraulic diagram brake system
5
15
4
4
6
3
14
7
8
9
2
2
2
2
10
11
1
12
16
13
017432 (A60531.01 00 ve r 02)

17

E Schematics – Common hydraulics E:5
1. Brake valve
2. Accumulator brake pressure
3. Parking brake caliper
4. Brake cylinder
5. Wheel brakes
6. Drive axle block
7. Brake pressure sensor (B7681)
8. Accumulator pressure sensor (B7683)
9. Sensor declutch
10. Accumulator charging valve
11. Sensor parking brake pressure (B7682)
13. Oil filter brake system
14. Thermal bypass valve
15. Cooler brake system
16. Oil tank brake system

Hydraulic diagram, basic machine
11
9
9
10
8
8
7
12
12
6
15
14
13
16
b
f
a
17
4
18
23
5
24
22
19
21
25
20
3
28
017431 (A40740.1100 ve r. 01)

3
29
26
2
30
1
27

1. Pressure feed to attachment

2. Distribution block hydraulic oil pump 3 and 2
3. High-pressure filter
4. Valve block servo pressure
a Shuttle valve pump 1
b Solenoid valve pump unloading (Y6093)
c Shuttle valve attachment
d Solenoid valve, engagement of hydraulics top lift (Y6003)
e Shuttle valve cab
f Pressure reducer
5. Accumulator servo pressure
6. Control valve lifting/lowering and extension
7. Servo filter
8. Valve block lift cylinder
9. Lift cylinder
10. Valve block extension cylinder
11. Extension cylinder
12. Hydraulic oil filter
4. Steering valve
5. Non-return valve
6. Cooler hydraulic oil
7. Bypass valve, hydraulic oil cooler
8. Fine filter hydraulic oil
9. Hydraulic oil tank
10. Pressure limiting valve 250 Bar
11. Priority valve
12. Pump cooling and filtration of hydraulic oil
15. Brake oil pump
17. Relief valve, attachment
18. Breather filter hydraulic oil tank

Hydraulic diagram top lift
6
5
7
8
9
9
13
10
11
12
11
4
12
1
3
1
1
017433 (A60787.0200 ve r. 01)

2

1. Tilt cylinder
2. Damping block (product alternative controllable tilt and tilt lock)
3. Damping block
5. Twistlock cylinders
6. Quick couplings for alternative attachment function
7. Valve block spreader motor
8. Spreader motor
9. Side shift cylinders
12. Brake rotation motor unit

Hydraulic diagram top lift, hydraulic levelling
7
6
6
7
6
6
5
5
8
9
10
10
14
12
11
13
4
12
13
1
3
1
1
017434 (A60787.0300 ve r. 01)

2

1. Tilt cylinder
3. Damping block
5. Levelling cylinders
6. Overcentre valve levelling
9. Spreader motor

Hydraulic diagram top lift, overheight legs
6
5
7
8
9
13
10
11
12
4
11
12
1
3
1
1
14
14
15
017435 (A60787.0100 ve r. 01)

2
16
14
14
1

1. Tilt cylinder
3. Damping block
6. Quick couplings for alternative attachment function
8. Spreader motor
14. Hydraulic cylinder, overheight jacks
15. Valve block overheight legs
16. Overcentre valve overheight jacks
Hydraulic diagram cab movement and support

jacks

15
15
6
4
14
14
7
13
3
16
b
f
a
e
2
12
11
017436 (A60532.0100 ve r. 01)

1
10

1. Distribution block hydraulic oil pump 3 and 2

2. Valve block servo pressure
a Shuttle valve pump 1
b Solenoid valve pump unloading (Y6093)
c Shuttle valve attachment
d Solenoid valve, engagement of hydraulics top lift (Y6003)
e Shuttle valve cab
f Pressure reducer
3. Control valve cab movement
4. Hydraulic motor sliding cab
5. Accumulator
6. Load control valve
7. Control valve cab movement
8. Hydraulic cylinder cab lift
9. Hydraulic oil pump 2 and 3
10. Brake oil pump
11. Distribution block hydraulic oil pump 1
13. Control valve support jacks
14. Overcentre valve
16. Hydraulic oil tank

E:16 E Schematics – Common electrics
Common electrics
Circuit diagrams, subdivision
Circuit diagrams are subdivided by cab, frame and attachment. The
different parts can cover more than one machine model, it is therefore
important to be observant that certain individual components may not
be fitted on the current machine, the same also applies to options and
variants.
Circuit diagram, description

A circuit diagram is divided into circuit names (drawing numbers) and
consists of a set of numbered pages.
The circuits and their contents are governed by the following set of
rules:
• 20015.0001 circuit drawings-post designations K-standard.
• K-standard 1: norms, rules
• K-standard 2: cables, general physical
• K-standard 5: Designation and marking system, item designations
circuit drawings
The following is an explanation of symbols and texts in a circuit diagram:

Connectors
Connectors
Connectors in the wiring start with an X followed by a number and end
-X080f -X080m with f = female or m = male. If a connector is connected to a component
0301A 1 1 then the component number is inherited into the connector's number,
e.g. XB72002Rm which is the connector for Sensor, contact front right
017472
(B7202R).
Under the connector's number the pin is specified with numbers or

letters depending on the connector.
Components
Components
+CHASSIS Components are described with component number (S220-2) and a
-S220-2 short descriptive text. Components (sensors, switches, etc.) are shown
P in standby mode i.e. de-energised mode or mechanical standby mode.
• S indicates the type of component, see Component designations,
1 1 2 1 page E:17.
013018
DECLUTCH • 220 is component number and indicates the function the

3,0MPa
component has.
• -2 indicates that it is the second component of this type for the
specific diagram.
Cable marking
Cable marking
A 01012 0525 W 212D

The cables are colour coded in accordance with the following: Red =
battery voltage. White = ignition voltage or signal. Black = grounding.
A 01011 0524 W 212C

Cable numbering is interpreted as follows:
• 0525: the number on a cable can usually be traced to a pin in a
connector, in this example, connector X052 pin 5.
A 01010 0523 W 212B
• W212: cables that start with W and serial number cannot be
traced directly to a connector.
A 01016 0527 W 212E • A01012: cables that start with A are in the electronic box in the cab.
• W212D: cables that end with a capital letter are jointed in the
wiring from a main cable with the same number. Each joint will
013019
W 212A
have its own letter.
Jointed cables are only located inside the cab, outside of the cab
the joints are routed out to a separate connector with strappings.

E Schematics – Common electrics E:17
References
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 also references for components that can then be part of a component
00816
/4 .0 _ 1 .B 1 5 1 whose other parts are on a different diagram. In some cases there is
013020
00816
/9 .1 0 _ 1 .A 2 also a help text where the cable connects.
Example: /11.5_1.D3 means page 11.5_1 coordinate D3.

Connection to control unit
Connection to control unit

Connections to control units are described as a table with two fields;
the upper one shows the type of connection, the lower one has a
-X 4 1 1
21 K 1 :2 1 A n a lo g In 0 -5 V +BO O M reference to the compilation of the control unit's connections. Together
/0 .0 _ 4 .D 5 -D 7 9 1 -1 with this there are descriptive texts that specify control unit and signal.
M E A S U R E P O IN T S C A L E 013021 For more information about the different connection types on the
control units, see section 11 Common electrics, group 11.5.5 Wiring.
Fuses
Fuse boxes always start with F99. Example: F9958-RD means a fuse
box with 8 fuses for battery voltage.
For most fuse boxes there is also a table and an explanation of the
circuits that the various fuses protect.
Component designations
The components in circuit diagrams have a prefix and number, the
prefix describes the type of component, the number which component.
Component list with component number, prefix and designation is

provided as an appendix after the circuit diagrams.
Prefix Description
B Converter from non-electric to electric signals or vice versa. Example: inductive sensor.
D Binary element, delay unit, memory. Example: control unit.
E White light. Example: work lighting.
F Protective device. Example: fuse.
G Alternator, power supply device. Example: battery.
H Signal device. Example: horn, brake lights.
K Relay, contactor. Example: power relay ignition key lock.
M Engine. Example: electric motor.
P Measuring instrument, testing equipment. Example: hour meter.
R Resistor. Example: potentiometer.
S Electric switch for control circuit, selector. Example: switch.
X Outlet/socket, connecting device. Example: connection terminal.
Y Electrically controlled mechanical device. Example: solenoid valve, hydraulic valve.
Circuit diagrams, compilation

Circuit diagrams are attached as an appendix in the following order.
• A55040.0100 Circuit diagram cab
• A55039.1200 Circuit diagram frame
• A56400.0100 Circuit diagram attachment
• A60822.0100 - 0600 Circuit diagram electric heater

E:18

1 2 3 4 5 6 7 8
A A
C
DRG 100-450 B
Kretsar / Wiring
not be imparted to a third party nor be used for any
written permission and the contents thereof must
unauthorized purpose. Contravention will be pro-

This document must not be copied without our
D D
secuted.
Chassie E
hörigen användas. Överträdelse härav beivras med
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe-
stöd av gällande lag.
F F
Benämning Produkt/Product Blad/Sheet

Ref. Nr Ändring Ändring nr Datum Sign. Datum/Date Huvudnr./Project no.
E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn MLG 120423 A55031.1200 KRETSSCHEMA,DRG, 2012 DRG 100-450 0
Name
1 See EO 131786 MLG 140107 MAC 120418 H.Grp:
6 Ritn.nr./ Drawing No. Utgåva/Issue
R
Konstr/Design
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr

MLG 120423 Klass/Class
WIRING DIAGRAM,DRG, 2012 A55039.1200 08
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A
-D7971 A
Pin Number Drawing Function Type Pin Number Drawing Function Type
1:1 /7.2_1.D1 DRG 450: Lift regenerating valve right Digital Output 1.5A 2:1 /9.6_1.D1 Roading light dipped, front left Digital Output 6A
DRG 100: Activate extra hydraulic pump lift 2:2 /9.6_1.C1 Roading light head, front left Digital Output 6A
2:3 /9.6_1.D1 Roading light dipped, front right Digital Output 6A
2:4 /9.6_1.D1 Roading light head, front right Digital Output 6A
1:2 /11.5_5.A5 CPU power startup from KCU Power supply 2:5 /9.6_3.C1 Working light fender left option Digital Output 6A
1:3 /11.6_1.B1 CAN 2:6 /9.6_3.E1 Working light fender right option Digital Output 6A
1:4 See pin C1:3 2:7 /4.3.B8 Brake pressure Dig/Ana Input
1:5 Analogue Input 0-5V 2:8 /4.5.D8 Accumulator pressure Dig/Ana Input 1
1:6 See pin C1:3 2:9 /1.7.C8 Feedback CAC Left Dig/Ana Input
1:7 See pin C1:3
1:8 /11.5_6.A1 5V Sensor supply 5V Analogue Ref 2:10 /8.2_1.B8 Lift pressure+ Left Dig/Ana Input
B 1:9 /11.5_6.B8 0V Sensor supply 0V Analogue Ref B
1:10 /11.5_6.C8 Safe ground, group 1 Boom valves Digital Output NPN
1:11 /7.2_1.E1 DRG 450: Lift Regenerating Valve Left Digital Output 1.5A 2:11 /8.2_1.B8 Lift pressure- Left Dig/Ana Input
1:12 /9.14.B8 Central lubrication feedback Digital Out/In 1.5A

1:13 /9.6_2.B1 Brake light rear Digital Out/In 1.5A 2:12 Dig/Ana/Freq Input
1:14 /10.4.A1 DRG Cut pump bom in Digital Output 1.5A
1:15 /10.4.C1 DRG 100-450,: Activate pump attachment Digital Output 1.5A 2:13 /8.2_1.C8 Lift pressure+ Right Dig/Ana Input
2:14 /8.2_1.C8 Lift pressure- Right Dig/Ana Input

KFU7970, Main C1 connector pinout
1:16 /9.6_1.B1 Side position light x4 Digital Out/In 1.5A

1:17 /4.5.B1 Parking brake Digital Output 1.5A
1:18 /9.7.A1 Reversing alarm Digital Output 1.5A 2:15 /8.2_1.E8 Tilt/boom angle Dig/Ana Input

1:19 /9.6_2.A1 Rear light x2 Digital Out/In 1.5A 2:16 /8.2_1.D8 Boom Extension Dig/Ana Input
C 1:20 /9.6_1.A1 Direction indicator left Digital Out/In 1.5A C
1:21 /1.7.F1 Fan direction control Digital Output 1.5A
1:22 /11.1.A1 Output status signal F Digital Output 1.5A 2:17 /4.5.C8 P-brakepressure sensor 0-5V Dig/Ana Input 1
1:23 /11.1.A1 Output status signal R Digital Output 1.5A
1:24 Digital Output 1.5A
1:25 2:18 Dig/Ana Input
/11.4.B8 Engine running D+ Digital Input D+
1:26 /9.6_1.A1 Direction indicator right Digital Out/In 1.5A
1:27 /7.2_1.A1 Lift PWM Output Group1 2:19 Dig/Ana Input
1:28 /7.2_1.B1 Lower PWM Output Group1 2:20 /1.7.B8 Visco Fan speed feedback Dig/Ana/Freq Input
1:29 /7.3.B1 Boom in PWM Output Group1


1:30 /11.5_6.D8 Safe ground, group 2 Digital Output NPN

1:31 See pin C1:3 2:21 /1.7.D8 Feedback CAC Right Dig/Ana/Freq Input
1:32 See pin C1:3 2:22 /9.9_2.B1 Rear view mirror heating Digital Output 6A
1:33 /7.3.B1 Boom out PWM Output Group1 2:23 /5.2.C8 EHPS error Dig/Ana Input
1:34 /7.3.D1 Boom out regenerating valve PWM Output Group1 2:24 /1.2.B7 Fuel level Ana/Temp/Rheo Input
D 1:35 /7.3.E1 Boom in block valve PWM Output Group1 2:25 /10.6.C1 Hydraulic oil temperature Ana/Temp/Rheo Input D
1:36 /7.2_1.B1 Boom down block valve Left PWM Output Group1
secuted.

1:37 /7.2_1.C1 Boom down block valve Right PWM Output Group1 2:28 Dig/Ana/Freq Input
2:29 /4.8.B1 Hydraulic brake oil temperature Ana/Temp/Rheo Input
1:38 /1.7.C1 CAC PWM Output Group1 2:30 Digital Output 1.5A
2:32 /11.5_6.E1 Supply sensors frame Digital Output 0.5A
1:39 /9.10.B1 Cab tilt down PWM Output Group1 2:33 Digital Output 0.5A
2:34 /9.4.B2 Ac compressor Digital Output 6A
2:35 /10.6.B1 Cooling fan hydraulic oil PWM 15A
2:36 /9.6_3.A1 Working light Boom, left Digital Output 6A
1:40 /9.10.B1 Cab Lower/REV valve PWM Output Group1 2:37 /4.8.A1 Cooling fan brake oil PWM 15A
2:38 /9.6_3.B1 Working light Boom, right Digital Output 6A
E 24V See pin C1:2 E
GND See pin C1:2
1:41 /9.10.C1 Cab Lift/FWD valve PWM Output Group1
1:42 /1.6.C7 Air intake filter low preasure Digital Out/In 1.5A
1:43 /1.11.A1 Engine starter Digital Output 3A
1:44 Digital Output 3A

1:45 /9.7.D1 Rotating beacon frame Digital Output 3A
1:46 /9.14.E1 Central lubrication chassi pump Digital Out/In 6A
1:47 /1.7.A1 Fan speed control valve PWM Output Group2
1:48 /5.2.C1 EHPS power supply PWM Output Group2
F 1:49 /1.11.B1 Ignition power Digital Out/In 6A F
1:50 /5.2.B1 EHPS valve steering PWM Output Group2

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No. Design change Change No. Date Ritad/Drawn MLG 120423 A55031.1200 KRETSSCHEMA,DRG, 2012 DRG 100-450 0.0_1
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-D7972
A A
1:1 Digital Output 1.5A 2:1 Digital Output 6A

1:2 /11.5_5.C5 Power supply 2:5 Digital Output 6A
1:3 /11.6_1.E1 CAN 2:6 Digital Output 6A
1:4 See pin C1:3 2:7 Dig/Ana Input
1:5 Analog Input 2:8 Dig/Ana Input
1:6 See pin C1:3 2:9 Dig/Ana Input
1:7 See pin C1:3
1:8 5V Analogue Ref 2:10 Dig/Ana Input
1:9 0V Analogue Ref
1:10 Digital Output NPN
B B
1:11 Digital Output 1.5A 2:11 Dig/Ana Input
1:12 Digital Out/In 1.5A

1:13 Digital Out/In 1.5A 2:12 Dig/Ana/Freq Input
1:14 /7.10.E1 Support jacks up Digital Output 1.5A
1:15 /7.10.F1 Support jacks down Digital Output 1.5A 2:13 Dig/Ana Input
2:14 /7.10.B8 Support jacks left lower position Dig/Ana Input


1:18 Digital Output 1.5A 2:15 /7.10.C8 Support jacks right upper position Dig/Ana Input

1:19 Digital Out/In 1.5A 2:16 /7.10.C8 Support jacks right lower position Dig/Ana Input
C 1:21 Digital Output 1.5A C
1:22 Digital Output 1.5A 2:17 Dig/Ana Input
1:25 2:18 Dig/Ana Input
Digital Input D+
1:27 PWM Output Group1 2:19 Dig/Ana Input
1:28 PWM Output Group1 2:20 Dig/Ana/Freq Input
1:29 PWM Output Group1
1:30 Digital Output NPN

1:31 See pin C1:3 2:21 Dig/Ana/Freq Input

1:32 See pin C1:3 2:22 /7.10.A1 Digital Output 6A
1:33 PWM Output Group1 2:23 /7.10.A8 Support jacks left upper position Dig/Ana Input
1:34 PWM Output Group1 2:24 Ana/Temp/Rheo Input
1:35 PWM Output Group1 2:25 Ana/Temp/Rheo Input
D 1:36 PWM Output Group1 2:26 Digital Output 0.5A D
secuted.
1:37 PWM Output Group1 2:28 Dig/Ana/Freq Input

2:29 Ana/Temp/Rheo Input
1:38 PWM Output Group1 2:30 Digital Output 1.5A
1:39 PWM Output Group1 2:33 Digital Output 0.5A
2:35 PWM 15A
1:40 PWM Output Group1 2:37 PWM 15A
24V See pin C1:2
GND See pin C1:2
E E

1:45 Power supply sensors Options Support jacks Digital Output 3A

1:46 Digital Out/In 6A
1:49 Digital Out/In 6A
F F

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1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
GND-CUBICLE
/11.5_4.B4
-X232m -X228f -X228m

1 23201 30 GN 0.75 8 8 22808 GN 0.75 30
A -X233m /1.0_A.C6 2 23202 YE 0.75 9 9 22809 YE 0.75

A
9937-201E06 BK 4 2 3 23203 WH 0.75 10 10 22810 WH 0.75
9958-RD-B2:2 9958-RD-B2 RD 4 1 -D7940 4
/11.5_3.A7
5 23205 30 GN 0.75 11 11 22811 GN 0.75 30
6 23206 YE 0.75 12 12 22812 YE 0.75
-X234f
4
3
5
6
1
B -X210m -XD7940 B
D7971-1:31/J1939_HI 1 21001 GN 0.75 30 1
/11.6_1.A6
D7971-1:32/J1939_LO 2 21002 YE 0.75 2
/11.6_1.A6
-X228f -X228m 3
9958-RD-A2:2 9958-RD-A2 RD 1.5 4 4 9958-RD-A2 RD 1.5 4
/11.5_3.A7
D7971-1:49 4 21004 WH 0.75 25102 WH 0.75 5
/1.11.B4
-X251m_BB -X251f
1 1 7
2 2 8
3 3
/1.0_A.A3
4 4
-X229f -X229m -X228f -X228m
-D7940
C 1 1 22803 WH 0.75 3 3 25103 WH 0.75
C
Diagnostic 3 3 9937-201E05 BK 0.75
connector 5 5 22801 GN 0.75 1 1 22905 GN 0.75 30
interface 2 2 22802 YE 0.75 2 2 22902 YE 0.75
-XG6600-D+
25104 -X228m -X228f
9937-201E04 BK 2.5 5 5 GND-CUBICLE
/11.5_4.A4
2
-G6600
GND-CUBICLE
/11.5_4.B4
W
-X210m -XG6600-D+
D7971-1:25 3 21003 WH 0.75 1 D+ B-
/11.4.B5 G
-X9937-203 GND-CHASSIS
D B+ D
secuted.
-M6540
W4
-XM6540-30-1 30 31 -XM6540-31-1
RD 70 W13 BK 70 GND-CHASSIS
/11.5_1.B2 M /11.5_4.B6
50
-Y6450
-X210m -X6450f
D7971-2:34 5 21005 WH 0.75 1 1 2
/9.4.B4
Magnetic clutch, compressor (opt)
E E
-X7590m -XB7590 -B7590 -XB7590

1 75901 WH 0.75 1 1 2 2
2 75902 WH 0.75
Circuit coolant level

F F

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No. Design change Change No. Date Ritad/Drawn MLG 120423 A55031.1200 KRETSSCHEMA,DRG, 2012 DRG 450 1.0_A
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-D7940-1
-X794-1m
1/50
A 2/50 A
-X228f -X228m 3/50
9958-RD-A2:2 9958-RD-A2 RD 1.5 4 4 22804 WH 1.5 4/50
/11.5_3.A7
-X228f -X228m -X286m_BB -X286f 5/50
9958-RD-B2:2 9958-RD-B2 RD 1.5 6 6 22806 WH 1.5 1 1 -X7940-1f 6/50
/11.5_3.A7
2 2 2822 WH 0.75 7 7/50
3 3 2823 WH 0.75 8 8/50
4 4 2824 WH 0.75 9/50
10/50
-X210m 11/50
D7971-1:31/J1939_HI 1 30 GN 0.75 21001
/11.6_1.A6 12/50
21002
-X248BB -X248f 13/50
1 1 30 1
B 14/50 B
2 2 21002 24802 GN 0.75 30
15/50
6 6 30 24806 GN 0.75 24804
-XR8200-3f -R8200-3 16/50
D7971-1:32/J1939_LO 2 30 YE 0.75 21002 24805 A A 1 2 -X287m_BB -X287f -X7940-1f
/11.6_1.A6 1 1 17 17/50
21001 3 3 30 B B
2 2 2832 WH 0.75 18 18/50
4 4 21001 24804 YE 0.75 30
3 3 2833 WH 0.75 19/50
5 5 30 28405 YE 0.75 24802
4 20/50
24806
21/50
22/50
23/50
D7971-1:49 4 21004 WH 0.75
/1.11.B4 24/50
-X228f -X228m 25/50
C GND-CUBICLE 9937-201E04 BK 2.5 5 5 22805 BK 1.5 26/50 C
/11.5_4.A4
-X288m_BB -X288f -X7940-1f 27/50
1 1 28 28/50
2 2 2842 BK 0.75 29 29/50
3 3 2843 BK 0.75 30 30/50
4 4 2844 BK 0.75 31/50
5 5 2845 BK 0.75 32/50
6 6 33/50
2846 BK 0.75

34/50
35/50
-K3600 36/50
-X210m -X7940-1f
D7971-1:43 6 21006 WH 1.5 86 85 30 37 37/50
/1.11.A4
24802 38 38/50
D 30 87 D
39 39/50
secuted.
Relay, starting solenoid 40 40/50

41/50
-G6600
42/50
-XG6600-D+ W 43/50
-X210m
D7971-1:25 3 21003 WH 1.5 D+ B- -XG6600-B- 44/50
/11.4.B5 G
-X7940-1f 45/50
B+ 30 46 46/50
-XG6600-B+ 24804 47/50
RD 48/50
-X7940-1f 49/50
E -XM6540:30-2 -XM6540:31-2 50 50/50 E
BK
-M6540
-XM6540:30-1 30 31 -XM6540:31-1
M /11.5_1.B2
-XM6540:30-3 50 -XM6540:31-3
ELECTRONIC CONTROL UNIT, ENGINE
-XM6450:50
-Y6450
-X210m -X6450f
D7971-2:34 5 21005 WH 1.5 1 1 2
/9.4.B4
F Magnetic clutch, compressor F

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No. Design change Change No. Date Ritad/Drawn MLG 121010 A55031.1200 KRETSSCHEMA,DRG, 2012 DRG 450 1.0_B
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-X7940-2m -X7940-2f
5/31 5 7940205 -X7590
WH 0.75 A
6/31 6 7940206 WH 0.75 B
C WH 0.75 C C
7/31 7 7940207 WH 0.75 D
19/31 19 7940219
-D7940-2
ELECTRONIC CONTROL UNIT, ENGINE

D D
secuted.
E E
F F

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No. Design change Change No. Date Ritad/Drawn MLG 121011 A55031.1200 KRETSSCHEMA,DRG, 2012 DRG 450 1.0_C
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
GND-CUBICLE
-X232m
1
-X233m /1.0_D.C6 2
2 3
1 -D7940 4
A 9958-RD-B2:2 5 A
6
-X210m
D7971-1:31/J1939_HI 1 21001 GN 0.75 30
/11.6_1.A6
D7971-1:32/J1939_LO 2 21002 YE 0.75 -X227m_BB -X227f
/11.6_1.A6
1 1
2 2
6 6
-X234f
4
3
5
6
1
-X227m_BB -X227f
B 3 3 B
-X226f 4 4 -XD7940f
1 22706 GN 0.75 30 5 5 30 22702 GN 0.75 1
HVT 2 22705 YE 0.75 22704 YE 0.75 2
-X228f -X228m 3
9958-RD-A2:2 9958-RD-A2 RD 1.5 4 4 9958-RD-A2 RD 1.5 4
/11.5_3.A7
25102 WH 0.75 5
-X210m -X251m_BB -X251f
D7971-1:49 4 21004 WH 0.75 1 1 7
/1.11.B4
2 2 8
-X226f 3 3 WH 0.75
/1.0_D.A3
3 25105 WH 0.75 4
C HVT 4 25106 WH 0.75 5 5
-D7940 C
6 6
-X229f -X229m -X228f -X228m

1 1 22803 WH 0.75 3 3 25103 WH 0.75
Diagnostic
3 3 9937-201E05 BK 0.75 -X228m -X228f
connector 30
5 5 1 1 5 5
22801 GN 0.75 22801 GN 0.75 9937-201E04 BK 2.5 GND-CUBICLE

interface /11.5_4.B4
2 2 22802 YE 0.75 2 2 22802 YE 0.75

GND-CUBICLE
/11.5_4.B4
D D
secuted.
-G6600
W
-X210m -XG6600-D+
D7971-1:25 3 21003 WH 0.75 1 D+ B-
/11.4.B5 G
-X9937-203 GND-CHASSIS
B+
-M6540
W4
-XM6540-30-1 30 31 -XM6540-31-1
RD 70 W13 BK 70 GND-CHASSIS
/11.5_1.B2 M /11.5_4.B6
50
E E
-Y6450
-X210m -X6450f
D7971-2:34 5 21005 WH 0.75 1 1 2
/9.4.B4
-X7590m -XB7590 -B7590 -XB7590
Magnetic clutch, compressor (opt) 1 1 1 2 2
Circuit coolant level

F F

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No. Design change Change No. Date Ritad/Drawn MLG 131106 A55031.1200 KRETSSCHEMA,DRG, 2012 DRG 450 1.0_D
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XB7570f -XB7570m -B7570

D7971-1:08 24008 WH 0.75 A A RD -XB7570m -XB7570f -XD7971-2
/11.5_6.A4 BK B B 7971-224 WH 0.75 24 C2:24 Ana/Temp/Rheo Input
-D7971
U /0.0_1.D5
Fuel level sensor Fuel level

-XB7570m -XB7570f
B BU C C 23908 WH 0.75 D7971-1:09 B
/11.5_6.C5
C C

D D
secuted.
E E
F F

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No. Design change Change No. Date Ritad/Drawn MLG 120423 A55031.1200 KRETSSCHEMA,DRG, 2012 DRG 100-450 1.2
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-B2710
P
-XB2710 -XB2710
1 1 2 2
3
B B
C1:42 Digital Out/In 1.5A

-D7971
/0.0_1.E2
Air intake filter low preasure
C C

D D
secuted.
E E
F F

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Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-M6580
-XD7971-1 -X210f -X210m -XM6580 -XM6580 -X228m -X228f
PWM Output Group2 C1:47 47 7971-147 WH 0.75 10 10 21010 WH 0.75 B C 22807 BK 0.75 7 7 9937-201G1 BK 1.5 GND-CUBICLE
-D7971 M /11.5_4.D4
/0.0_1.F2
Fan speed control valve
-XM6580 -X210m -X210f -XD7971-2

E 21009 WH 0.75 9 9 7971-220 WH 0.75 20 C2:20 Dig/Ana/Freq Input
-D7971
/0.0_1.D5
-X210f -X210m -XM6580 -XM6580 -X210m -X210f
D7971-1:08 24010 WH 0.75 7 7 21007 WH 0.75 A D 21008 WH 0.75 8 8 23910 WH 0.75 D7971-1:09 Visco Fan speed feedback
/11.5_6.B4 /11.5_6.C5
B B
-XD7971-1 -X299f -X299m

PWM Output Group1 C1:38 38 7971-138 WH 0.75 A A WH 0.75
-D7971
/0.0_1.D2
C CAC -X298m_BB -X298f C
1 1 299A -XM6590-LE -XM6590-LE -X299m -X299f -XD7971-2
2 2 29802 WH 0.75 B C 299B WH 0.75 B B 7971-209 WH 0.75 9 C2:9 Dig/Ana Input
PWM Feedback -D7971
3 3 29803 /0.0_1.B5
-M6590-LE Feedback CAC Left
-X300F -X300m -XM6590-LE -XM6590-LE -X300m -X300F
9958-BK-D1
9958-BK-D1 WH 4 1 1 30001 WH 4 E G 30003 BK 4 3 3 9937-201G2 BK 4 GND-CUBICLE
/11.5_3.C7 M /11.5_4.D4

-XM6590-RI -XM6590-RI -X299m -X299f -XD7971-2

WH 0.75 B C 299C WH 0.75 C C 7971-221 WH 0.75 21 C2:21 Dig/Ana/Freq Input
PWM Feedback -D7971
/0.0_1.D5
Feedback CAC Right
-M6590-RI
D -X300F -X300m -XM6590-RI -XM6590-RI -X300m -X300F D
9958-BK-E1
9958-BK-E1 WH 4 2 2 30002 WH 4 E G 30004 BK 4 4 4 9937-201G3 BK 4 GND-CUBICLE
secuted.
/11.5_3.C7 M /11.5_4.D4
E E
-Y6092
-XY6092 -XY6092
Digital Output 1.5A C1:21 1 1 2 2
-D7971 /11.5_4.D1
/0.0_1.C2
F Fan direction control F

Cooling fan speed control valve direction

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Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Cummins QSB6,7
-XD7971-1 -X210f
Digital Output 3A Cummins QSB6,7 Tier4I
C1:43 43 7971-143 WH 0.75 6 D7971-1:43
-D7971 /1.0_B.D1 Cummins QSM11 3A
/0.0_1.E2
A A
Engine starter
Cummins QSB6,7 Tier3

Cummins QSB6,7 Tier4I
/1.0_A.B2 Volvo TAD 1360
-XD7971-1 -X210f /1.0_B.C1
Digital Out/In 6A C1:49 49 7971-149 WH 0.75 4 D7971-1:49
Cummins QSM11 3A
-D7971 /1.0_D.C2 Volvo D8 D11
/0.0_1.F2
Ignition power
B B
C C

D D
secuted.
E E
F F

E³ DRAWING
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Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
GND-CUBICLE
/11.5_4.B4
-XD7930-1
9937-201E07 BK 1.5 1
VM1
9958-RD-F1 9958-RD-F1 9958-RD-F1 RD 1.5 23
/11.5_3.B7 VPE1
A 9958-RD-F2 9958-RD-F2 9958-RD-F2 RD 1.5 68 A
/11.5_3.B7 VPE2
-XB7580
1 1 404 WH 0.75 4
-B7580 VMG2
2 2 462 WH 0.75 62
EF4
3 3
Drive shaft speed
9958-BK-F2 9958-BK-F2A
/11.5_3.D7
9958-BK-F1 9958-BK-F1 45
/11.5_3.C7 VPI
9958-BK-F2 9958-BK-F2B
/11.5_3.D7
-X209
1 9958-BK-F2B WH 0.75
2 415 WH 0.75 415 WH 0.75 15
SDDK
Diagnostic 3 9937-201E08A GND-CUBICLE
/11.5_4.B4
B 4 418 WH 0.75 418 WH 0.75 18 B
EUPR
9937-201E08B 2
VM2
GND-CUBICLE
/11.5_4.C4
D7971-1:31/J1939_HI 20701 GN 0.75 30 20701 GN 0.75 25 CANF_H
/11.6_1.B7
D7971-1:32/J1939_LO 20702 YE 0.75 20702 YE 0.75 26
/11.6_1.B7 CANF_L
C -XA3 C
1 456 WH 0.75 56
Y1 AIP1
2 410 WH 0.75 10
Y5 AIP2
3 432 WH 0.75 32
Y3 AIP3
4 455 WH 0.75 55
Y4 AIP4
5 409 WH 0.75 9
Y2 AIP5
6 451 WH 0.75 51
Y6 AIP6
12
412 WH 0.75
VPS1
7 WH 1.5 413 WH 0.75 13

VPS1 (+) VPS1
8 439 WH 0.75 39
TEMP ER1
-D7930-2-A3
9 446A WH 0.75 46
TEMP VMGA2
D -X268m_BB -X268f D
1 1 412B
secuted.
-X267m_BB -X267f 2 2 412

1 1 446A 3 3 413
2 2 446B -B7660
-XB7660 -XB7660
3 3 446C WH 0.75 2 2 T 1 1 449 WH 0.75 49
ER2
4 4 446D U
Oil temp gear box
-B7551
-X266m_BB -X266f T
1 1 403A -XB7551 -XB7551
2 2 403B WH 0.75 2 2 1 1 417 WH 0.75 17
E ER3 E
3 3 403C Filter
4 4
-XB7530 403D
-B7530 1 1 WH 0.75 30 419 419 WH 0.75 19
EF1
2 2 WH 0.75
Engine speed 403A WH 0.75 3
VMG1
-XB7510
-B7510 1 1 WH 0.75 30 441 441 WH 0.75 41

EF2
2 2 WH 0.75
Turbin speed
-XB7520
-B7520 1 1 WH 0.75 30 442 442 WH 0.75 42
F EF3 F
2 2 WH 0.75 -D7930-2-A1
Internal gear chain speed

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn MLG 120423 A55031.1200 KRETSSCHEMA,DRG, 2012 DRG 450 2.0_A
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
C C

D D
secuted.
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn MLG 2013-11-12 A55031.1200 KRETSSCHEMA,DRG, 2012 DRG 450 2.0_B
Name
R
Konstr/Design

MLG 120423 Klass/Class WIRING DIAGRAM,DRG, 2012 A55039.1200 08
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
C C

D D
secuted.
E E
F F

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Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XB7681f -B7681 -XB7681f

D7971-1:08 24002 WH 0.75 2 2 1 1 23902 WH 0.75 D7971-1:09
/11.5_6.A4 P /11.5_6.B5
4 4
U
Brake pressure sensor 0-5V
B -XD7971-2 B
7971-207 WH 0.75 7 C2:7 Dig/Ana Input
-D7971
/0.0_1.B5
Brake pressure
C C

D D
secuted.
E E
F F

E³ DRAWING
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R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6420
-XD7971-1 -XY6420 -XY6420
Digital Output 1.5A C1:17 17 7971-117 WH 0.75 1 1 2 2 9937-201C01 BK 0.75 GND-CUBICLE
-D7971 /11.5_4.C1
/0.0_1.C2
Parking brake
Parking brake
-XB7682f -B7682 -XB7682f

B D7971-1:08 24007 WH 0.75 2 2 1 1 23907 WH 0.75 D7971-1:09
B
/11.5_6.A4 P /11.5_6.B5
4 4
U
P-brake pressure sensor 0-5V

-XB768m -XB768m
2 76802 WH 0.75 1
-XD7971-2
WH 0.75 4 7971-217 WH 0.75 17 C2:17 Dig/Ana Input
-D7971
/0.0_1.C5
1 P-brakepressure sensor 0-5V
+TLX
-XB7682f -B7682 -XB7682f
WH 0.75 2 2 1 1 76801
P
C 4 4 76804
C
U
P-brake pressure sensor 0-5V
Use when TLX axel is used


-XB7683f -B7683 -XB7683f

D7971-1:08 24005 WH 0.75 2 2 1 1 23905 WH 0.75 D7971-1:09
/11.5_6.A4 P /11.5_6.B5
4 4
U
Accumulator pressure sensor 0-5V
D D
secuted.
-XD7971-2
7971-208 WH 0.75 8 C2:8 Dig/Ana Input
-D7971
/0.0_1.B5
Accumulator pressure
E E
F F

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Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-M6740
-XD7971-2 -XM6740 -XM6740
PWM 15A C2:37 37 7971-237 WH 2.5 1 1 2 2 9937-201C06 BK 2.5 GND-CUBICLE
-D7971 M /11.5_4.D1
/0.0_1.E5
Cooling fan brake oil
Cooling fan brake oil
-B7720
-XD7971-2 -XB7720 -XB7720
Ana/Temp/Rheo Input C2:29 29 7971-229 WH 0.75 1 1 T 2 2 23909 WH 0.75 D7971-1:09
-D7971 /11.5_6.C5
/0.0_1.D5 U
B B
Hydraulic brake oil temperature Hydraulic brake oil temperature sensor
C C

D D
secuted.
E E
F F

E³ DRAWING
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Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B -Y6150 B
-XD7971-1 -XY6150f
PWM Output Group2 C1:50 50 7971-150 WH 0.75 1 1 3 3 9937-201C05 BK 0.75 GND-CUBICLE
-D7971 /11.5_4.D1
/0.0_1.F2 7971-148 WH 0.75 4 4 2 2 7971-223 WH 0.75
EHPS valve steering
Stee valve EHPS
-XD7971-1 -XD7971-2
PWM Output Group2 C1:48 48 23 C2:23 Dig/Ana Input
-D7971 -D7971
/0.0_1.F2 /0.0_1.D5
EHPS power supply EHPS error
C C

D D
secuted.
E E
F F

E³ DRAWING
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R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-Y6005
A -XD7971-1 -XY6005 -XY6005 A
PWM Output Group1 C1:27 27 7971-127 WH 0.75 1 2 23802 WH 0.75 D7971-1:10
-D7971 /11.5_6.C5
/0.0_1.C2
Lift
Lift valve
-Y6004
-XD7971-1 -XY6004 -XY6004
-D7971 /11.5_6.C5
/0.0_1.D2
Lower
Lower valve
B B
-Y6045-LE
-XD7971-1 -XY6045-LE -XY6045-LE
-D7971 /11.5_6.D5
/0.0_1.D2
Boom down block valve Left
Boom down block valve Left
-Y6045-RI
-XD7971-1 -XY6045-RI -XY6045-RI
-D7971 /11.5_6.D5
/0.0_1.D2
Boom down block valve Right
C Boom down block valve Right C
-Y6089

DRG 100: Activate extra hydraulic pump lift
D D
secuted.
-Y6051-RI
-XD7971-1 -XY6051-RI/XY6089 -XY6051-RI/XY6089
Digital Output 1.5A C1:1 1 7971-101 WH 0.75 WH 0.75 1 2 24702 BK 0.75 GND-CUBICLE
-D7971 /11.5_7.A5
/0.0_1.A2
DRG 450: Lift regenerating valve right
DRG 100: Activate extra hydraulic pump lift DRG 450: Lift regenerating valve right
E E
-Y6051-LE
-XD7971-1 -XY6051-LE -XY6051-LE
Digital Output 1.5A C1:11 11 7971-111 WH 0.75 WH 0.75 1 2 24703 BK 0.75 GND-CUBICLE
-D7971 /11.5_7.A5
/0.0_1.B2
DRG 450: Lift Regenerating Valve Left
Lift Regenerating Valve Left
F F

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Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6007
-XD7971-1 -XY6007 -XY6007
PWM Output Group1 C1:29 29 7971-129 WH 0.75 1 1 2 2 23804 WH 0.75 D7971-1:10
-D7971 /11.5_6.C5
/0.0_1.D2
Boom in
Boom in valve
B B
-Y6006
-XD7971-1 -XY6006 -XY6006
PWM Output Group1 C1:33 33 7971-133 WH 0.75 1 1 2 2 23805 WH 0.75 D7971-1:10
-D7971 /11.5_6.D5
/0.0_1.D2
Boom out
Boom out valve
C C

-Y6051-1
-XD7971-1 -X402f -X402m -XY6051-1 -XY6051-1 -X402m -X402f
PWM Output Group1 C1:34 34 7971-134 WH 0.75 4 4 4024 1 2 4025 WH 0.75 5 5 24708 BK 0.75 GND-CUBICLE 1
-D7971 /11.5_7.B5
/0.0_1.D2
D Boom out regenerating valve D
secuted.
Boom out regenerating valve
-Y6050
-XD7971-1 -X403m -X403f -XY6050 -XY6050 -X403f -X403m
PWM Output Group1 C1:35 35 7971-135 WH 0.75 4 4 4034 1 2 4035 WH 0.75 5 5 23703 WH 0.75 D7971-1:30_NPN
-D7971 /11.5_6.E5
/0.0_1.D2
Boom in block valve
Boom in block valve
E E
F F

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Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XB7222-LE
A A
BN
-B7222-LE -XB7222-LE -XD7972-2
BK C C 7972-223 WH 0.75 23 C2:23 Dig/Ana Input
-D7972
/0.0_2.D6
A LEFT SUPPORT JACK, UPPER POS A
BU Support jacks left upper position
-XD7972-2
Digital Output 6A C2:22 22 7972-222 WH 0.75
-D7972 -XB7222-LE
/0.0_2.D6 B B BK 0.75
-XB7223LE
A A
-X296m_BB -X296f BN
1 1 -B7223-LE -XB7223LE -XD7972-2
2 2 29602 WH 0.75 -D7972
/0.0_2.C6
3 3 29603 WH 0.75 LEFT SUPPORT JACK, LOWER POS
BU Support jacks left lower position
4 4 29604 WH 0.75
B 5 5 29605 WH 0.75 -XB7223LE B
B B
-XB7222-RI
A A
BN
-B7222-RI -XB7222-RI -XD7972-2
-D7972
/0.0_2.C6
RIGHT SUPPORT JACK, UPPER POS
BU Support jacks right upper position
-XB7222-RI
B B
C C
-XB7223-RI -XB7223-RIm
A A
BN
-B7223-RI -XB7223-RIm -XB7223-RI -XD7972-2
-D7972
/0.0_2.C6
RIGHT SUPPORT JACK, LOWER POS
BU Support jacks right lower position

-XB7223-RIm -XB7223-RI
B B
D D
29701 BK 1.5 GND-CUBICLE
secuted.
/11.5_5.B7
-X297f -X297m_BB
1 1
29702 2 2
BK 0.75 29703 3 3
BK 0.75 29704 4 4
+CHASSIS BK 0.75 29705 5 5
-Y6063
-XD7972-1 -XY6063 -XY6063 6 6
Digital Output 1.5A C1:14 14 7972-114 WH 0.75 1 1 2 2 BK 0.75 29707 7 7
-D7972
/0.0_2.B2 BK 0.75 29708 8 8
Support jacks up
E E
SUPPORT JACKS UP
+CHASSIS
-Y6064
-XD7972-1 -XY6064 -XY6064
Digital Output 1.5A C1:15 15 7972-115 WH 0.75 1 1 2 2

-D7972
/0.0_2.B2
Support jacks down
SUPPORT JACKS DOWN
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn MLG 130705 A55031.1200 KRETSSCHEMA,DRG, 2012 DRG450 7.10
Name
1 See EO 131786 MLG 140107 MLG 130705 H.Grp:
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
D7971-1:08 WH 0.75 23903 WH 0.75 D7971-1:09
/11.5_6.A4 /11.5_6.B5
-X256f -X256m_BB
1 1
2 2
3 3
4 4
5 5
-X255m_BB -X255f
1 1 24003 -XB7226-1f -XB7226-1f
-B7226-1
2 2 25502 WH 0.75 2 1 25602 WH 0.75 -XD7971-2
P
3 3 25503 4 7971-210 WH 0.75 10 C2:10 Dig/Ana Input
U -D7971
4 4 25504 /0.0_1.B5
B B
5 5 25505 Lift pressure+ Left Lift pressure+ Left
-XB7226-3f -B7226-3 -XB7226-3f

WH 0.75 2 1 25603 WH 0.75 -XD7971-2
P
4 7971-211 WH 0.75 11 C2:11 Dig/Ana Input
U -D7971
/0.0_1.B5
Lift pressure- Left Lift pressure- Left
-XB7226-2f -B7226-2 -XB7226-2f

WH 0.75 2 1 25604 WH 0.75 -XD7971-2
P
4 7971-213 WH 0.75 13 C2:13 Dig/Ana Input
U -D7971
/0.0_1.C5
C C
Lift pressure+ Right Lift pressure+ Right
-XB7226-4f -B7226-4 -XB7226-4f

WH 0.75 2 1 25605 WH 0.75 -XD7971-2
P
4 7971-214 WH 0.75 14 C2:14 Dig/Ana Input
U -D7971
/0.0_1.C5
Lift pressure- Right
Lift pressure- Right


-XB7686m -XB7686f -X403f -X403m -XD7971-2

C C 4033 WH 0.75 3 3 7971-216 WH 0.75 16 C2:16 Dig/Ana Input
-D7971
/0.0_1.C5
D D
Boom Extension
secuted.
-B7686
-X402f -X402m -XB7686f -XB7686m -XB7686m -XB7686f
3
D7971-1:08 24004 WH 0.75 1 1 4021 WH 0.75 WH 0.75 A A 1 2 B B 2624
/11.5_6.A4
Boom length sensor
-X262m_BB -X262f
1 1
2 2 2622
6 6 2626 -XB7241m -XB7241f -X402m -X402f -XD7971-2
C C 4023 WH 0.75 3 3 7971-215 WH 0.75 15 C2:15 Dig/Ana Input
-D7971
/0.0_1.C5
Tilt/boom angle
E -B7241 E
-XB7241f -XB7241m -XB7241m -XB7241f
3
A A B B
WH 0.75 1 2 2625
Boom angle sensor

-X402m -X402f
4022 2 2 23904 WH 0.75 D7971-1:09
/11.5_6.B5
-X262f -X262m_BB
3 3
WH 0.75 4 4
WH 0.75 5 5
1 F F

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Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X222f -X222m
9958-BK-C1 9958-BK-C1 WH 0.75 1 1 222 WH 0.75
/11.5_3.C7
A 09905 WH 0.75 2 2 A
-X281f
D7971-2:32_24V 24405 WH 0.75 1
/11.5_6.E3
GND-CUBICLE 9937-201D04 BK 0.75 2
/11.5_4.E1 See heater project
-X222m
1 22201 WH 0.75 3 A60821.0100
B 2 22202 WH 0.75 4 B
-X222f -X222m
1 1 22201 WH 0.75
22202 WH 0.75 2 2
C C

D D
secuted.
E E
-X099f
5 See cabin project
A55032.0900
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
/1.0_A.E2 Volvo D13 3B

-XD7971-2 -X210f /1.0_B.F2 Cummins QSM11 3A
Digital Output 6A C2:34 34 7971-234 WH 0.75 5 D7971-2:34
-D7971 /1.0_D.E2 Volvo D8/D11 Stage 4
/0.0_1.E5
Ac compressor
B B
C C
-X099f -X278f -X278m -XB1 -XS1

See cabin project 12 2 2 2 2/8 Start up/diagnostics
09912 WH 0.75 BU/WH


A55032.0900 11 09911 WH 0.75 1 1 BK/RD 3 3/8

Wake Up
GN 4 4/8
Fuel metering pump
-XB8 -XB8
VT 2 2/2
D Water pump D
BN 1 1/2
secuted.
Water pump
-M2.12
Water pump
1 -XB8 -XB8
2 + - 1
M
-XB4 -XS8
9958-GN-F1 RD 1 1/2 Pre battery power
/11.5_3.E7
2 2/2
GND
-E6690
Eberspächer hydronic II C
E BN
E
-M2.2
Fuel metering pump

-XS6 -XB6 -XB6 -XB6 -XB6 -XS6 -XSP9937-201:E-3
GN 2 2 BN/GN 2 + - 1 BN 1 1 BN GND-CUBICLE
M /11.5_4.A4
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-H4220-FL
-XD7971-1 -XH4220-FLf -XH4220-FLm -XH4220-FLm -XH4220-FLf
Digital Out/In 1.5A C1:20 20 7971-120 WH 0.75 24602 3 3 BU 1 2 WH 4 4 9937-201A03 BK 0.75 GND-CUBICLE
-D7971 /11.5_4.A1
/0.0_1.C2
-X246m_BB -X246f
Direction indicator left 1 1 Direction indicator, front left
2 2
A 6 6 24606 WH 0.75 D7971-1:20
A
/9.6_2.C2
-H4220-FR
-XD7971-1 -XH4220FRf -XH4220FRm -XH4220FRm -XH4220FRf
Digital Out/In 1.5A C1:26 26 7971-126 WH 0.75 24604 3 3 BU 1 2 WH 4 4 9937-201A04 BK 0.75 GND-CUBICLE
-D7971 /11.5_4.A1
/0.0_1.C2
-X246m_BB -X246f
Direction indicator right 3 3 Direction indicator, front right
4 4
5 5 24605 WH 0.75 D7971-1:26
/9.6_2.C2
-H4160-FL
-XD7971-1 -XH4160-FLf -XH4160-FLf
Digital Out/In 1.5A C1:16 16 7971-116 WH 0.75 25702 WH 0.75 1 1 2 2 9937-201A07 BK 0.75 GND-CUBICLE
-D7971 /11.5_4.B1
/0.0_1.C2
-X257m_BB -X257f
B Side position light x4 1 1 Position light, front left B
2 2 -H4160-FR
-XH4160-FRf -XH4160-FRf
3 3 25703 WH 0.75 1 1 2 2 9937-201A08 BK 0.75 GND-CUBICLE
/11.5_4.B1
4 4
5 5 25704 WH 0.75 D7971-1:16 Position light, front right
/9.6_2.D2
25705 WH 0.75 D7971-1:16
/9.6_2.D2
C C
-E4000-LE
-XD7971-2 -XE4000-LEf/XE4020-LEf -XE4000-LEm/XE4020-LEm -XE4000-LEm/XE4020-LEm -XE4000-LEf/XE4020-LEf
Digital Output 6A C2:2 2 7971-202 WH 0.75 B B WH 1 2 BU C C 9937-201A01 BK 0.75 GND-CUBICLE
-D7971 /11.5_4.A1
/0.0_1.A5
Roading light head, front left Roading light head, front left
-E4020-LE
-XD7971-2 -XE4000-LEf/XE4020-LEf -XE4000-LEm/XE4020-LEm


Digital Output 6A C2:1 1 7971-201 WH 0.75 A A RD 1 2

-D7971
/0.0_1.A5
Roading light dipped, front left Roading light dipped, front left
-E4000-RI
D -XD7971-2 -XE4000-RIf/XE4020-RIf -XE4000-RIm/XE4020-RIm -XE4000-RIm/XE4020-RIm -XE4000-RIf/XE4020-RIf D
Digital Output 6A C2:4 4 7971-204 WH 0.75 B B WH 1 2 BU C C 9937-201A02 BK 0.75 GND-CUBICLE
secuted.
-D7971 /11.5_4.A1
/0.0_1.B5
Roading light head, front right Roading light head, front right
-E4020-RI
-XD7971-2 -XE4000-RIf/XE4020-RIf -XE4000-RIm/XE4020-RIm
Digital Output 6A C2:3 3 7971-203 WH 0.75 A A RD 1 2
-D7971
/0.0_1.A5
Roading light dipped, front right Roading light dipped, front right
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design
1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-H4120-LE
-XD7971-1 -X230f -X230m -X230m -X230f
Digital Out/In 1.5A C1:19 19 7971-119 WH 0.75 25202 WH 0.75 1 1 BK 1 2 WH 4 4 9937-201A05 BK 1.5 GND-CUBICLE
-D7971 /11.5_4.A1
/0.0_1.C2
Rear light x2 Rear light rear left
-X252m_BB -X252f -X253f -X253m_BB
1 1 1 1
2 2 -H4120-RI 25302 BK 0.75 2 2
-X231f -X231m -X231m -X231f
6 6 25206 WH 0.75 1 1 BK 1 2 WH 4 4 25303 BK 0.75 3 3
25304 BK 0.75 4 4
Rear light rear right 25305 BK 0.75 5 5
GND-CUBICLE 25306 BK 0.75 6 6
/9.7.A4
-H4110-LE
-XD7971-1 -X230f -X230m
Digital Out/In 1.5A C1:13 13 7971-113 WH 0.75 25204 WH 0.75 2 2 RD 1 2
B -D7971 B
/0.0_1.B2
Brake light rear Brake light rear left
-X252m_BB -X252f
3 3
4 4 -H4110-RI
-X231f -X231m
5 5 25205 WH 0.75 2 2 RD 1 2
Brake light rear right
-H4220-RL
-X230f -X230m
D7971-1:20 24606 WH 0.75 3 3 YE 1 2
/9.6_1.A4
Direction indicator rear left
C C
-H4220-RR
-X231f -X231m
D7971-1:26 24605 WH 0.75 3 3 YE 1 2
/9.6_1.B4
Direction indicator rear right
-H4160-RL
-XH4160-RL -XH4160-RL

D7971-1:16 25704 WH 0.75 1 1 2 2

/9.6_1.B4
Position light, rear left
-H4160-RR
-XH4160-RR -XH4160-RR
D D7971-1:16 25705 WH 0.75 1 1 2 2 D
/9.6_1.B4
secuted.
Position light, rear right
-E4050-RL
-X099f -XE4050-RLf -XE4050-RLm -XE4050-RLm -XE4050-RLf
31 09931 WH 1.5 1 1 1 2 2 2 9937-201B02 BK 1.5 GND-CUBICLE
/11.5_4.B1
Reverse light, frame, left
E See cab project E
A55032.0900
-E4050-RR
-X099f -XE4050-RRf -XE4050-RRm -XE4050-RRm -XE4050-RRf
30 09930 WH 1.5 1 1 1 2 2 2 9937-201B01 BK 1.5 GND-CUBICLE
/11.5_4.B1
Reverse light, frame, right
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-E4043-LE-A
-XD7971-2 -X402f -X402m -XE4043-LEf -XE4043-LEf
Digital Output 6A C2:36 36 7971-236 WH 2.5 6 6 4026 WH 2.5 1 1 2 2 401-2B1 BK 2.5 GND-CUBICLE
-D7971 /11.5_4.C5
/0.0_1.E5
Working light Boom, left Working light boom, left
A A
-E4043-LE-A
-Xm -XAf -XAf -Xm
1 1 WH 1.5 -XSP1 1A WH 1.5 1 1 2 2 2A BK 1.5 -XSP2 2 BK 1.5 2
Working light boom, left
-E4043-LE-B
-XBf -XBf
1B WH 1.5 1 1 2 2 2B BK 1.5
Working light boom, left (opt)
-E4043-RI-A
B -XD7971-2 -X403m -X403f -XE4043-RIf -XE4043-RIf B
Digital Output 6A C2:38 38 7971-238 WH 2.5 6 6 4036 WH 2.5 1 1 2 2 BK 2.5 401-2B2 BK 2.5 GND-CUBICLE
-D7971 /11.5_4.C5
/0.0_1.E5
Working light Boom, right Working light boom, right
-E4043-RI-A
-Xm -XAf -XAf -Xm
1 1 WH 1.5 -XSP1 1A WH 1.5 1 1 2 2 2A BK 1.5 -XSP2 2 BK 1.5 2
Working light boom, right
-E4043-RI-B
-XBf -XBf
1B WH 1.5 1 1 2 2 2B BK 1.5
C C
Working light boom, right (opt)
-E4041-LE-A
-XD7971-2 -X269f -X269m -XE4041-LEf -Xm -XAf1 -XAf1 -Xm -XE4041-LEf -X269m -X269f
Digital Output 6A C2:5 5 7971-205 WH 0.75 1 1 26901 WH 1.5 1 1 1 WH 1.5 -XSP3 1A WH 1.5 1 1 2 2 2A BK 1.5 -XSP4 2 BK 1.5 2 2 26903 BK 1.5 3 3 9937-201B03 BK 1.5 GND-CUBICLE
-D7971 /11.5_4.C1
/0.0_1.B5
Working light fender left option Working light front fender, right (opt)

-E4041-LE-B
-XBf1 -XBf1
1B WH 1.5 1 1 2 2 2B BK 1.5
Working light front fender, right (opt)

D D
secuted.
-E4041-RI-A
-XD7971-2 -X269f -X269m -XE4041-RIf -Xm -XAf2 -XAf2 -Xm -XE4041-RIf -X269m -X269f
Digital Output 6A C2:6 6 7971-206 WH 0.75 2 2 26902 WH 1.5 1 1 1 WH 1.5 -XSP5 1A WH 1.5 1 1 2 2 2A BK 1.5 -XSP6 2 BK 1.5 2 2 26904 BK 1.5 4 4 9937-201B04 BK 1.5 GND-CUBICLE
-D7971 /11.5_4.C1
/0.0_1.B5
Working light fender right option Working light front fender, right (opt)
E E
-E4041-RI-B
-XBf2 -XBf2
1B WH 1.5 1 1 2 2 2B BK 1.5
Working light front fender, right (opt)

F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XD7971-1 -X9650f -X9650m -H9650

Digital Output 1.5A C1:18 18 WH 0.75 7971-118 WH 0.75 1 1 BK +
-D7971
/0.0_1.C2 GND-CUBICLE 25306 BK 0.75 2 2 RD -
/9.6_2.B7
Reversing alarm
Reversing alarm
-K3016-2
B -X099f B
From Cab 21 09921 WH 0.75 86 86 85 85 9937-201D05 BK 0.75 GND-CUBICLE
/11.5_4.E1
9958-BK-H1 9958-BK-H1 WH 2.5 30 30 87 87 3016-2-87

/11.5_3.D7
87A
-M8501
Compressor horn and STD
Compressor horn and STD
WH 2.5 + + - - 9937-201D06 BK 2.5 GND-CUBICLE
M /11.5_4.E1
C C
-H4281
Rotating warninglight
-XD7971-1 -X4281f -X4281m -XH4281-1 -XH4281-2 -X4281m -X4281f
Digital Output 3A C1:45 45 7971-145 WH 1.5 1 1 GY + - BK 2 2 BK 1.5 9937-201A06 BK 1.5 GND-CUBICLE
-D7971 M /11.5_4.B1
/0.0_1.F2
-X4281m -X4281m

Rotating beacon frame 1 2

Frame
+Rear right
-H4281
D -X302m_BB -X302f Rotating warninglight -X302f -X302m_BB D
1 1 42811 WH 1.5 -XH4281-RR -XH4281-RR BK 1.5 42812 3 3
secuted.
2 2 30202 WH 1.5 1 + - 2 BK 1.5 30204 4 4

M
6 6 30206 WH 1.5 BK 1.5 30205 5 5
Frame
+Rear left
-H4281
-XH4281-RL -XH4281-RL
1 + - 2
M
E Frame E
-H4283
-X099f -X403m -X403f -X4283f -X4283m -XH4283-1 -XH4283-2 -X4283m -X4283f -X403f -X403m
See cabin project 22 09922 WH 1.5 7 7 4037 WH 1.5 1 1 GY + - BK 2 2 4038 BK 1.5 8 8 9937-201D03 BK 1.5 GND-CUBICLE
A55032.0900 M /11.5_4.E1
F
Bom F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X070f
3 0703 WH 0.75
A -X303m_BB -X303f A
1 1
LEFT MIRROR FRONT
2 2 3032 WH 0.75 -X8021Lf -X8021Lm
6 6 3036 WH 0.75 1 1 OR
OR
-X070f M
2 0702 WH 0.75 2 2 YE
YE
UP/DOWN
4 0704 WH 0.75 3 3 BN
BN
M
D7971-2:22 2721 WH 1.5 4 4 GN GN LEFT/RIGHT
/9.9_2.C3
-X304m_BB -X304f
1 1 5 5 RD
RD
B 2 2 3042 WH 1.5
B
HEATER
6 6 3046 WH 1.5 6 6 BK
BK
X070 To lever
Adjustable mirrors
-X070f
6 0706 WH 0.75
-X303m_BB -X303f
C 3 3 C
RIGHT MIRROR FRONT
4 4 3034 WH 0.75 -X8021Rf -X8021Rm
5 5 3035 WH 0.75 1 1 OR
OR
-X070f M
7 0707 WH 0.75 2 2 YE
YE UP/DOWN
5 0705 WH 0.75 3 3 BN
BN
M

GND-CUBICLE 2722 BK 1.5 4 4 GN

/9.9_2.C7 GN
LEFT/RIGHT
-X304m_BB -X304f
3 3 5 5 RD
RD
4 4 3044 BK 1.5
HEATER
D 5 5 3045 BK 1.5 6 6 BK D
BK
secuted.
-XF9958-BK-F2
1
24V
-X070f
1 0701 WH 1.5
8 0708 BK 1.5
E E
-X9937-004
1
GND
CAB Se Cab project

A55032.0900
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-XD7971-2 -X099f
Digital Output 6A C2:22 22 18
See Cabin project
-D7971
/0.0_1.D5 A55032.0900
Rear view mirror heating
-X272f -Xm -XAf -E8020-RI -XAf -Xm -X272f

1 1 1 WH 1.5 -XSP1 1A WH 1.5 1 2 2A BK 1.5 -XSP2 2 BK 1.5 2 2 9937-201D02
BK 0.75 GND-CUBICLE
C /11.5_4.E1 C
Mirror heater front right
-X272m -X272m
1 D7971-2:22 GND-CUBICLE 2
/9.9_1.B2 /9.9_1.D2
-XBf -E8020-LE -XBf
1B WH 1.5 1 2 2B BK 1.5
Mirror heater front left


-X273m_BB -X273f
D 1 1 7971-222 D
secuted.
2 2 27302
3 3 27303
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-Y6047
-XY6047 -XY6047
A 1 1 2 2 A
Cab tilt up valve 1
-Y6048
-XD7971-1 -XY6048 -XY6048
PWM Output Group1 C1:39 39 1 1 2 2
-D7971
/0.0_1.E2
Cab tilt down
Cab tilt down valve
B -Y6017 B
-XD7971-1 -XY6017 -XY6017
PWM Output Group1 C1:40 40 7971-140 WH 0.75 1 1 2 2 23706 WH 0.75 D7971-1:30_NPN
-D7971 /11.5_6.E5
/0.0_1.E2
Cab Lower/REV valve
Cab Lower/REV valve
-Y6016
-XD7971-1 -XY6016 -XY6016
PWM Output Group1 C1:41 41 7971-141 WH 0.75 1 1 2 2 23707 WH 0.75 D7971-1:30_NPN
-D7971 /11.5_6.E5
/0.0_1.E2
Cab Lift/FWD valve
Cab Lift/FWD valve
C C
-X099f -X276f -X276m
8 09908 WH 0.75 6 6 WH 0.75
-XB7255m -XB7255f -X276m -X276f -X099f

C C WH 0.75 2763 3 3 09917 WH 0.75 17
-X276m -X276f -X099f
-X277m_BB -X277f BK 0.75 2 2 09924 BK 0.75 24
-B7255
1 1
2766 -XB7255f -XB7255m -XB7255m -XB7255f


3 -X277f -X277m_BB
2 2 2772 WH 0.75 A A 1 2 B B BK 0.75
2762 3 3
6 6 2773
2792 4 4
Cab angle sensor
2793 5 5
D D
secuted.
-XB7254m -XB7254f -X276m -X276f -X099f

C C WH 0.75 2765 5 5 09925 WH 0.75 25
-B7254
-XB7254f -XB7254m -XB7254m -XB7254f
3
WH 0.75 A A 1 2 B B BK 0.75
Cab length sensor
E E
-X099f -X276f -X276m -XB7248f -XB7248m

23 09923 WH 0.75 1 1 2761 WH 0.75 A A
BN
-XB7248m -XB7248f -X276m
Damp sensor -B7248

BK C C 2765 WH 0.75 5
Sliding cab
BU
-XB7248m -XB7248f -X276m
B B 2762 BK 0.75 2
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XB7242-1f -XB7242-1m
A D7971-2:32_24V 24402 WH 0.75 A A BN
A
/11.5_6.E3
BN
-B7242-1
BK
Central lubrication feedback sensor

BU
1
1
B B
-XB7242-1m -XB7242-1f -XD7971-1
BU C C 7971-112 WH 0.75 12 C1:12 Digital Out/In 1.5A
-D7971
/0.0_1.B2
Central lubrication feedback
C C

D D
1
secuted.
1
1
-M6930-1
Central lubrication
-XD7971-1 -XM6930-1f -XM6930-1m -XM6930-1m -XM6930-1f
Digital Out/In 6A C1:46 46 7971-146 WH 0.75 1 1 BU + - BN 2 2 9937-201B05 BK 0.75 GND-CUBICLE
-D7971 M /11.5_4.C1
/0.0_1.F2
Central lubrication chassi pump
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6093
-XD7971-1 -XY6093 -XY6093
Digital Output 1.5A C1:14 14 7971-114 WH 0.75 1 1 2 2 24706 BK 0.75 GND-CUBICLE
-D7971 /11.5_7.A5
/0.0_1.B2
DRG Cut pump bom in
Cut pump bom in
B B
-Y6003
-XD7971-1 -XY6003 -XY6003
Digital Output 1.5A C1:15 15 7971-115 WH 0.75 1 2 24704 BK 0.75 GND-CUBICLE
-D7971 /11.5_7.A5
/0.0_1.C2
DRG 100-450,: Activate pump attachment
Activate pump attachment
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-M6680
-XD7971-2 -XM6680 -XM6680
PWM 15A C2:35 35 7971-235 WH 2.5 1 1 2 2 9937-201C04 BK 2.5 GND-CUBICLE
-D7971 M /11.5_4.D1
/0.0_1.E5
B B
Cooling fan hydraulic oil
Cooling fan hydraulic oil
-B7760
-XD7971-2 -XB7760 -XB7760
Ana/Temp/Rheo Input C2:25 25 7971-225 WH 0.75 1 1 T 2 2 23906 WH 0.75 D7971-1:09
-D7971 /11.5_6.B5
/0.0_1.D5 U
Hydraulic oil temperature Hydraulic oil temperature sensor
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XD7971-1 -X242f -X242f

Digital Output 1.5A C1:22 22 7971-122 WH 0.75 1 2 9937-201E02A BK 0.75 GND-CUBICLE
-D7971 /11.5_4.A4
/0.0_1.C2
A A
Output status signal F
-XD7971-1 -X243f -X243f

Digital Output 1.5A C1:23 23 7971-123 WH 0.75 1 2 9937-201E02B BK 0.75 GND-CUBICLE
-D7971 /11.5_4.A4
/0.0_1.C2
Output status signal R
B B
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
D+ Volvo D13 3B /1.0_A.D2

-X210f -XD7971-1
D+ Cummins QSM11 3A /1.0_B.E1 D7971-1:25 3 7971-125 WH 0.75 25 C1:25 Digital Input D+
D+ Volvo D8/D11 Stage 4 /1.0_D.D2 -D7971
/0.0_1.C2
Engine running D+
B B
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-G9930-1 -G9930-2
-XG9930-1:+ -XG9930-1:- -XG9930-2:+ -XG9930-2:-
W3 RD 70 + + - - W2 + + - - W1 BK 70 GND-CHASSIS
/11.5_4.A6
A A
12V, 140Ah -X9940f -X9940f 12V, 140Ah
1440-103 BK 35 + - 9937-20004 BK 35 GND-CHASSIS
/11.5_4.A6
HELP START OUTLET (OPT)
Power to Starter
Battery Power fuses
/1.0_A.D2 Volvo D13 3B 9952-2:1b Frame
-XS1440:2-2 /1.0_B.E4 Cummins QSM11 3A
W4,W4 RD 70 9952-2:2b Cabin
/1.0_D.E2 Volvo D8/D11 Stage 4
Ignition power fuses
B 9954-1:1b Frame B
9954-1:2b Cabin
-XS1440:1-3 9954-1:3b KFU 7971, KFU 7972
9954-1:4b KAU Attachment
-S1440
-XS1440:1-1 -XS1440:2-1/XK1440:88a -XF9952-1:1 -XF9952-1:2
-F9952-1 -XF9952-2:1 -F9952-2 -XF9952-2:2
1 2 1440201 RD 25 9952-102 RD 25 9952-202 RD 16 9952-202
1 2 1 2 /11.5_3.B3
100A /11.5_1.C3 50A /11.5_1.C6
-XS1440:1-2 -XF9952-2:3 -F9952-2 -XF9952-2:4

315030 RD 25 9952-204 RD 16 -X098-30 See Cabin project
3 4
50A /11.5_1.C6 A55032.0900
BATTERY DISCONNECTING SWITCH
-XK3150:30 -K3150 -XK3150:87

-XF9952-1:3 -F9952-1 -XF9952-1:4 -XF9954-1:1a -F9954-1 -XF9954-1:1b
1440102 RD 16 9952-104 RD 16 9952-104 30 87 315087 WH 25 9954-101B WH 10 9954-101B
C 3 4 /11.5_3.F3 1a 1b /11.5_3.D3 C
50A /11.5_1.C3 /11.5_1.F5 50A
Ignition power relay
-F9954-1 -XF9954-1:2b 9954-102b WH 16 -X098-15 See cabin project
2a 2b
50A A55032.0900
-F9954-1 -XF9954-1:3b-1 9954-103B1 WH 16 9954-103
3a 3b /11.5_5.A1
50A -XF9954-1:3b-2
9954-103b2 WH 10 9954-103
/11.5_5.B1
-F9954-1 -XF9954-1:4b 9954-104B2
4a 4b
50A -X401-1 -X401-1A
-X500-1
WH 16 RD RD 16 500-1A1 WH 16 9954-104
/11.5_5.D1
D -X401-1
500-1A2 WH 16 9954-104 D
Boom /11.5_5.E1
secuted.
Frame
Attachment
E E
-K3150
-X099f -XK3150 -XK3150
See cabin project 13 09913 WH 0.75 1 86 85 2 9937-201E01 BK 0.75 GND-CUBICLE
/11.5_4.A4
A55032.0900
F Ignition power relay F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XK1440:2-2
+24V Starter Volvo Tier4VE
-XK1440:2-3
+24V
Starter Cummins
-XK1440:2-4
B +24V
-S1440 Starter Cummins Tier4I B
-XK1440:88 -K1440 -XS1440:2-1/XK1440:88a -XF9952-1:1-F9952-1
1 2 -XS1440:2-1 W6 1440201 RD 25
1 2
/11.5_2.C6 100A
-XS1440:2-2 Electric main power switch
-K1440
-F9951-1 -X254f -X254m -X254m -X254f -X099f
-XK1440:86 -XK1440:85 See cabin project
BATTERY DISCONNECTING SWITCH 1440202 9951-102b 1 1 25401 RD 0.75 86 85 25402 BK 0.75 2 2 09914 BK 0.75 14
2a 2b
5A /11.5_2.B2 A55032.0900
Electric main power switch
C C
-XK1440:2-2
+24V
Starter Volvo Tier4VE
-XK1440:2-3
+24V
-S1440 Starter Cummins
-XK1440:88 -K1440 -XK1440:2-4
-XS1440:2-1
1 2 W6 +24V
Starter Cummins Tier4I

-XS1440:2-1/XK1440:88a -XF9952-1:1-F9952-1
Electric starter motor switch
1440201 RD 25
1 2
100A
BATTERY DISCONNECTING SWITCH
D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XF9958-RD-AB
-F9958-RD A:2 9958-RD-A2 RD 1.5 9958-RD-A2:2
/1.0_B.A1 Cummins QSM11 3a
-F9958-RD 15A A:2 9958-RD-A2 RD 1.5 9958-RD-A2:2
1 D7940 VOLVO STAGE3B 15A/ CUMMINS QSM11 3A 15A 1:1 A:1 /1.0_D.B2 Volvo stage 4
1:2 A:2 A:2 9958-RD-A2 RD 1.5 9958-RD-A2:2
2 D7940 VOLVO STAGE3B EATS 30A/ CUMMINS QSM11 3A 10A /1.0_A.B2 Volvo stage3b
A 3 30A/10A B:2 9958-RD-B2 RD 1.5 9958-RD-B2:2
A
2:1 B:1 /1.0_B.A1 Cummins QSM11 3a
4 2:2 B:2 B:2 9958-RD-B2 RD 4 9958-RD-B2:2 Volvo stage3b EATS
5
/1.0_A.A2
6 TCU7930-1 ZF 5A 3:1 C:1
7 3:2 C:2
8
4:1 D:1
/11.5_3.B5 4:2 D:2
5:1 E:1
5:2 E:2 -XF9958-RD-EF
5A F:1 9958-RD-F1 RD 1.5 9958-RD-F1
6:1 F:1 /2.0_A.A2 TCU 7930-2 ZF
6:2 F:2 F:2 9958-RD-F2 RD 1.5 9958-RD-F2
/2.0_A.A2 TCU 7930-2 ZF
7:1 G:1
7:2 G:2
B 8:1
30A
H:1 B
8:2 H:2
/11.5_3.A1
-XF9958:RD X:RD BATTERY
9952-202 9952-202 RD 16
/11.5_1.B7
-F9958-BK
-F9958-BK
1 1:1 A:1
1:2 A:2
2
3 START INTERLOCK 5A 2:1 B:1
4 2:2 B:2 -XF9958-BK-CD
5 C:1 9958-BK-C1 WH 0.75 9958-BK-C1
5A Start interlock
6 TCU7930-1 ZF 5A 3:1 C:1 /9.2.A1
C 7 3:2 C:2 -XF9958-BK-CD C
8 STD HORN 5A COMPRESSOR HORN 15A 25A D:1 9958-BK-D1 WH 4 9958-BK-D1
4:1 D:1 /1.7.C2 CAC-LE Power
/11.5_3.D5 4:2 D:2 -XF9958-BK-EF
25A E:1 9958-BK-E1 WH 4 9958-BK-E1
5:1 E:1 /1.7.D2 CAC-RI Power
5:2 E:2 -XF9958-BK-EF
5A F:1 9958-BK-F1 WH 1.5 9958-BK-F1
6:1 F:1 /2.0_A.B2 TCU 7930-2 ZF
6:2 F:2 F:2 9958-BK-F2A WH 0.75 9958-BK-F2
TCU 7930-2 ZF
/2.0_A.A2
9958-BK-F2B WH 0.75 9958-BK-F2 TCU 7930-2 ZF

7:1 G:1 /2.0_A.B2

7:2 G:2 -XF9958-BK-GH

5A/15A H:1 9958-BK-H1 WH 2.5 9958-BK-H1
Std Horn/Compressor Horn
8:1 H:1 /9.7.B2
8:2 H:2
/11.5_3.C1
-XF9958:BK X:BK IGNITION
D 9954-101B 9954-101B WH 10 D
/11.5_1.C7
secuted.
-F9958-GN
-F9958-GN
1 1:1 A:1
1:2 A:2
2
3 2:1 B:1
4 2:2 B:2
5 BATTERY PRE MAIN SWITCH 10A CAB
6 BATTERY PRE MAIN SWITCH EBERSPÄCHER 20A 3:1 C:1
7 3:2 C:2
E 8
4:1 D:1 E
/11.5_3.F5 4:2 D:2 -XF9958-GN-EF -X099f
E:1 15
10A 09915 RD 1.5

5:1 E:1 See wiring cab
5:2 E:2 1
20A F:1 RD 9958-GN-F1
6:1 F:1 /9.4.E1 Eberspächer
6:2 F:2
7:1 G:1
7:2 G:2
8:1 H:1
8:2 H:2
/11.5_3.E1
F 9952-104 9952-104 RD 16
-XF9958:GN X:GN F
/11.5_1.C3 IGNITION/
D+

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X9937-201:A-1 -X9937-201:E-1 -X9937-200-1

GND-CUBICLE 9937-201A01 BK 0.75 GND-CUBICLE 9937-201E01 BK 0.75 GND-CHASSIS W1 BK 70
/9.6_1.C8 /11.5_1.F7 /11.5_1.A7
-X9937-201:A-2 -X9937-201:E-2 -X9937-200-4
GND-CUBICLE 9937-201A02 BK 0.75 GND-CUBICLE 9937-201E02A BK 0.75 GND-CHASSIS 9937-20004 BK 35
/9.6_1.D8 /11.1.A8 /11.5_1.A7
GND-CUBICLE 9937-201E02B BK 0.75
-X9937-201:A-3 /11.1.A8 -X9937-200-2
A GND-CUBICLE 9937-201A03 BK 0.75 GND-CHASSIS 9937-20002 BK 25
/9.6_1.A8 -X9937-201:E-3 /11.5_4.E4 A
GND-CUBICLE BN
-X9937-201:A-4 /9.4.E8 -X098-31 -X9937-200-3
GND-CUBICLE 9937-201A04 BK 0.75 9937-20003 BK 25
/9.6_1.A8 -X9937-201:E-4
GND-CUBICLE 9937-201E04 BK 2.5
-X9937-201:A-5 /1.0_B.C1 See cabin project
GND-CUBICLE 9937-201A05 BK 1.5
/9.6_2.A8 -X9937-201:E-4 A55032.0900
-X9937-201:A-6 /1.0_A.D7
GND-CUBICLE 9937-201A06 BK 1.5
/9.7.D8 -X9937-201:E-4
-X9937-201:A-7 /1.0_D.D7 /1.0_A.D6 -X9937-200-5
GND-CUBICLE 9937-201A07 BK 0.75 GND-CHASSIS W13,W13 BK 70
/9.6_1.B8 -X9937-201:E-5 /1.0_D.E5
-X9937-201:A-8 /1.0_A.D7
GND-CUBICLE 9937-201A08 BK 0.75 -X9937-200 GND-CHASSIS
/9.6_1.B8 -X9937-201:E-5
/1.0_D.D7
B -X9937-201:A GND-CUBICLE B
-X9937-201:E-6
GND-CUBICLE 9937-201E06 BK 4
-X9937-201:B-1 /1.0_A.A7
GND-CUBICLE 9937-201B01 BK 1.5
/9.6_2.E7 -X9937-201:E-7
-X9937-201:B-2 /2.0_A.A7
/9.6_2.E7 -X9937-201:E-8
GND-CUBICLE 9937-201E08A BK 0.75
-X9937-201:B-3 /2.0_A.B3
GND-CUBICLE 9937-201B03 BK 1.5 GND-CUBICLE 9937-201E08B BK 0.75
/9.6_3.C8 /2.0_A.B6
-X9937-201:E GND-CUBICLE -X9937-201:F-1
-X9937-201:B-4
/9.6_3.E8
-X9937-201:F-2
-X9937-201:B-5
GND-CUBICLE 9937-201B05 BK 0.75 A56402.0100
/9.14.E8 -X9937-201:F3
Attachment project -X500-2 -X401-2
GND-CUBICLE BU BU 16 9937-201F3
C -X9937-201:B GND-CUBICLE /11.5_5.D8
GND-CUBICLE
boom--> attachment C
/11.5_5.E8
-X9937-201:C-1 GND-CUBICLE 401-2B1 BK 2.5 -X9937-201:F GND-CUBICLE
GND-CUBICLE 9937-201C01 BK 0.75 /9.6_3.A8
/4.5.B8 GND-CUBICLE 401-2B2 BK 2.5
/9.6_3.B8
-X9937-201:C-2
-X9937-201:C-3 -X9937-201:G-1
GND-CUBICLE 9937-201G1 BK 1.5
/1.7.F8 /1.7.A8
-X9937-201:C-4 -X9937-201:G-2
GND-CUBICLE 9937-201C04 BK 2.5 GND-CUBICLE 9937-201G2 BK 4

/10.6.B8 /1.7.C7
-X9937-201:C-5 -X9937-201:G-3
GND-CUBICLE 9937-201C05 BK 0.75 GND-CUBICLE 9937-201G3 BK 4
/5.2.B8 /1.7.D7
-X9937-201:C-6 -X9937-201:G-4
D GND-CUBICLE 9937-201C06 BK 2.5 D
/4.8.A8
secuted.
-X9937-201:C GND-CUBICLE -X9937-201:G GND-CUBICLE
-X9937-201:D-1
GND-CUBICLE 9937-201D01 BK 0.75
/11.5_7.A8
-X9937-201:D-2
/9.9_2.C8
-X9937-201:D-3
/9.7.F8
-X9937-201:D-4 -X9937-201:K-1
GND-CUBICLE 9937-201D04 BK 0.75 GND-CHASSIS 9937-20002 BK 25
/9.2.B1 /11.5_4.A6
-X9937-201:D-5 -X9937-201:K-2
E GND-CUBICLE 9937-201D05 BK 0.75 GND-CUBICLE 9937-201K02 BK 16
/9.7.B6 /11.5_5.A8 E
-X9937-201:D-6 -X9937-201:K-3
GND-CUBICLE 9937-201D06 BK 2.5 GND-CUBICLE 9937-201K03 BK 10

/9.7.C7 /11.5_5.B8
-X9937-201:D GND-CUBICLE -X9937-201:K GND-CUBICLE

F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1
-D7971
-XD7971-3
A 9954-103 9954-103B1 WH 16 24V
/11.5_1.D7 24V IGNITION POWER -XD7971-4 A
-X099f -X200m -X200f -XD7971-1 GND 9937-201K02 BK 16 GND-CUBICLE
See cabin project Ground /11.5_4.E4
6 09906 WH 0.75 WH 0.75 3 3 20003 WH 0.75 2 C1:2
CPU POWER
A55032.0900
CPU power startup from KCU /0.0_1.B2

-X271m_BB -X271f Power supply
1 1
2 2 27102
3 3 27103
4 4
-X200m
B 3 20602 WH 0.75 BK 1.5 GND-CUBICLE
B
/7.10.D8
1
-D7972 -XD7972-42
-XD7972-3 29701
9954-103 9954-103b2 WH 10 24V -XD7972-4
/11.5_1.D7 24V IGNITION POWER
-X200f -XD7972-1 GND 9937-201K03 BK 10 GND-CUBICLE
Ground /11.5_4.E4
3 20003 WH 0.75 20603 WH 0.75 2 C1:2
CPU POWER
/0.0_2.A2
-X206m_BB -X206f Power supply
1 1
2 2
C 3 3 C
4 4
-D7911
-XD7911-3
9954-104 WH 16 24V -XD7911-4
-XD7911-1 GND
Ground
2 C1:2 500-2A1 GND-CUBICLE

CPU POWER /11.5_4.C5
-X400Af -X400Am -X501Af -X501Am

WH 0.75 C C GY C C Power Supply
D D
secuted.
-D7912
-XD7912-3
9954-104 24V -XD7912-4
E GND 501-2A2 GND-CUBICLE
-XD7912-1 Ground /11.5_4.C5 E
2 C1:2
CPU POWER
Power Supply
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XD7971-1
5V Analogue Ref C1:8 8 7971-108 WH 0.75
-D7971
/0.0_1.B2
-X240m_BB -X240f
5V Sensor supply 1 1
2 2 24002 WH 0.75 D7971-1:08
/4.3.B1
A 3 3 24003 WH 0.75 D7971-1:08
A
/8.2_1.A1
4 4 24004 WH 0.75 D7971-1:08
/8.2_1.D1
5 5 24005 WH 0.75 D7971-1:08
/4.5.D1
6
7 7 24007 WH 0.75 D7971-1:08
/4.5.B1
8 8 24008 WH 0.75 D7971-1:08
/1.2.B1
9
10 10 24010 WH 0.75 D7971-1:08
/1.7.B2
11 -XD7971-1
12 7971-109 WH 0.75 9 C1:9 0V Analogue Ref
-D7971
/0.0_1.B2
-X239f -X239m_BB
1 1 0V Sensor supply
B D7971-1:09 23902 WH 0.75 2 2 B
/4.3.B8
D7971-1:09 23903 WH 0.75 3 3
/8.2_1.A8
D7971-1:09 23904 WH 0.75 4 4
/8.2_1.E8
D7971-1:09 23905 WH 0.75 5 5
/4.5.D8
D7971-1:09 23906 WH 0.75 6 6
/10.6.C8
D7971-1:09 23907 WH 0.75 7 7
/4.5.B8
D7971-1:09 23908 WH 0.75 8 8
/1.2.B7
D7971-1:09 23909 WH 0.75 9 9
/4.8.B8
D7971-1:09 23910 WH 0.75 10 10
/1.7.B7
11
12
-XD7971-1
7971-110 WH 0.75 10 C1:10 Digital Output NPN
C -D7971 C
/0.0_1.B2
-X238f -X238m_BB
1 1 Safe ground, group 1 Boom valves
D7971-1:10 23802 WH 0.75 2 2
/7.2_1.A7
D7971-1:10 23803 WH 0.75 3 3
/7.2_1.B7
D7971-1:10 23804 WH 0.75 4 4
/7.3.B6
D7971-1:10 23805 WH 0.75 5 5
/7.3.B6
6 6
D7971-1:10 23806 WH 0.75

/7.2_1.B7
D7971-1:10 23807 WH 0.75 7 7

/7.2_1.C7
8
D D
secuted.
-XD7971-1
7971-130 WH 0.75 30 C1:30 Digital Output NPN
-D7971
/0.0_1.D2
-X237f -X237m_BB
1 1 Safe ground, group 2
1 2 2
D7971-1:30_NPN 23703 WH 0.75 3 3
/7.3.D7
D7971-1:30_NPN 4 4
-XD7971-2
Digital Output 0.5A C2:32 32 7971-232
D7971-1:30_NPN 5 5 Cab, block boom valves
-D7971 D7971-1:30_NPN 23706 WH 0.75 6 6
/0.0_1.E5 /9.10.B8
D7971-1:30_NPN 23707 WH 0.75 7 7
Supply sensors frame /9.10.C8
8 8
E -X244m_BB -X244f E
1 1
2 2
24402 D7971-2:32_24V
/9.14.A1
3
Frame 4 -X244f
5 5 24405 D7971-2:32_24V
/9.2.B1
6
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
9937-201D01 BK 0.75 GND-CUBICLE

/11.5_4.D1
-X247f -X247m_BB
1 1
A GND-CUBICLE 24702 BK 0.75 2 2 A
/7.2_1.D7
/7.2_1.E7
/10.4.C7
5
/10.4.A7
7
1 GND-CUBICLE 24708 BK 0.75 8 8
/7.3.D7
B B
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Cummins QSB6,7
Cummins QSB6,7 Tier4I
/1.0_A.B2 Volvo TAD 1360
-XD7971-1 -X210f /1.0_B.B1 Cummins QSM11 3A
C1:31 31 7971-131 GN 0.75 30 24102 GN 0.75 30 1 D7971-1:31/J1939_HI
CAN + /1.0_D.A2 Volvo D8/D11 Stage 4
CAN J1939 C1:32 32 7971-132 YE 0.75 24105 YE 0.75
- -X241m_BB -X241f
A 1 1 A
2 2
Cummins QSB6,7
C1:3 3 7971-103 GN 0.75 30 3 3
HI Cummins QSB6,7 Tier4I
CAN Normal C1:4 4 7971-104 YE 0.75 10 10 /1.0_A.B2 Volvo TAD 1360
LO /1.0_B.B1 Cummins QSM11 3A
11 2 D7971-1:32/J1939_LO
/1.0_D.A2 Volvo D8/D11 Stage 4
-D7971 12
/0.0_1.B2 C1:6 6 7971-106 GN 0.75 30
HI
CAN Red C1:7 7 7971-107 YE 0.75
LO -X241m_BB -X241f
4 4 -X207m -X207f
5 5 24103 GN 0.75 30 A A 20701 GN 0.75 30 D7971-1:31/J1939_HI
/2.0_A.B2
6 6 24106 YE 0.75 B B 20702 YE 0.75 D7971-1:32/J1939_LO ZF
/2.0_A.C2
7 7
B 8 B
9
-X211m -X211f
24110 GN 0.75 30 A A
J1939 DIAGNOSTIC
24107 YE 0.75 B B
C C
D7971-1:4/R_LO D7971-1:4/R_LO
/11.6_2.A1 /11.6_2.A8
D7971-1:3/R_HI D7971-1:3/R_HI
/11.6_2.A1 /11.6_2.A8
-X200f -X200m -X099f

1 1 30 30 3
20001 GN 0.75 09903 GN 0.75

From D7902

2 2 20002 YE 0.75 09904 YE 0.75 4

See circuit cab
-X099f
1 From D7901
2 See circuit cab
D D
secuted.
CAN C1:31
+
CAN J1939 C1:32
-
E -XD7972-1 -X200f E
C1:3 3 7972-103 GN 0.75 30 1
HI
CAN Normal 4
C1:4 7972-104 YE 0.75 2

LO
-D7972 -X200m
/0.0_2.B2 C1:6 6 7972-106 GN 0.75 30 1
HI
CAN Red C1:7 7 7972-107 YE 0.75 2
LO
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1
A A
-X400Af -X400Am -X501Af -X501Am -X501Bf -X501Bm -X400Bf -X400Bm

D7971-1:3/R_HI 20001 30 GN 0.75 A A A A A A A A D7971-1:3/R_HI
/11.6_1.C6 /11.6_1.C7
D7971-1:4/R_LO 20002 YE 0.75 B B B B B B B B D7971-1:4/R_LO
/11.6_1.C6 /11.6_1.C7
B B
C C
C1:31 CAN
+
C1:31 C1:32 CAN J1939
+ CAN -
C1:32 CAN J1939
-
-XD7911-1
-XD7912-1 3 C1:3
HI
3 4 CAN Normal
C1:3 C1:4
HI LO
4 C1:4 CAN Normal

LO
-D7911
-D7912 6 C1:6
HI
6 C1:6 7 C1:7 CAN Red
HI LO
7 C1:7 CAN Red
D LO D
secuted.
COMBI
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
DCG/DRG C

Wiring CAB
D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Kretsschema DCG,DRG DCG,DRG 0 1
Name
1 Relay K3461-3 A on sheet 9.3_9 131594 SOF 131002 H.Grp:
R
Konstr/Design

RSO 120416 Klass/Class
Wiring Diagram DCG,DRG A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A A
12/24V Climate
Door switches
A55184.0100 Wipers, washers and horn

B B
C
EL-Central Accelerator
C
Eget kablage under matta

Brake pedal
Cabin floor
New harness Lever/Micro steering

A56380.0100
D 24V Ref D7901 C2p05 D
Electric mirror switch

A55185.0100
Seat
E
Interface chassi Fuse box E
harness A55186.0100
KCU A57059.0100
Electric mirrors
Ignition
MATA MED 5:1
Electric main switch
A56629.0100 Search light A59534.0100 FNR
Gnd KID #1
F Steering sensor F
Multi light
Horn
STD harness switches Indicator
Ind Panel 24V Ref C4p01 24V REF C5p01
G
KID #2 G
Radio
A55179.0100
A55190.0100 A55180.0100
Interface right
A55183.0100 Manouver panel
H
KPU-1 Joystick/levers
H
A55181.0100
24V Ref C3p09
A55182.0100
Interior light X063 to splice in
Extra KPU
Speaker Right Manouvre switch
J
24V Ref C8p01 J
A55187.0100 Rear wiper

Layout harnesses lights roof

secuted.
K
Interior light K
Speaker Left
Wiper roof
Temp ambient
L L
A55190.0100
Interface left
All red texts are linked to docment

M Ref. Ändring
Benämning Produkt/Product Blad/Sheet M
Nr Ändring nr Datum Sign. Datum/Date Huvudnr./Project no.
Sign.
Ruta
Kablage översikt DCG/DRG DCG,DRG 0.0_0 1
E³ DRAWING
Design change
Sq.
No. Change No. Date Ritad/Drawn RSO 120416 A55032.0900
Name
1 Relay K3461-3 A on sheet 9.3_9 131594 SOF 131002 Konstr/Design H.Grp:
R

Harnesses overview DCG/DRG A55040.0100 04
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
A A
-D7901
1:1 /9.4_4.A2 Sw. AC pressure in range=clutch active Dig In 2:1 /7.9_2.C1 Ind. unlocked TW 0,5A / Dig out
B 1:2 /9.4_4.A2 Sw. AC pressure >16 bar Max fan speed Dig In 2:2 /7.9_2.D1 Ind. locked TW 0,5A / Dig out B
1:3 /11.6_1.B8 CAN CAN Clamp pressure ok
1:4 See pin K1:3 2:3 /7.9_2.D1 Ind. alignment 0,5A / Dig out
1:5 CAN Shield / Ana In
1:6 See pin K1:3 Tilt control
1:7 See pin K1:3 2:4 /7.9_2.C1 Ind. support jacks down 0,5A / Dig out
1:8 /11.5_5.D1 Ref Air distr. / heat valve 5V Ref 2:5 /11.5_5.B1 24V Supply Lever/Micro steering 0,5A
1:9 /11.5_5.B8 Ref Sensors 0V Ref 2:6 /9.9_2.C1 Rear window heater 0,5A
1:10 /9.5_2.B8 Wiper front left feedback Dig In 2:7 /9.3_2.C1 Lamp fasten seat belt 1,5A
2:8 /9.5_2.A1 Wiper front left (relay) 1,5A
1:11 /9.5_2.D8 Wiper front right feedback Dig In 2:9 /9.5_2.C1 Wiper front right (relay) 1,5A
1:12 /9.5_1.B8 Wiper rear feedback Dig In 2:10 /9.5_2.E1 Motor washer 2x front relay 1,5A
1:13 /9.5_1.C8 Wiper roof feedback Dig In
1:14 /9.5_1.C8 Washer fluid level switch Dig In 2:11 /11.5_1.E1 Main relay ignition K3150 1,5A
1:15 2:12 /9.7_1.D1 Horn 3A
KCU D7900-1, Main C1 connector pinout
/9.4_3.B8 Climate Air Filter Ind. Pressure Sw Dig In

1:16 /9.10_1.D8 Cab in upper position (tilt) Dig In 2:13 /9.7_2.B1 Rotating beacon 3A
C 1:17 /9.3_5.B1 Seat in driving position Dig In 2:14 /9.4_5.D1 Paus heater 3A C
KCU D7900-1, Main C2 connector pinout

1:18 /5.2_2.D12 Mini/Leversteering on/off Dig In 2:15 /9.5_1.E1 Motor washer front/roof 6A
1:19 /5.2_2.D12 Mini/Leversteering gear forward Dig In 2:16 /9.5_1.D1 Motor washer rear 6A
1:20 /5.2_2.E12 Mini/Leversteering gear neutral Dig In 2:17 /9.5_1.B1 Wiper rear 6A
2:18 /9.6_4.A1 Extra worklight left C 6A
1:21 /5.2_2.E12 Mini/Leversteering gear reverse Dig In 2:19 /9.5_1.C1 Wiper roof/combined front/roof 6A
1:22 /5.2_2.F12 Mini/Leversteering indicator left Dig In 2:20 /9.6_2.B1 Working light reverse left 6A
1:23 /5.2_2.F12 Mini/Leversteering indicator right Dig In
1:24 /5.2_2.E12 Mini/Leversteering aut. Head light Dig In 2:21 /9.6_2.C1 Working light reverse right 6A
1:25 /5.2_2.G12 Armrest in position Dig In 2:22 /9.6_3.A1 Extra worklight left A 6A
See pin K1:3 2:23 /9.6_3.D1 Extra worklight right B 6A

1:26
1:27 See pin K1:3 2:24 /9.4_2.A1 Air distributor valve close PWM
1:28 /9.4_2.B8 Air distributor valve Dig In / Ana In 2:25 /9.4_2.A1 Air distributor valve open PWM
1:29 /9.4_2.C8 Heat valve(air mix) Dig In / Ana In 2:26 /9.4_2.B1 Heat valve Close PWM
1:30 Dig In / Ana In 2:27 /9.4_2.B1 Heat valve Open PWM
2:28 /9.4_2.E1 Motor, recirculation PWM
1:31 /9.10_1.E8 Cab lower pos (tilt) Dig In / Ana In 2:29 /9.4_2.D1 Motor, recirculation PWM
D 1:32 /9.10_1.E8 Cab moving damp sensor Dig In / Ana In 2:30 /9.6_1.E1 Interior light, step light PWM D
secuted.
1:33 /9.4_1.C8 Temp. indoor Resistance In

1:34 /9.4_1.C8 Temp. fan air Resistance In 2:31 /2.1.F1 Output status FWD 0,5A / Dig In
1:35 /9.4_1.D8 De-icing Resistance In 2:32 /2.1.F1 Output status REV 0,5A / Dig In
1:36 /9.4_1.D8 Temp. ambient Resistance In 2:33 /5.2_2.D2 Indication Mini/Leversteering on/off 0,5A / Dig Out
1:37 /5.2_2.C12 Micro/Lever-Steering sensor Ch1 Dig In / Ana In 2:34 /9.3_5.C1 Seat Unlock (TDS 15/30deg) 0,5A / Dig In
1:38 /5.2_2.C12 Micro-Steering sensor Ch2 Dig In / Ana In 2:35 /11.6_1.C7 Dig Out CPU Power
1:39 Dig In / Ana In 2:36 /9.6_4.D1 Extra worklight right D PWM 15A
1:40 Dig In / Ana In Condenser roof
2:37 /9.4_2.C1 Heating fan PWM 15A
1:41 Dig In / Ana / Freq 2:38 /11.5_1.C4 CPU Power
1:42 Dig In / Ana / Freq
1:43 /9.6_1.D8 Steplight Dig In Start up M5: 24V See pin K1:2
1:44 /9.4_5.B7 External heater Dig In Start up M5: GND See pin K1:2
1:45 /11.5_3.C8 Door switch right Dig In Start up
1:46 /11.5_3.B8 Door switch left Dig In Start up
E 1:47 /11.5_3.D8 Startup hazard Dig In Start up E
1:48 /11.5_3.D8 Interior light Dig In Start up
1:49 /11.5_3.A8 Ignition key Dig In Start up

1:50 /9.3_1.E8 Seat switch Dig In Start up

F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Korsreferenser DCG,DRG 0.0_1 1
Name
R
Konstr/Design

Wiring Cross References A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-D7902
C1 1:1-1:2 /11.5_1.D5 Power C4 4:10 /7.5_1.B8 Option 5 Dig In

A 1:3-1:7 /11.6_1.E8 CAN-BUS Spreading 20-40 A
1:8 Ana In
PLH+
1:9 /9.3_6.C8 Steering panel up/down feedback Ana In
1:10 /11.5_3.D5 Sw interior light S1160 In (Sw Inside light) Clamp legs
1:11 /11.5_3.D5 Sw. hazard S1090 In(Sw. Hazard) 4:11 /9.10_1.A8 Cab moving left/reverse Dig In
1:12 /11.5_3.D4 Supply +30 Supply +30 4:12 /9.10_1.B8 Cab moving right/forward Dig In
4:13 /8.2_3.A8 Dead mans grip Dig In
C2 2:1 Motors 5V Ref 4:14 /9.10_1.C8 Option 6 Dig In
2:2 /11.5_5.B8 Motors Console/Seat 0V Ref
2:3 /9.3_3.B8 Motor canoe fwd/rev feedback Ana In Cabtilt up
2:4 /9.3_3.D8 Motor canoe up/down feedback Ana In Turible seat C.C.W
2:5 /9.3_6.B1 Steering panel up/down NPN / PNP 3A 4:15 /9.10_1.C8 Option 6 Dig In
2:6 /9.3_6.B8 Steering panel up/down NPN / PNP 3A Cab tilt down
2:7 /9.3_3.B1 Motor canoe fwd/rev NPN / PNP 3A Turnible seat C.W
2:8 /9.3_3.B8 Motor canoe fwd/rev NPN / PNP 3A 4:16 /5.2_1.D8 Sensor steering wheel Dig In
2:9 /9.3_3.C1 Motor canoe up/down NPN / PNP 3A
B 2:10 /9.3_3.C8 Motor canoe up/down NPN / PNP 3A B
4:17 /7.10_1.A8 Option 7 Dig In
C3 3:1 /11.5_5.C1 Lever/Joystick 5V Ref Support jacks up
3:2 /11.5_5.B8 Lever/Joystick 0V Ref
Upper Arms Height up
3:3 /7.1_1A.D8 Sensor Lift/lower Ana In 4:18 /7.10_1.B8 Option 7 Dig In
3:4 /7.1_1A.C8 Sensor Boom/tilt - in/out Ana In
3:5 /7.1_1A.D8 Sensor Sideshift Ana In Support jacks down
3:6 /7.1_1A.E8 Rotation Ana In Upper Arms Height down
Spread(L)
C5 5:1 /11.5_5.B1 24V Supply Island 4 0,5A
Extension left
5:2 /4.5.B8 Sw. parking brake Dig In
Clamp(L) 5:3 /2.1.C8 Sw. forward gear Dig In
3:7 /7.1_1B.D8 Levelling/5th funct/ Ana In 5:4 /2.1.B8 Sw. neutral gear Dig In
5:5 /2.1.C8 Sw. center gear Dig In
Rear legs up/Spread R/ 5:6 /2.1.B8 Sw. reverse gear Dig In
Clamp R 5:7 /9.6_1.B8 Sw. indicator right Dig In
C 3:8 /7.1_1B.E8 Extension R Ana In C
6th funct 5:8 /9.6_1.B8 Sw. indicator left Dig In
5:9 /9.6_1.C8 Sw. High Low Beam Dig In
Rear legs down
5:10 /9.7_1.A8 Sw. horn Dig In
3:9 /7.1_1A.B1 24V Supply Island 1 0,5A 5:11 /11.5_1.A8 Operating switch Dig In
3:10 /11.5_5.B1 Lever/Joystick PWM 1,5A 5:12 /5.2_1.B8 Sensor steering wheel Dig In
3:11 /8.2_1.B8 Sw. override safety keyswitch Dig In 5:13 /9.2_1.A8 Start interlock device Dig In
3:12 /7.9_1.B8 Sw. lock TW Dig In 5:14 /9.3_2.B8 Seat belt Dig In
PLH on/off
C8 8:1 /11.5_5.A1 24V Supply Island 2 0,5A
3:13 /7.1_1A.B8 Option 1 Dig In

8:2 Seat switch Dig In

Lock Levelling 8:3 /1.1_1.E8 Pedals 0V Ref

Lock arm 1 8:4 /11.5_5.C1 Supply pedals 5V Ref
3:14 /7.10_2.C8 Option 1 Dig In 8:5 /1.1_1.D8 Throttle position B Ana In
Front legs up 8:6 /1.1_1.E8 Throttle position A Ana In
8:7 /4.1.D8 Brake pedal pos. B Ana In
D 3:15 /8.2_2.B8 Override height Dig In 8:8 /4.1.E8 Brake pedal pos. A Ana In D
Override rotation
secuted.
C6 6:1-6:20 Wiper & drive train control panel Ribbon cable

Lock arm 2
3:16 /7.5_2.B8 Aut 20-40 on-off Dig In C7 5:1-5:30 Climate control panel Ribbon cable
Differential lock
3:17 /9.10_2.B8 Aut cab tilt on/off Dig In C9 6:1-6:20 Light control panel Ribbon cable
Diffrential Lock
3:18 /7.5_3.B8 Sw. 30-35 stop Dig In
3:19 /1.3_1.B8 DPF Regen Inhibit Dig In
3:20 /9.9_2.B8 Sw. window heater & mirror heater Dig In
C4 4:1 /11.5_5.A1 24V Supply Island 3 0,5A

4:2 /7.1_1A.B1 LED right locked levelling/opt 0,5A
4:3 /7.1_1A.C1 LED left locked tilt/opt 0,5A
E 4:4 /7.1_1A.A8 Shift button Dig In E
4:5 /7.1_1A.B8 Switch Auto clamp Dig In
Release in lever 1
Switch Unlock TW
4:6 /7.10_2.C8 Opt. 1 Dig In
Front legs down
4:7 /7.1_1A.C8 Sw. lock tilt/extender Dig In
4:8 /7.1_1A.C8 Sw. horn Dig In

4:9 /7.5_1.B8 Option 5 Dig In
Spreading 40-20
PLH-
Release legs
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Korsreferenser DCG,DRG 0.0_2 1
Name
R
Konstr/Design

Wiring Cross References A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-X106m -XD7902-6 -XA3700f -A3700

1/20 1 1 1/20
2/20 2 2 2/20
3/20 3 3 3/20
C 4/20 4 4 4/20 C
5/20 5 5 5/20
6/20 6 6 6/20
7/20 7 7 7/20
8/20 8 8 8/20
9/20 9 9 9/20
10/20 10 10 10/20
11/20 11 11 11/20
12/20 12 12 12/20
13/20 13 13 13/20
14/20 14 14 14/20
15/20 15 15 15/20
D 16/20 16 16 16/20 D
secuted.
17/20 17 17 17/20
18/20 18 18 18/20
19/20 19 19 19/20
20/20 20 20 20/20
-D7902 -Drive_Train_Panel
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Manöverpanel Drive train/Wipers DCG,DRG 1.1_0 1
Name
R
Konstr/Design

Wiring Control Panel Drive Train A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
0544D D7902-804-5VRef
/4.1.C2
0544C D7902-804-5VRef
/4.1.C2
C C
-X054f -X054m
D7902-804-5VRef 7902-804 4 4 0544 -XSP544
/11.5_5.C3

-XR6900m -XR6900f
RD 1 1
D 5V 0544B D
secuted.
-X054m -X054f -XD7902-8

BU 2 2 1 1 5 Ana In
Out B 0541 7902-805 C8:5
/0.0_2.D5
-D7902
Throttle position B
BK 3 3
0V 0543D
4
5V 0544A
-X054m -X054f -XD7902-8

WH 5 5 2 2 6 Ana In
Out A 0542 7902-806 C8:6
/0.0_2.D5
-D7902
E B6900 Throttle position A E
6
Speed control 0V 0543C
-X054m -X054f -XD7902-8

-XSP3 0543 3 3 7902-803 3 C8:3 0V Ref
-D7902
/0.0_2.D5
Pedals
0543A D7902-303-0VRef
/4.1.F7
F F
0543B D7902-303-0VRef
/4.1.F7

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Gaspedal DCG,DRG 1.1_1 1
Name
R
Konstr/Design

Wiring Speed Control A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1049
C
A
-XS1049 -XS1049 -XS8150-4m -XS8150-4f -XD7902-3
D7902-309-24V 8150-47H 3 3 4 4 8150-413 13 13 7902-319 19 C3:19 Dig In
/7.5_3.B2 -D7902
1 1 8150-42H /0.0_2.E3
D7902-309-24V 8150-47J
B /9.9_2.B2 DPF Regen Inhibit DPF Regen Inhibit
B
D7902-302-0VRef
/7.5_3.B7
8150-42J D7902-302-0VRef
/9.9_2.B7
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Regen Inhibit DCG,DRG 1.3_1 1
Name
R
Konstr/Design

Wiring Regen Inhibit A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A 13101 D7902-501-24V A
/9.6_1.A2
-S1310
B -XD7902-5 B
4 C5:4 Dig In
-D7902
-X055f -X055m -XS1310f -S1310 N1 /0.0_2.C5
D7902-501-24V 7902-501 1 1 0551 1 1
/11.5_5.B3 Sw. neutral gear
N2 -S1310 -XS1310f
5 5 0554 -XD7902-5
6 C5:6 Dig In
-D7902
R -S1310 /0.0_2.C5
3 3 0553
Sw. reverse gear
F -S1310
2 2 0552 -XD7902-5
3 C5:3 Dig In
-D7902
Q -S1310 /0.0_2.C5
6 6 0555
Sw. forward gear
C -X055m -X055f -XD7902-5 C

5 5 7902-505 5 C5:5 Dig In
/4.5.B4 -D7902
/0.0_2.C5
Sw. center gear
-X055m
-X055m
-X055m
2
3

-X055f
-X055f
-X055f
2
3
D Opt. Lift lever D
secuted.
-S1310-2 Gear selector

-XR8070-1f -XS1310-1m -XS1310-1f
F WH 7 13102 2 2 7902-503B
-XR8070-1f N1 8 1305B 7902-503A

D7902-309-24V 8150-17H 6
GY + 5 7902-504B
/9.7_1.C5 BU
N2 9 13105A 5 7902-504A
R 10 13103 3 3 7902-506B
GN 7902-506A
-XS1310-1f
9968-BK:1 7902-101C 1
/11.5_1.D2
E E
-XD7901-2 -X036f
0,5A / Dig In C2:31 31 7901-231 3
-D7901
/0.0_1.D5
Output status FWD
F -XD7901-2 -X036f
0,5A / Dig In C2:32 32 7901-232 4
F
-D7901
/0.0_1.D5
Output status REV

E³ DRAWING
Sign.
Ruta
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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Växling DCG,DRG 2.1 1
Name
R
Konstr/Design

Wiring Gear A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
C C
D7902-804-5VRef
/1.1_1.B5
D7902-804-5VRef
/1.1_1.C5

D D
-XR8092m -XR8092f
secuted.
RD 1 1
5V 0544C
-X054m -X054f -XD7902-8

BU 2 2 5 5 7 Ana In
Out B 0545 7902-807 C8:7
/0.0_2.D5
-D7902
Brake pedal pos. B

BK 3 3
0V 0543B
4
5V 0544D
-X054m -X054f -XD7902-8

E WH 5 5 6 6 8 Ana In E
Out A 0546 7902-808 C8:8
/0.0_2.D5
-D7902
-R8092 Brake pedal pos. A

6
Brake control 0V 0543A
D7902-303-0VRef
/1.1_1.F7
D7902-303-0VRef
/1.1_1.F7
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Broms DCG,DRG 4.1 1
Name
R
Konstr/Design

Wiring Brake A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1310
/2.1.C4
B P -S1310 -XS1310f -X056m -X056f -XD7902-5 B
4 4 0562 2 2 7902-502A 2 C5:2 Dig In
-D7902
/0.0_2.C5
Sw. parking brake
-XS1310-1m -XS1310-1f
13104 4 4
7902-502
-XS1310-1m
6 D7902-502 Switch P-brake
/9.3_9.B1
C 1 C

D D
secuted.
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Paerkeringsbroms DCG,DRG 4.5 1
Name
R
Konstr/Design

Wiring Parking Brake A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XB7700f -XB7700m
D7902-501-24V 160031 1 1 -XSP16
/9.6_1.C2
BN
-B7700-2 -XB7700m -XB7700f -X055m -X055f -XD7902-5
BK 3 3 0557 7 7 7902-512 12 C5:12 Dig In
B -D7902 B
/0.0_2.C5
Sensor steering wheel
BU Sensor steering wheel
-XB7700m -XB7700f -X055m -X055f -X060m -X060f -X035m -X035f
2 2 558A 0558 8 8 06012 12 12 0354 4 4 9937-00108 CHASSIS
/11.5_6.A5
-XSP17 -XSP9
C C
558B CHASSIS
/11.5_4.B7

BN
-B7700-1 -XB7700m -XB7700f -X055m -X055f -XD7902-4
BK 4 4 0556 6 6 7902-416 16 C4:16 Dig In
-D7902
/0.0_2.B5
Sensor steering wheel
BU Sensor steering wheel
D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets ministyrning DCG,DRG 5.2_1 1
Name
R
Konstr/Design

Wiring ministeering A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12
A A
B Leversteering -X066m B
WH 3
-R8250-1
-X066m -X066m
1 RD BK 2
Sensor Ch1
-X066m -X066f -X058m -X058f -X040m -X040f -XD7901-1
Microwheelsteering WH 3 3 0584 4 4 0404 4 4 7901-137 37 C1:37 Dig In / Ana In
-D7901
/0.0_1.D2
-R8250-1 Micro/Lever-Steering sensor Ch1

-X040f -X040m -X058f -X058m -X066f -X066m -X066m -X066f -X058m -X058f -X040m -X040f
D7901-108-5VRef 7901-108C 2 2 0402 2 2 0582 1 1 RD BK 2 2 0581 1 1 0401 1 1 7901-109D D7901-109-0VRef
/9.4_2.B3 /9.4_1.A4
C Sensor Ch1 C
-X065m -X065f -X059f -X059m -X040m -X040f -XD7901-1
BU 3 3 0598 8 8 0405 5 5 7901-138 38 C1:38 Dig In / Ana In
-R8250-2 -D7901
/0.0_1.D2
Micro-Steering sensor Ch2
Sensor Ch2
-0673 -H5992 -0671

-XD7901-2 -X040f -X040m -X059m -X059f -X067f -X067m -X067m -X067f -X059f -X059m -X040m -X040f
0,5A / Dig Out C2:33 33 7901-233 6 6 0406 9 9 0599 3 3 0673 2 2 1 1 0671 1 1 05910 10 10 0407 7 7 9937-00203 CHASSIS
-D7901 /11.5_6.A8
/0.0_1.D5 + -S1130
Indication Mini/Leversteering on/off Ministeering on/off
-X040f -X040m -X058f -X058m -X067f -X067m -0672A -0674 -X067m -X067f -X059f -X059m -X040m -X040f -XD7901-1
7901-205A 3 3 0403 3 3 0583 -XSP058 0583A 2 2 0672 -XSP067 0672A 1 1 2 2 0674 4 4 05911 11 11 0408 8 8 7901-118 18 C1:18 Dig In
D D7901-205-24V 7901-205 -XSP0025 -D7901 D
/11.5_5.B3 /0.0_1.C2
Ministeering on/off
Mini/Leversteering on/off
-X067m -X067f -X059f -X059m -X040m -X040f -XD7901-1

0675 5 5 0591 1 1 0409 9 9 7901-119 19 C1:19 Dig In
-S1310-3 Gear selector -D7901
/0.0_1.C2
-0675 Mini/Leversteering gear forward
0672B
F 5 1
7901-205B D7901-205-24V
/9.5_1.C2 -0672B N1 6
1234
-X059f -X059m -X041m -X041f -XD7901-1
+ 0592 2 2 0411 1 1 7901-120 20 C1:20 Dig In
-0676 -X067m -X067f -D7901
N2 8 0676 6 6 /0.0_1.C2
7901-205C D7901-205-24V
/9.10_1.E2 R 7 1 Mini/Leversteering gear neutral
-0677
-X067m -X067f -X059f -X059m -X041m -X041f -XD7901-1
E 0677 7 7 0593 3 3 0412 2 2 7901-121 21 C1:21 Dig In E
-D7901
0672C /0.0_1.C2
-S1992 Mini/Leversteering gear reverse
-0672C -06711 -X067m -X067f -X059f -X059m -X041m -X041f -XD7901-1

1 1 2 06711 11 05912 12 12 0416 6 6 7901-124 24 C1:24 Dig In
-D7901
0583B /0.0_1.D2
Lever/mini steering Head Light
Mini/Leversteering aut. Head light
-S1470
-X067m -X067f -X059f -X059m -X041m -X041f -XD7901-1

1
0 0678 8 8 0594 4 4 0413 3 3 7901-122 22 C1:22 Dig In
2 -XS1470-3 -D7901
-X067f -X067m -XS1470-2 3 3 /0.0_1.C2
10 10 06710 2 2
1 1 Mini/Leversteering indicator left
11
-X067m -X067f -X059f -X059m -X041m -X041f -XD7901-1
F Ministeering direction indicator 0679 9 9 0595 5 5 0414 4 4 7901-123 23 C1:23 Dig In F
-D7901
secuted.
0583C /0.0_1.C2
Mini/Leversteering indicator right
-B7250
-XB7250f -XB7250m -XB7250m -XB7250f -X059f -X059m -X041m -X041f -XD7901-1

1 1 1 2 2 2 0596 6 6 0415 5 5 7901-125 25 C1:25 Dig In
-D7901
Switch armrest in position /0.0_1.D2
Armrest in position
G G
H H

Sign.
Ruta
Krets ministyrning DCG,DRG 5.2_2 1
E³ DRAWING
Design change
Sq.
Name
R

Wiring ministeering A55040.0100 04
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8
-S1008-2
A
B 7902-409B D7902-409
/7.5_1.A7
C
D7902-309-24V 7902-309C -XS1008-2 -XS8150-3m -XS8150-3f
A /7.5_2.B2 -XS8150-3f -XS8150-3m -XS1008-2 4 4 8150-35 5 5 A
D7902-309-24V 7902-309B 7 7 8150-37A 3 3
/7.5_1.B1 2 2 8150-36 6 6
6 6 1 1 8150-32A 2 2
D7902-310-24V 7902-310B 1 1 8150-36A
/7.5_1.C1 Clamp/Release legs 7902-410B D7902-410
D7902-310-24V 7902-310C /7.5_1.B7
/9.10_1.B2
/7.1_1A.D7
7902-302D D7902-302-0VRef
/7.1_1B.D8
7902-302E D7902-302-0VRef
/7.5_2.B8
B B
-S1006R
A
B 7902-307B D7902-307
/7.1_1B.D8
C
-XS1006R -XS8150-3m -XS8150-3f
-XS1006R 4 4 8150-33 3 3
8150-37B 3 3
D7902-309-24V 8150-37C 2 2 8150-34 4 4
/7.10_1.A2
8150-36B 6 6 1 1 8150-32B
Rear legs
7902-308B D7902-308
C /7.1_1B.E8 C
D7902-310-24V 8150-36C
/7.10_1.B2
8150-32C D7902-302-0VRef
/7.10_1.B7

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets kombi funktioner DCG,DRG 7.0_2 1
Name
R
Konstr/Design

Wiring Combi/OHC functions A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Lever 8150 -XD7902-4

7902-404 4 C4:4 Dig In
-D7902
S1991 /0.0_2.E3
-XD7902-3 -XS8150-1f -XS8150-1f
0,5A 7 GN BN 8 Shift button
C3:9 9 7902-309 7 8
-D7902
/0.0_2.C3 -XD7902-4
7902-405 5 C4:5 Dig In
24V Supply Island 1 S1020 -D7902
WH /0.0_2.E3
9 9
Switch Auto clamp
D7902-309-24V Release in lever 1
Sw 3 Switch Unlock TW
B RD / WH
-XD7902-3 B
10 10 7902-313 13 C3:13 Dig In
-D7902
/0.0_2.D3
-XD7902-4
0,5A 12 OG H1037 Option 1
C4:2 2 7902-402 12 +
-D7902 Lock Levelling
/0.0_2.E3
Lock arm 1
LED right locked levelling/opt
S7251 -XD7902-4
VT 7902-407 7 C4:7 Dig In
11 11 -D7902
/0.0_2.E3
-XD7902-4 Sw. lock tilt/extender
0,5A 13 BK / WH H5993 GY 14
C4:3 3 7902-403 13 + 14 7902-302A D7902-302-0VRef
-D7902 /11.5_5.B6
/0.0_2.E3
LED left locked tilt/opt
S8500-2
-XD7902-4
GN / WH 15 Dig In
C 15 7902-408 8 C4:8
C
-D7902
/0.0_2.F3
1 RD Sw. horn
D7902-301-5VRef 7902-301A 1
/11.5_5.C4 Lever X Tilt/Boom in/out
-XD7902-3
BU 3 Ana In
3 7902-304 4 C3:4
-D7902
/0.0_2.B3
7902-302D D7902-302-0VRef
BK /7.0_2.B7 Sensor Boom/tilt - in/out
2 2
7902-302B -XS8150-2f
D7902-301-5VRef 7902-301B
/7.1_1B.D2 Lever Y Lift/Lower 7902-302C 2

-XD7902-3
YE 4 Ana In
4 7902-303 3 C3:3
-D7902
/0.0_2.B3
Sensor Lift/lower
D D
Thumb X Sideshift
secuted.
-XD7902-3
BU 5 Ana In
5 7902-305 5 C3:5
-D7902
/0.0_2.B3
Sensor Sideshift
Thumb Y
-XD7902-3
YE 6 Ana In
6 7902-306 6 C3:6
-D7902
/0.0_2.B3
Rotation
Spread(L)
Extension left
Clamp(L)
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Joystick DCG,DRG 7.1_1A 1
Name
R
Konstr/Design

Wiring Joystick A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XR8070-1m -XR8070-1f -XS8150-1m -XS8150-1f -XD7902-3

A WH 3 3 8150-14 4 4 7902-303 3 C3:3 Ana In A
-D7902
/7.1_1A.D8
Sensor Lift/lower
-XD7902-3 -XS8150-1f -XS8150-1m
5V Ref -XSP8150-11 -R8070-1
C3:1 1 7902-301A 1 1 8150-11A 8150-11B-XR8070-1f -XR8070-1m -XR8070-1m -XR8070-1f -XD7902-3
-D7902
/11.5_5.C2 1 1 GY BN 2 2 8150-114B -XSP8150-114 8150-114A 14 14 7902-302A 2 C3:2 0V Ref
-D7902
Lever/Joystick 7902-302B /11.5_5.B7
Lift / Lower D7902-302-0VRef 2 Lever/Joystick
/7.1_3.B6
7902-302C
-XR8070-2m -XR8070-2f -XD7902-3

WH 3 3 8150-13 3 3 7902-304 4 C3:4 Ana In
-D7902
/7.1_1A.C8
-R8070-2 Sensor Boom/tilt - in/out

-XR8070-2f -XR8070-2m -XR8070-2m -XR8070-2f
B 8150-11C 1 1 GY BN 2 2 8150-114C B
Tilt
-XR8070-3m -XR8070-3f -XD7902-3

WH 3 3 8150-15 5 5 7902-305 5 C3:5 Ana In
-D7902
/7.1_1A.D8
-R8070-3 Sensor Sideshift

-XR8070-3f -XR8070-3m -XR8070-3m -XR8070-3f
8150-11D 1 1 GY BN 2 2 8150-114D
Sideshift (Rotation paper)
C C
-XR8070-4m -XR8070-4f -XD7902-3
WH 3 3 8150-16 6 6 7902-306 6 C3:6 Ana In
-D7902
/7.1_1A.E8
-R8070-4 Rotation
-XR8070-4f -XR8070-4m -XR8070-4m -XR8070-4f
Spread(L)
8150-11E 1 1 GY BN 2 2 8150-114E
Extension left
Clamp(L)
Extension left / Spreading(left) / Clamp paper (left) 7902-307B D7902-307
/7.0_2.B7

-XR8070-5m -XR8070-5f -XS8150-2m -XS8150-2f -XD7902-3

WH 3 3 8150-23 3 3 7902-307A 7 C3:7 Ana In
-D7902
/0.0_2.C3
-R8070-5 Levelling/5th funct/

-XS8150-2f -XS8150-2m -XR8070-5f -XR8070-5m -XR8070-5m -XR8070-5f
D 7902-301B 1 1 8150-21A -XSP8150-21 8150-21B 1 1 GY BN 2 2 8150-22D -XSP8150-22 8150-22C 2 2 7902-302C
Rear legs up/Spread R/ D
Clamp R
secuted.
D7902-302-0VRef
-XS8150-2f /7.0_2.B7
5th function/Levelling/Spreading right/Rotation paper
D7902-301-5VRef 7902-301B 1 8150-22A D7902-302-0VRef
/7.1_1A.D2 /7.5_1.C7
-XR8070-6m -XR8070-6f -XD7902-3
WH 3 3 8150-24 4 4 7902-308A 8 C3:8 Ana In
-D7902
/0.0_2.C3
-R8070-6 Extension R
-XR8070-6f -XR8070-6m -XR8070-6m -XR8070-6f
6th funct
8150-21C 1 1 GY BN 2 2 8150-22E
Rear legs down
Extension right / 6th funct. 7902-308B D7902-308

/7.0_2.C7
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Spakar DCG,DRG 7.1_1B 1
Name
R
Konstr/Design

Wiring Levers A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S8070-2
-XR8070-2f -XR8070-2m -XR8070-2m -XR8070-2f -XS8150-1m -XS8150-1f -XD7902-4

D7902-309-24V 8150-17E 4 4
RD 1 2
GY 5 5 8150-18 8 8 7902-404 4 C4:4 Dig In
/9.7_1.C5 -D7902
/7.1_1A.A8
Tilt control
Shift button
B B
-S8070-3

D7902-309-24V 8150-17F 4 4
RD 1 2
GY 5 5 8150-111 11 11 7902-407 7 C4:7 Dig In
/9.7_1.C5 -D7902
/7.1_1A.C8
Extender
Sw. lock tilt/extender
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Spakbrytare DCG,DRG 7.1_2 1
Name
R
Konstr/Design

Wiring Lever Switches A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1990-1/S1037/S1023-1
C
A
-XS1990-1 -XS1990-1 -XS8150-1m -XS8150-1f -XD7902-3
D7902-309-24V 8150-17D 3 3 4 4 8150-110 10 10 7902-313 13 C3:13 Dig In
/9.7_1.C5 -D7902
1 1 8150-12 2 D7902-302-0VRef /7.1_1A.B8
B /7.1_1B.B6 B
Option 1 Option 1
Lock Levelling
Lock levelling Lock arm 1
Arm lock 1
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Skevningslås DCG,DRG 7.1_3 1
Name
R
Konstr/Design

Wiring Lock Levelling A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
7902-409B D7902-409
/7.0_2.A7
D7902-309-24V 8150-27B
/7.10_2.C2
-S1990-5/S1012/S1008/1028-29
A
B
C
-XS1990-5 -XS8150-2m -XS8150-2f -XD7902-4
-XS8150-2f -XS8150-2m -XS1990-5 4 4 8150-25 5 5 7902-409A 9 C4:9 Dig In
D7902-309-24V 7902-309B 7 7 8150-27A 3 3 -D7902
/7.0_2.A1 2 2 8150-26 6 6 /0.0_2.F3
8150-210A 6 6 1 1 Option 5
Spreading 40-20
D7902-309-24V 7902-309A Option 5
/9.7_1.A3 PLH-
Spreading 20-40/40-20 Release legs
Release legs -XD7902-4
B 7902-410A 10 C4:10 Dig In B
PLH +/- -D7902
/0.0_2.A5
-XS8150-2f -XS8150-2m Option 5
D7902-310-24V 7902-310A 10 10 Spreading 20-40
/11.5_5.B3
PLH+
Clamp legs
7902-410B D7902-410
/7.0_2.A7
D7902-310-24V 8150-210B
/7.10_2.C2
8150-22A D7902-302-0VRef
/7.1_1B.D7
C C
D7902-310-24V 7902-310B
/7.0_2.A1
8150-22B D7902-302-0VRef
/7.10_2.D7

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets spridning 20-40 DCG,DRG 7.5_1 1
Name
R
Konstr/Design

Wiring Spreading 20-40 A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1012-2
C
A
-XS8150-4f -XS8150-4m -XS1012 -XS1012 -XS8150-4m -XS8150-4f -XD7902-3
D7902-309-24V 7902-309C 7 7 8150-47A 3 3 4 4 8150-43 3 3 7902-316 16 C3:16 Dig In
/7.0_2.A1 -D7902
D7902-309-24V 8150-47B 1 1 8150-42A 2 2 /0.0_2.D3
/8.2_2.B2
Aut. spreading on-off Aut 20-40 on-off
Differential lock
7902-302E D7902-302-0VRef
/7.0_2.B7
7902-302F D7902-302-0VRef
/8.2_1.C8
B B
8150-42B D7902-302-0VRef
/8.2_2.B8
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Automatisk Spridning DCG,DRG 7.5_2 1
Name
R
Konstr/Design

Wiring Automatic Spreading A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1004
C
A
-XS1004 -XS1004 -XS8150-4m -XS8150-4f -XD7902-3
D7902-309-24V 8150-47G 3 3 4 4 8150-412 12 12 7902-318 18 C3:18 Dig In
/9.10_1.C2 -D7902
1 1 8150-42G /0.0_2.E3
D7902-309-24V 8150-47H
/1.3_1.B2 30-35 stop Sw. 30-35 stop
B B
D7902-302-0VRef
/9.10_1.D8
8150-42H D7902-302-0VRef
/1.3_1.B7
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets 30-35 Stopp DCG,DRG 7.5_3 1
Name
R
Konstr/Design

Wiring 30-35 Stop A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-S1027
C
A
3 4
A A
1
PLH on/off
D7902-401-24V 7902-401B
/9.8_2.B3 -S1003
A
B -XD7902-3
C 7902-312A 12 C3:12 Dig In
-D7902
-XS1003 4 4 7902-312B /0.0_2.C3
D7902-401-24V 7902-401A 3 3
/8.2_1.B2 2 2 Sw. lock TW
10 5 PLH on/off
10 5
Lock TW 7902-302G D7902-302-0VRef
/8.2_1.C8
B B
1 7902-302H
7902-302I D7902-302-0VRef
/9.8_2.B7
7902-312C
C C
-S8070-1

D7902-309-24V 8150-17C 4 4
RD 1 2
GY 5 5 8150-19 9 9 7902-405 5 C4:5 Dig In
/9.7_1.C5 -D7902
/7.1_1A.B8
Switch Auto clamp
Switch Auto clamp
Release in lever 1 Release in lever 1
Unlock TW lock
Switch Unlock TW
D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Twistlock DCG,DRG 7.9_1 1
Name
R
Konstr/Design

Wiring Twistlock A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X049m -X049f
8 8 9937-00208 CHASSIS
/11.5_6.A8
B B
Headup display
-XD7901-2 -X049f -X049m -XA3720-1m
0,5A / Dig out C2:4 4 7901-204 7 7 1/4 ----------
-D7901 -XA3720-1f
/0.0_1.B5 0498 2 2/4 GND
Ind. support jacks down 0497 3 3/4 Support jacks down (GN)
-X047f -X047m
D7901-108-5VRef 7901-108B 9 9 0479 4 4/4 5V
/9.4_2.B3
-XD7901-2 -X049f -X049m -XA3720-2f -XA3720-2m H5620-2

0,5A / Dig out C2:1 1 7901-201 4 4 0494 1 1/3
-D7901
C /0.0_1.B5 C
Ind. unlocked TW Unlocked (RD)
-XD7901-2 -X049f -X049m H5630-2

0,5A / Dig out C2:2 2 7901-202 6 6 0496 2 2/3
-D7901
/0.0_1.B5
Ind. locked TW Locked (GN)

Clamp pressure ok
D H5640-2 D
-XD7901-2 -X049f -X049m
secuted.
0,5A / Dig out C2:3 3 7901-203 5 5 0495 3 3/3

-D7901
/0.0_1.B5
Ind. alignment Alignment (YE)
Tilt control
-A3720
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Indikeringslampor DCG,DRG 7.9_2 1
Name
R
Konstr/Design

Wiring Indication Lamps A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1990-7/S1013/S2992
A
B -XD7902-4
C 17 C4:17 Dig In
-XS1990-7 -XS8150-3m -XS8150-3f -D7902
-XS1990-7 4 4 8150-38 8 8 7902-417 /0.0_2.B5
D7902-309-24V 8150-37C 3 3
/7.0_2.C1 2 2 8150-39 9 9 7902-418 Option 7
6 1 Support jacks up
D7902-310-24V 8150-36C 6 1 8150-32C
/7.0_2.C1 Upper Arms Height up
Option 7 -XD7902-4
Support jacks 18 C4:18 Dig In
-D7902
Upper arms height /0.0_2.B5
Option 7
Support jacks down
B Upper Arms Height down B
8150-32C D7902-302-0VRef
/7.0_2.C7
-S8070-4/S1024
C C
-XR8070-4f -XR8070-4m -XR8070-4m -XR8070-4f -XS8150-2m -XS8150-2f
D7902-309-24V 8150-17G 4 4
RD 1 2
GY 5 5 8150-215 15 15 7902-314B D7902-314
/9.7_1.C5 /7.10_2.B7
Short arm on/off

-S8070-5/S1006-FR
-XR8070-5f -XR8070-5m -XR8070-5m -XR8070-5f -XS8150-2m -XS8150-2f

D7902-309-24V 8150-27C 4 4
RD 1 2
GY 5 5 8150-211 11 11 7902-406B D7902-406
D /7.10_2.C2 /7.10_2.C7 D
Extra function/Front legs down
secuted.
E E
F F

E³ DRAWING
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Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Stödben/Option DCG,DRG 7.10_1 1
Name
R
Konstr/Design

Wiring Support jacks/Option A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
7902-314B D7902-314
/7.10_1.C7
-S1990-2/S1006FR/S1031 -XD7902-3
A Dig In
B 7902-314A 14 C3:14
-D7902
D7902-309-24V 8150-27C C /0.0_2.D3
/7.10_1.D2 -XS1990-2 -XS8150-2m -XS8150-2f
-XS1990-2 4 4 8150-28 8 8 Option 1
D7902-309-24V 8150-27B 3 3 Front legs up
/7.5_1.A3 2 2 8150-29 9 9
C D7902-310-24V 8150-210B 6 6 1 1 C
/7.5_1.C3 -XD7902-4
Opt 2 7902-406A 6 C4:6 Dig In
-D7902
Front legs up /0.0_2.E3
Overheight Opt. 1
Front legs down
7902-406B D7902-406
/7.10_1.D7

8150-22B D7902-302-0VRef
/7.5_1.C7
D D
secuted.
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets OPT 1 DCG,DRG 7.10_2 1
Name
R
Konstr/Design

Wiring OPT 1 A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1017 Toggle wheel
-XS1017 -X7950
1 1 7950-10 10 C1:10 5V Dig In
-D7950
-XS1017 /11.6_1.C2
D7902-804-5VRef 7950-08 2 2
B /11.5_5.D4 Toggle wheel
B
3 3
-X7950
7950-11 11 C1:11 5V Dig In
-D7950
/11.6_1.C2
Toggle wheel
C C

D D
secuted.
E E
F F

E³ DRAWING
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Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Toggle Wheel DCG,DRG 8.1_1 1
Name
R
Konstr/Design

Wiring Thoggle Wheel A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1005
B C B
D7902-401-24V 7902-401A -XD7902-3
/7.9_1.B2 A
7902-311A 11 C3:11 Dig In
-XS1005 -XS1005 -D7902
D7902-401-24V 7902-401 -XSP7902-401 7902-401A 3 3 4 4 /0.0_2.C3
/11.5_5.A3
6 6 1 1 Sw. override safety keyswitch
Override safety keyswitch

7902-302F D7902-302-0VRef
/7.5_2.B8
7902-311B
7902-401B D7902-401-24V 7902-302G D7902-302-0VRef

/9.3_6.B3 /7.9_1.B8
C 7902-401C D7902-401-24V
/9.3_3.B3 C
7902-401D D7902-401-24V
/9.3_3.C3

D D
secuted.
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Förbikoppling DCG,DRG 8.2_1 1
Name
R
Konstr/Design

Wiring Override A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A -S1023-2 A
C
A
3 4
1
Lock Arm 2
-S1990-3/S1015/1014
C
D7902-309-24V 8150-47C A -XS8150-4m -XS8150-4f -XD7902-3
/9.10_2.B2 -XS1990-3 -XS1990-3 8150-44A 4 4 7902-315 15 C3:15 Dig In
-D7902
D7902-309-24V 8150-47B 3 3 4 4 /0.0_2.D3
B /7.5_2.B2 B
6 6 1 1 8150-42B Override height
Override rotation
Option 3 Lock arm 2
Override height
Override rotation D7902-302-0VRef
/7.5_2.B8
8150-44B
8150-42C D7902-302-0VRef
/9.10_2.C8
C C

D D
secuted.
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Förbikoppling Höjd/OPT2 DCG,DRG 8.2_2 1
Name
R
Konstr/Design

Wiring Override Height/OPT2 A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1752
C
D7902-309-24V 8150-47F A
/9.10_1.C2 -XS1752 -XS1752 -XS8150-4m -XS8150-4f -XD7902-4
D7902-309-24V 8150-47E 3 3 4 4 8150-49 9 9 7902-413 13 C4:13 Dig In
/9.10_1.A2 -D7902
D7902-310-24V 8150-41B 6 6 1 1 8150-42E /0.0_2.A5
/9.10_1.B2
Dead mans grip Dead mans grip
D7902-310-24V 8150-41C
/9.10_1.C2
D7902-302-0VRef
/9.10_1.B7
B 8150-42F D7902-302-0VRef
/9.10_1.C8 B
C C

D D
secuted.
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Dödmans grepp DCG,DRG 8.2_3 1
Name
R
Konstr/Design

Wiring Dead man grip A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
08712
08713
B B
-D7950-2
-X087f -X087f 0876
13 K1:13 CAN 2 K1:6 6
L+ + -XSP087-06
12 K1:12 CAN K1:5 5 0875
L- -
8 K1:8 K1:4 -XSP087-05
+ Shield
RS232
K1:11 K1:3 3 30
R+ TX
K1:10 CAN K1:2 2
R- RX
K1:7 K1:1 1
+ GND
9 K1:9 0V REF BUZZER K1:14
C KID C
0871
0391
0878
0879
0872
0392

-X088f
25 0872
TX2
26 0873 -X039m
RX2 30 1 CAN+
/11.6_1.A4 CAN+
30 08830 -XSP088-30 0871 2 CAN-
D GND /11.6_1.A4 CAN- D
secuted.
0878 3 9968-BK-B:1
3 0883
/11.5_2.B7 IGNITION
+15 0879 5 CHASSIS
GND
13 08813 /11.5_2.B7 GND
14 0399 -X039f
Batt+ 9 9
28 08828
TX1
0895
-A9110
29 08829
MIU RX1
E E
09915A
30
-X089m
4
3
5
6
7
8
9
1
F See circuit -X099m

15 09915 -XSP09915 09915B X09915
F
chassi /9.4_5.C5
Batt. + before main switch (fuse 5A)

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets RMI DCG,DRG 8.2_4 1
Name
R
Konstr/Design

Wiring RMI A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Connect interlocklock device

A instead of jumper. A
-XA9120f-1
-1 RD 9968-RD:1
/11.5_2.A5 -X110m -X110f -XD7902-5
2 2 7902-513 13 C5:13 Dig In
-XA9120f-2 -D7902
-2 BK /0.0_2.C5
1102 1 1 1101
Start interlock device
-XA9120f-3
-3 BU 9968-BK:1
/11.5_2.C5
B B
-A9120
Dräger Interlock device
-XA9120f-13 -X110-1Am -X110-1m -X110-1f

-13 1 BN 1 110-11 1 1 0612
-XA9120f-14
-14 GY 2 2 2 0356
-X9937-005:3
C C
-X099m -X035f -X035m -X061m -X061f
3
See circuit 5 0356 6 6 2 2
-X9937-005 CHASSIS
chassi
-XA9120Af-1
-1A 1 RD 9968-RD:1
/11.5_2.A5

-S1061
-3A 1 BK
-12A 1 RD 1 2
D D
-13A 1 GN 9968-BK:1
secuted.
/11.5_2.C5
-18A 1 GY
-X9120B -X110-1m
-A9120 -1B 1 BK 1
Foxguard Interlock device
-2B 2 BK 2
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Startlås DCG,DRG 9.2_1 1
Name
R
Konstr/Design

Wiring Start Lock A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
9968-BK:5 9968-BK-E1 -XSP9968-1 9968-BK-E1A 9968-BK:5

/11.5_2.C5 /9.3_1.C1
9968-BK-E1B 9968-BK:5
/9.3_1.E1
9968-BK-E1C 9968-BK:5
/9.3_1.D1
/11.5_6.A2
/11.5_6.A3
/11.5_6.A1
9968-BK-E1D 9968-BK:5
/9.3_4.B1
B B
CHASSIS
CHASSIS
CHASSIS
0617D
0617E
0617C
-S2680
-M6700
P COMPRESSOR
-X037f -X037m -X061m -X061f -XE8030m -XE8030f AIR-SUSPENDED SEAT -XE8030f -XE8030m -X061f -X061m -X037m -X037f
9968-BK:5 9968-BK-E1A 3 3 0373 6 6 0616 5 5 GN 1 2 + - BK 6 6 0617A 0617 7 7 0374 4 4 9937-00204 CHASSIS
/9.3_1.A4 M -XSP0617
/11.
COMPRESSOR
C C
AIR CUSHIONED SEAT
-S8151 Kontigt att jorda ner

borde styra fläkt motsv


0617B
P
-X038f -X038m -X061m -X061f -XE8030m -XE8030f -XE8030f -XE8030m
9968-BK:5 9968-BK-E1C 2 2 0382 11 11 06111 11 11 1 2 12 12 06110B CHASSIS
/9.3_1.B4 /9.3_4.C7
D D
To be defined compressor seat pressure
secuted.
-X037f -X037m -X061m -X061f -XE8030m -XE8030f -E8030 -XE8030f -XE8030m

9968-BK:5 5 5 0375 8 8 0618 -XSP0618 0618A 1 1 BU 1 2 1 2 BK 2 2
/9.3_1.A4
Seat heater
E E
0618B 9968-BK:5
/9.3_2.B2
-XE8030m -XE8030f -B2300 -XE8030f -XE8030m -X061f -X061m -X038m -X038f -XD7901-1
YE BK Dig In Start up
9968-RD:1 0613C 3 3 1 2 4 4 06112 12 12 0388 8 8 7901-150 50 C1:50
/11.5_3.E4 -D7901
/0.0_1.E2
Seat switch
Seat switch
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Stolsfunktioner DCG,DRG 9.3_1 1
Name
R
Konstr/Design

Wiring Seat Functions A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XE8030m -XE8030f -B2250 -XE8030f -XE8030m -XD7902-5

9968-BK:5 0618B 7 7 1 2 8 8 7902-514 14 C5:14 Dig In
/9.3_1.E5 -D7902
/0.0_2.C5
Safety belt
Seat belt
B B
-H5991
-XD7901-2 -X048f -X048m -XH5991-1 -XH5991-2 -X048m -X048f
1,5A C2:7 7 7901-207 4 4 59911 1 1 2 2 59912 5 5 9937-00403 CHASSIS
-D7901 /11.5_6.C8
/0.0_1.C5
C C
Lamp fasten seat belt Fasten seat belt

D D
secuted.
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Indikering Säkerhetsbälte DCG,DRG 9.3_2 1
Name
R
Konstr/Design

Wiring Indication Safety Belt A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Canoe panel fwd/rev

-M6941
-XD7902-2 -XM6941-1f -XM6941-1m -XM6941-1m -XM6941-1f -XD7902-2
NPN / PNP 3A C2:7 7 7902-207 1 1 BN 5 6 WH 2 2 7902-208 8 C2:8 NPN / PNP 3A
-D7902 M -D7902
/0.0_2.B3 /0.0_2.B3
Motor canoe fwd/rev Motor canoe fwd/rev
-XM6941-2f -XM6941-2f
D7902-401-24V 7902-401C 3 10 8 1 7902-202C D7902-202-0VRef
/8.2_1.C3 /9.3_6.B6
9
-XM6941-2f
2
B B
-XD7902-2
7902-203 3 C2:3 Ana In
-D7902
/0.0_2.B3
Motor canoe fwd/rev feedback
Canoe panel up/down

C -M6942 C
-D7902 M -D7902
/0.0_2.B3 /0.0_2.B3
Motor canoe up/down Motor canoe up/down
-XM6942-2f -XM6942-2f
D7902-401-24V 7902-401D 3 10 8 1 7902-202D D7902-202-0VRef
/8.2_1.C3 /9.3_6.B6
9
-XM6942-2f
2
D -XD7902-2 D
7902-204 4 C2:4 Ana In
secuted.
-D7902
/0.0_2.B3
Motor canoe up/down feedback
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Motor Armstöd DCG,DRG 9.3_3 1
Name
R
Konstr/Design

Wiring Motor Armrest A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-M6570-2
-X037f -X037m -X061m -X061f -XE8030m -XE8030f -XE8030f -XE8030m -X061f -X061m -X038m -X038f
9968-BK:5 9968-BK-E1D 9 9 0379 9 9 0619 9 9 1 2 1 2 10 10 06110A 10 10 0381 1 1 9937-00305 CHASSIS
B /9.3_1.B4 M /11.5_6.B6 B
Ventilation seat
C 06110B CHASSIS
/9.3_1.D8 C

D D
secuted.
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Stolsventilation DCG,DRG 9.3_4 1
Name
R
Konstr/Design

Wiring Seat Air Ventilation A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S7212-2 -S7212-1
BK 1 2
GY BK 1 2
GY
Seat unlocked Seat in driving pos
-X111f -X111m
9968-GN:5 9968-GN-E1 -XSP9968-GN:5 9968-GN-E1A 1 1
B -XD7901-1:17 /11.5_2.E5 B
Dig In C1:17 1 7901-117 2 2
-D7901
/0.0_1.C2
Seat in driving position
-K3460
-XD7901-2:34 -XK3460 -XK3460
0,5A / Dig In C2:34 1 7901-234 86 86 85 85 3460-85 CHASSIS
-D7901 /11.5_6.D5
/0.0_1.D5
Seat Unlock (TDS 15/30deg)
C C
Seat unlock device
-XM3460f -XM3460m
-M3460
-XK3460 -K8882 -XK3460 3460-30 1 1/4 WH Sig
30 30 87 87 3460-87 2 2/4 WH Sig
3 3/4 Gnd
CHASSIS 9937-00508 BK
/11.5_6.D5
9968-GN-E1B 4 4/4 RD 24V
D D
secuted.
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Stolsvridning DCG,DRG 9.3_5 1
Name
R
Konstr/Design

Wiring Seat Rotation A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Steering wheel panel up/down

-M6943
-D7902 M -D7902
/0.0_2.B3 /0.0_2.B3
Steering panel up/down Steering panel up/down
-XM6943-2f -XM6943-2f
B D7902-401-24V 7902-401B 3 10 8 1 7902-202B
B
/8.2_1.C3
9 D7902-202-0VRef 7902-202C -XSP6 7902-202A D7902-202-0VRef
-XM6943-2f
/9.3_3.B6 /11.5_5.B6
2
D7902-202-0VRef 7902-202D
/9.3_3.C6
-XD7902-1
7902-109 9 C1:9 Ana In
-D7902
/0.0_2.A3
Steering panel up/down feedback
C C

D D
secuted.
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Motor Flytta Rattpanel DCG,DRG 9.3_6 1
Name
R
Konstr/Design

Wiring Motor Moving Steering Panel A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12
A A
-X056Am -X056Af
1 9 1
2 10 2
B 3 11 3 B
4 12 4
5 13 5
-X057Am -X057Af
1 14 1
2 15 2
3 16 3
4 17 4
5 18 5
6 19 6
C 7 20 7 C
8 21 8
-X058Am -X058Af
1 22 1
2 23 2
3 24 3
4 25 4
D D
-X059Af -X059Am
1 26 1
2 27 2
3 28 3
4 29 4
5 30 5
6 31 6
7 32 7
8 33 8
9 34 9
10 35 10
11 36 11
12 37 12
E E
-X060Am -X060Af
1 30 5 1
2 6 2
3 38 3
4 BK 4
5 5
WH
6 30 7 6
7 8 7
8 39 8
9 40 9
F 10 41 10 F
secuted.
11 42 11
12 43 12
-X061Af -X061Am
1 44 1
2 45 2
3 46 3
4 47 4
5 48 5
6 49 6
7 BN 7
G G
8 GN/YE 8
9 50 9
10 10
51
11 52 11
12 53 12
H H

Sign.
Ruta
Krets kablage förlängning TDS DCG,DRG 9.3_7 1
E³ DRAWING
Design change
Sq.
Name
R

Wiring extension harness TDS A55040.0100 04
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8
A A
-M6750R
-X218m -XM6750Rf -XM6750Rm -XM6750Rm -XM6750Rf -X218m
1 21801 WH 0.75 1 1 RD 31 50 BK 2 2 21802 WH 0.75 2
M
-X284_BB -X284f -X284f -X284_BB
1 1 WH 0.75 3 3
2 2 28402 WH 0.75 -M6750L 28404 WH 0.75 4 4
-XM6750Lf -XM6750Lm -XM6750Lm -XM6750Lf
6 6 28406 WH 0.75 1 1 RD 31 50 BK 2 2 28405 WH 0.75 5 5
M
B B
-Y6760R
-X218m -XM6750Rf -XM6750Rm -XM6750Rm -XM6750Rf -X218m
3 21803 WH 0.75 3 3 BK BK 4 4 21805 BK 0.75 5
-Y6760L
-X218m -XM6750Lf -XM6750Lm -XM6750Lm -XM6750Lf -X218m
4 21804 WH 0.75 3 3 BK BK 4 4 21806 BK 0.75 6
C C

-XB7770m -XB7770f -X218m

D WH C C 21708 WH 0.75 8 D
secuted.
-B7770
-X218m -XB7770f -XB7770m -XB7770m -XB7770f -X218m
2
7 21707 WH 0.75 A A RD 1 3 BK B B 21709 WH 0.75 9
Position TDS
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn RSO 2012-11-08 A55032.0900 Krets vändning stol DCG,DRG 9.3_8 1
Name
R
Konstr/Design

Wiring seat turning A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-K3461-1
-XS1310-1f -X037m -X037f -XK3461-1 -XK3461-1
B D7902-502 Switch P-brake 6 0376 6 6 0376 86 86 85 85 3461-185 3461-185
B
/4.5.C6
SWAP POLARITY (OPT)
-K3461-2
-XK3461-2 -XK3461-2
0376A 86 86 85 85 3461-285
SWAP POLARITY (OPT)
C C
-K3461-3 -K3461-1 -M6944 -K3461-2

-XK3461-3 -XK3461-3 -XK3461-1 -XK3461-1 -X037f -X037m -XM6944f -XM6944m -XM6944m -XM6944f -X037m -X037f -XK3461-2 -XK3461-2
9968-GN:6 3461-330 30 30 87 87 3461-387 87 87 30 30 0377 7 7 0377 1 1 BN 50 31 BU 2 2 0378 8 8 0378 30 30 87 87 3461-287
/11.5_2.E5 M
87A 87a 87A 87A 87a
/9.3_9.D2
LEFT ARMREST ON (OPT) SWAP POLARITY (OPT) LEFT ARMREST UP/DOWN SWAP POLARITY (OPT)
3461-187a 3461-187a
-K3461-3
-XK3461-3 -XK3461-3 3461-187 3461-187
24V-D7900-1/10:9 3461-386 86 86 85 85 3461-385
/11.5_3.A6
/9.3_9.D2
LEFT ARMREST ON (OPT)
D D
secuted.
-X9937-005
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn RSO 130617 A55032.0900 Krets Motor vänster armstöd DCG,DRG 9.3_9 1
Name
R
Konstr/Design
Wiring Motor left armrest A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-XD7902-7m -XD7902-7f -XA3702f -AX3702m
1 1 1/31
2 2 2/31
3 3 3/31
4 4 4/31
5 5 5/31
6 6 6/31
7 7 7/31
8 8 8/31
9 9 9/31
10 10 10/31
C 11 11 11/31 C
12 12 12/31
13 13 13/31
14 14 14/31
15 15 15/31
16 16 16/31
17 17 17/31
18 18 18/31

19 19 19/31
20 20 20/31
21 21 21/31
22 22 22/31
D 23 23 23/31 D
/1.1_0.E1 24 24 24/31
secuted.
/9.6_0.F1 25 25 25/31
-D7902 26 26 26/31
-A3702-ECC_Panel
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Manöverpanel Klimatsystem DCG,DRG 9.4_0 1
Name
R
Konstr/Design

Wiring Panel Climate Control A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
D7901-109-0VRef 7901-109 -XSP00191 7901-109D D7901-109-0VRef

/11.5_5.B6 /5.2_2.C12
7901-109C D7901-109-0VRef
/9.4_2.A8
B B
-B7751
-X081f -X081m -XB7750-1 -XB7750-1 -X081m -X081f -X031m -X031f -XD7901-1
0301B 6 6 1 1 T 2 2 7 7 0318 8 8 7901-133 33 C1:33 Resistance In
-D7901
U /0.0_1.D2
C C
Temp. indoor Temp. indoor
-B7752
-X030f -X030m -X080f -X080m -XB7750-2 -XB7750-2 -X080m -X080f -X030m -X030f -XD7901-1
7901-109B 1 1 0301A 1 1 1 1 T 2 2 2 2 0302 2 2 7901-134 34 C1:34 Resistance In
-D7901
U /0.0_1.D2
Temp. fan air (distributor) Temp. fan air

-B7753
-XB7750-3 -XB7750-3 -X080m -X080f -X030m -X030f -XD7901-1
1 1 T 2 2 3 3 0303 3 3 7901-135 35 C1:35 Resistance In
-D7901
U /0.0_1.D2
D D
De-icing sensor De-icing
secuted.
-B7740
-X045f -X045m -X7740 -X7740 -X045m -X045f -XD7901-1
7901-109A 1 1 0451 1 1 T 2 2 0452 2 2 7901-136 36 C1:36 Resistance In
-D7901
U /0.0_1.D2
Temp. ambient (outdoor) Temp. ambient
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Klimatsystem DCG,DRG 9.4_1 1
Name
R
Konstr/Design

Wiring Climate Control A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XD7901-2 -X030f -X030m -X080f -X080m

PWM C2:24 24 7901-224 7 7 0307 7 7
-D7901
/0.0_1.D5
A A
Air distributor valve close
-XD7901-2 -X030f -X030m -Y6720 Air distributor
PWM C2:25 25 7901-225 8 8 0308 8 8
-D7901 5 M 6
/0.0_1.D5
Air distributor valve open
-X030f -X030m -X080m -X080f -X031m -X031f
D7901-108-5VRef 7901-108 -XSP00181 7901-108A 9 9 0309 9 9 10 10 0311 1 1 7901-109C D7901-109-0VRef
/11.5_5.D4 10 8 /9.4_1.A4
7901-108B D7901-108-5VRef 9
/7.9_2.C2
7901-108C D7901-108-5VRef -X031m -X031f -XD7901-1
/5.2_2.C2
11 11 0312 2 2 7901-128 28 C1:28 Dig In / Ana In
-D7901
/0.0_1.D2
-XD7901-2 -X030f -X030m -X080f -X080m
PWM C2:26 26 7901-226 4 4 0304 4 4 Air distributor valve
-D7901
/0.0_1.D5
B Heat valve B
Heat valve Close
-XD7901-2 -X030f -X030m -Y6730
PWM C2:27 27 7901-227 5 5 0305 5 5 5 6
-D7901 M
/0.0_1.D5
Heat valve Open
10 8
9
-X080m -X080f -X030m -X030f -XD7901-1
6 6 0306 6 6 7901-129 29 C1:29 Dig In / Ana In
-D7901
/0.0_1.D2
Heat valve(air mix)
-XD7901-2
PWM 15A C2:37 37 7901-237
-D7901
/0.0_1.E5 -M6570
C -X032f -X032m -X081f -X081m C
Heating fan 1 1 0321 1 1
1
CHASSIS 9937-00104 2 2 0322 2 2

/11.5_6.A5 31
Heating fan

D -XD7901-2 -X031f -X031m -X081f -X081m D

PWM C2:29 29 7901-229 5 5 0315 3 3 -Y6120
secuted.
-D7901
/0.0_1.D5 10 +12V
Motor, recirculation
CHASSIS 9937-00207 7 7 0317 5 5 7 GND
/11.5_6.A8 M
-XD7901-2
PWM C2:28 28 7901-228 6 6 0316 4 4 8 Signal
-D7901
/0.0_1.D5
Motor, recirculation MOTOR, RECIRCULATION
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-B2190
P
B -X034f -X034m -X081f -X081m -X081m -X081f -X031m -X031f -XD7901-1 B
D7901-205-24V 0336 9 9 0349A 8 8 1 2 9 9 0313 3 3 7901-115 15 C1:15 Dig In
/9.5_1.A2 -D7901
Air Filter Ind. Pressure Switch /0.0_1.C2
Climate Air Filter Ind. Pressure Sw
D7901-205-24V
/9.4_4.B2
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XD7901-1 -X036f -X036m -X080f -X080m -X2460f WH/RD

Dig In C1:1 1 7901-101 6 6 0366 14 14 RD D 0.75
-D7901
/0.0_1.B2
Sw. AC pressure in range=clutch active
A A
-B2460
P
-XD7901-1 -X036f -X036m -X080f -X080m -X2460f RD/BU
Dig In C1:2 2 7901-102 7 7 0367 15 15 VT B 0.75 2 1
-D7901
/0.0_1.B2 PRESSURE SENDER AC
Sw. AC pressure >16 bar Max fan speed
2 1
-X080f -X080m -X2460f WH/BK PRESSURE SENDER AC

D7901-205-24V 0349B 12 12 BK C 0.75
/9.4_3.C3
B B
0349C
-X2460f WH/BU
13 13 BU A 0.75
C C
-M810-1

-XM8100m + -
D7901-C2p36 1
/9.6_4.F4
CHASSIS 2
D /9.6_4.F6 D
secuted.
-M810-2
+ -
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X099m -XD7901-1
From heater E6690 11 7901-144 44 C1:44 Dig In Start up
-D7901
see circuit chassi /0.0_1.E2
External heater
B B
-X053f -X053m -XD7440f -XD7440m

X09915 09915B 1 1 RD 1 1/9
/8.2_4.F8
-X053f -X053m 2/9
9937-0054 3 3 BN 3 3/9
C -X099m -X053f -X053m 4/9 C
-X9937-005:4
12 09912 5 5 BU/WH 5 5/9
6/9
7/9
1
8/9
CHASSIS 9/9
Eberspächer Easystart T
-D7440

D D
secuted.
-M6670
-XD7901-2 -X036f -X036-5m -XM6670f
3A C2:14 14 7901-214 5 1 0365 1
-D7901
/0.0_1.C5
Paus heater
M
-XM6670f =
CHASSIS 9937-00408 2
/11.5_6.B8
Pause Heater Pump

E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
0336A D7901-205-24V
/9.5_2.B4
-X033f -X033m 0336B D7901-205-24V
D7901-205-24V 0336 6 6 0336 -XSP8 /9.5_2.D4
/9.4_3.B2
0492
-M6502
-XD7901-2 -X049f -X049m -XM6502m -XM6502f -XM6502f -XM6502m
6A C2:17 17 7901-217 1 1 0491 2 2 RD 53 31 BK 4 4 0458A
-D7901 M
/0.0_1.C5
Wiper rear -
B -X049f -X049m -XM6502m -XM6502f 31b -XM6502f -XM6502m -X049m -X049f -XD7901-1 B
2 2 0492 1 1 YE 53a GN 3 3 0493 3 3 7901-112 12 C1:12 Dig In
-D7901
Rear wiper /0.0_1.C2
Wiper rear feedback
0457
-M6503
-XD7901-2 -X045f -X045m -XM6503f -XM6503m -XM6503m -XM6503f -X045m -X045f
6A C2:19 19 7901-219 6 6 0456 2 2 BU 53 31 BK 4 4 0458B 8 8 9937-00206 CHASSIS
-D7901 M /11.5_6.A8
/0.0_1.C5
Wiper roof/combined front/roof -
-X045f -X045m -XM6503f -XM6503m 31b -XM6503m -XM6503f -X045m -X045f -XD7901-1
7 7 0457 1 1 BU 53a LBU 3 3 0459 9 9 7901-113 13 C1:13 Dig In
-D7901
D7901-205-24V 7901-205B Front/Roof wiper /0.0_1.C2
/5.2_2.E4
Wiper roof feedback
C C
-XB2991 -B2991 -XB2991 -X031m -X031f -XD7901-1

0336D 1 1 2 2 0314 4 4 7901-114 14 C1:14 Dig In
-D7901
/0.0_1.C2
Washer fluid level switch
Washer fluid level switch

CHASSIS
0332A
/9.5_2.F6
-M6512
Rear washer
-XD7901-2 -X033f -X033m -XM6512f -XM6512f -X033m -X033f
6A C2:16 16 7901-216 3 3 0333 1 + - 2 0332B 2 2 9937-00103 CHASSIS
D -D7901 M /11.5_6.A5 D
/0.0_1.C5
secuted.
Motor washer rear
-M6513
Front/Roof washer
-XD7901-2 -X033f -X033m -XM6513f -XM6513f
6A C2:15 15 7901-215 4 4 0334 1 + - 2 0332C
-D7901 M
/0.0_1.C5
Motor washer front/roof
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Torkare & Spolare DCG,DRG 9.5_1 1
Name
R
Konstr/Design

Wiring Wiper & Washer A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-K6501-LE
-XD7901-2 -XK6501-LE -XK6501-LE
1,5A C2:8 8 7901-208 86 86 85 85 9937-0047ACHASSIS
-D7901 /11.5_6.B8
/0.0_1.C5
A /9.5_2.B3 A
Wiper front left (relay)
-M6501-LE
-XK6501-LE -K6501-LE -XK6501-LE -X033f -X033m -XM6501-LEf -XM6501-LEm -XM6501-LEm -XM6501-LEf
9968-GN:2 9968-GN-B1 -XSP65001 9968-GN-B1A 30 30 87 87 6501-LE-87 5 5 0335 2 2 RD 53
M
31 BK 4 4 0338A
B /11.5_2.E5 /9.5_2.A3 B
-XM6501-LEf -XM6501-LEm - -XM6501-LEm -XM6501-LEf -X033m -X033f -XD7901-1
31b
D7901-205-24V 0336A 1 1 YE 53a GN 3 3 0337 7 7 7901-110 10 C1:10 Dig In
/9.5_1.A5 -D7901
Front left wiper /0.0_1.C2
Wiper front left feedback
9968-GN-B1B
-K6501-RI
C -XD7901-2 -XK6501-RI -XK6501-RI C
1,5A C2:9 9 7901-209 86 86 85 85 9937-0047B CHASSIS
-D7901 /11.5_6.B8
/0.0_1.C5 /9.5_2.D3
Wiper front right (relay)
CHASSIS
/11.5_6.B8

D -M6501-RI D
-XK6501-RI -K6501-RI -XK6501-RI -X032f -X032m -XM6501-RIf -XM6501-RIm -XM6501-RIm -XM6501-RIf -X033m -X033f
secuted.
30 30 87 87 6500-2-87 8 8 0328 2 2 RD 53 31 BK 4 4 0338B 8 8 CHASSIS

M /11.5_6.A5
/9.5_2.C3
-XM6501-RIf -XM6501-RIm - -XM6501-RIm -XM6501-RIf -X032m -X032f -XD7901-1

31b
D7901-205-24V 0336B 1 1 YE 53a GN 3 3 0327 7 7 7901-111 11 C1:11 Dig In
/9.5_1.A5 -D7901
Front right wiper /0.0_1.C2
9937-0047C
Wiper front right feedback
-K6511
-XD7901-2 -XK6510-1 -XK6510-1
E 1,5A C2:10 10 7901-210 85 86 85 86 E
-D7901
/0.0_1.C5 /9.5_2.F3
Motor washer 2x front relay

9968-GN-B1C
-M6511
Front washer 2xfront (relay)

-XK6510-1 -K6511 -XK6510-1 -X033f -X033m -XM6511f -XM6511f
87 30 87 30 6510-1-30 1 1 0331 1 + - 2 0332A CHASSIS
/9.5_2.E3 M /9.5_1.D6
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Torkare & Spolare 2x fram DCG,DRG 9.5_2 1
Name
R
Konstr/Design

Wiring Wiper & Washer 2x front A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-XD7902-9m -XD7902-9f -XA3701f -XA3701m

1 1
2 2
3 3
4 4
C 5 5 C
6 6
7 7
8 8
9 9
10 10
11 11
12 12

13 13
14 14
15 15
16 16
D 17 17 D
18 18
secuted.
19 19
20 20
21 21
22 22
23 23
24 24
25 25
26 26
27 27
28 28
E 29 29 E
30 30
31 31
32 32
/9.4_0.D1
33 33
34 34
-D7902
-A3701Lights_Panel
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Manöverpanel belysning DCG,DRG 9.6_0 1
Name
R
Konstr/Design

Wiring Control panel Lights A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A D7902-501-24V 13101
/2.1.A4 A
D7902-501-24V 160049a
/9.6_1.C2
-S1600
INDICATOR -XS1600-49a
49a 49a -XD7902-5
8 C5:8 Dig In
-XS1600-R -X055m -X055f -D7902
R R 05510 10 10 7902-508 /0.0_2.C5
Sw. indicator left
-XS1600-L -X055m -X055f
L L 05511 11 11 7902-507 -XD7902-5
/9.6_1.C5 Dig In
7 C5:7
/9.7_1.A5 -D7902
/0.0_2.C5
Sw. indicator right
B B
-S1600
/9.6_1.B5
HEAD LIGHT -XS1600-56d -X055m -X055f -XD7902-5
56d 56d 05512 12 12 7902-509 9 C5:9 Dig In
-D7902
-XS1600-31 /0.0_2.C5
C 31 31 C
Sw. High Low Beam
/9.7_1.A5
D7902-501-24V 160031
/5.2_1.B1
D7902-501-24V 160049a
/9.6_1.A2

-X099m -XD7901-1
D See circuit 10 7901-143 43 C1:43 Dig In Start up D
-D7901
chassi
secuted.
/0.0_1.E2
Steplight
-E4340-LE
-XD7901-2 -X045f -X045m -XE4330-LE -XE4330-LE -X045m -X045f
PWM C2:30 30 7901-230A 3 3 0453A 1 1 2 2 0454B 4 4 9937-00205 CHASSIS
-D7901 /11.5_6.A8
/0.0_1.D5
Interior light, step light Interior light left
E E
-E4340-RI
-XE4330-RI -XE4330-RI
0453B 1 1 2 2 0454C
Interior light right

0454A CHASSIS
/9.7_2.B7
-X099m
7901-230B 9
See circuit
F chassi F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets belysning DCG,DRG 9.6_1 1
Name
R
Konstr/Design

Wiring Lights A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-E4050-LE
-XD7901-2 -X047f -X047m -X090Lf -X090Lm -XE4050-LEf -XE4050-LEf -X090Lm -X090Lf -X047m -X047f
6A C2:20 20 7901-220A 1 1 0471 5 5 0905 1 1 2 2 0906 6 6 0473 3 3 9937-00301A CHASSIS
-D7901 /11.5_6.C6
/0.0_1.C5
Working light reverse left Working light reverse left (FLT)
B -X099m
See circuit B
7901-220B 31
chassi
Reversing light rear left (FLT)
Tilt suspension
-E4050-RI
C -XD7901-2 -X047f -X047m -X090Rf -X090Rm -XE4050-RIf -XE4050-RIf -X090Rm -X090Rf -X047m -X047f C
6A C2:21 21 7901-221A 2 2 0472 5 5 0905 1 1 2 2 0906 6 6 0474 4 4 9937-00301B CHASSIS
-D7901 /11.5_6.C6
/0.0_1.C5
Working light reverse right Working light reverse right (FLT)
-X099m
See circuit
7901-221B 30
chassi
Reversing light rear right (FLT)
Tilt suspension
D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Belysning DCG,DRG 9.6_2 1
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XD7901-2 -X048f -X048m -X090Lf -X090Lm -X090Lm -X090Lf -X048m -X048f

6A C2:22 22 7901-222A 6 6 0486 1 1 2 2 0488 8 8 9937-00309
A -D7901 A
/0.0_1.D5
Extra worklight left A 7901-222B
0901 0902
-E4042-LE
-X099m -XE4042-LEf -XE4042-LEf
28
See circuit 1 1 2 2
chassi
Work light left Work light roof rear
Tilt suspension
B B
-E4042-LE
-XE4042-LEm -XE4042LEf -XE4042LEf -XE4042-LEm
1 40421 1 1 2 2 40422 2
Work light roof front
-E4042-LEA
-XE4042-LEm -XE4042-LEAf -XE4042-LEAf -XE4042-LEm
1 40421 -XSP4042-1 40421A 1 1 2 2 4042A -XSP4042-2 40422 2
Work light roof rear

C -E4042LEB C
-XE4042-LEBf -XE4042-LEBf
40421B 1 1 2 2 4042B


-XD7901-2 -X048f -X048m -X090Rf -X090Rm -X090Rm -X090Rf -X048m -X048f

6A C2:23 23 7901-223A 7 7 0487 1 1 2 2 0489 9 9 9937-00308 CHASSIS
-D7901 /11.5_6
/0.0_1.D5
Extra worklight right B
7901-223B
D D
0901 0902
secuted.
-E4042-RI
-X099m -XE4042-RIf -XE4042-RIf
29
See circuit 1 1 2 2
chassi
Work light right Work light roof rear
Tilt suspension
-E4042-RI
-XE4042-RIm -XE4042-RIf -XE4042-RIf -XE4042-RIm
1 40421 1 1 2 2 40422 2
E E
Work light roof front
-E4042RIA
-XE4042-RIm -XE4042-RIAf -XE4042-RIAf -XE4042-RIm
1 40421 -XSP4042-1 4042A 1 1 2 2 4042A -XSP4042-2 4042 2
-E4042RIB
-XE4042-RIBf -XE4042-RIBf
F 4042B 1 1 2 2 4042B F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Beslysning DCG,DRG 9.6_3 1
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XD7901-2 -X029f -X029m -X029m -X029f -X047f -X047m -X090Lf -X090Lm -X090Lm -X090Lf -X047m -X047f
6A C2:18 18 7901-218 3 3 0293 4 4 0294A -XSP13 0294B 5 5 0475 3 3 4 4 0476 6 6 9937-00302
-D7901
/0.0_1.C5
A A
Extra worklight left C 0903 0904
-X099m -E4042-1LE
CHASSIS
0294C 26 -XE4042-1f -XE4042-1f
1 1 2 2
Work light left
Tilt suspension
/11.5_6.C6
See circuit
chassi -E4042-1LEA
-XE4042-1m -XE4042-1LEAf -XE4042-1LEAf -XE4042-1m
1 40421 -XSP4042-1 40421A 1 1 2 2 40422A -XSP4042-2 40422 2
-X029m -X029m
3 4
B B
-E4042-1LEB
-XE4042-1LEBf -XE4042-1LEBf
0293 0294 40421B 1 1 2 2 40422B
-K3040
-E4042-1LEA
-XK3040 -XK3040 -XE4042-1m -XE4042-1Af -XE4042-1Am -XE4042-1LEAf -XE4042-1LEAf -XE4042-1Am -XE4042-1Af -XE4042-1m
86 86 85 85 3017-1-85 CHASSIS 1 40421 -XSP404-3 40421A 1 1 4042A1-XSP4042-1 4042A1A 1 1 2 2 4042A2A -XSP4042-2 4042A2 2 2 40422A -XSP404-4 40422 2
/11.5_6.B6
-XK3040 -XK3040 -E4042-1LEB
9968-BK:7 9968-BK-G1 30 30 87 87 -XE4042-1LEBf -XE4042-1LEBf
C /11.5_2.D5 4042A1B 1 1 2 2 4042A2B C
Work light 4x70W
-E4042-1RIA
-XE4042-1Bf -XE4042-1Bm -XE4042-1RIAf -XE4042-1RIAf -XE4042-1Bm -XE4042-1Bf
40421B 1 1 4042B1-XSP4042-1 4042B1A 1 1 2 2 4042B2A -XSP4042-2 4042B2 2 2 40422B

-E4042-1RIB
-XE4042-1RIBf -XE4042-1RIBf
4042B1B 1 1 2 2 4042B2B
D Used with relay K3040. Work light roof rear

D
secuted.
-E4042-1RI
-XD7901-2 -X047f -X047m -X090Rf -X090Rm -XE4042-1f -XE4042-1f -X090Rm -X090Rf -X047m -X047f
PWM 15A C2:36 36 7901-236A -XSP14 7901-236B 7 7 0477 3 3 0903 1 1 2 2 0904 4 4 0478 8 8 9937-00303
-D7901
/0.0_1.D5
Extra worklight right D Work light roof rear
Condenser roof
CHASSIS
-X099m
7901-236C 27
See circuit -E4042-1RIA
-XE4042-1m -XE4042-1RIAf -XE4042-1RIAf -XE4042-1m
1 40421 -XSP404-1 40421A 1 1 2 2 40422A -XSP404-2 40422 2
Work light right chassi
/11.5_6.B6
E Tilt suspension Work light roof rear E
-E4042-1RIB
-XE4040L-4f1 -XE4040L-4f1
40421B 1 1 2 2 40422B

D7901-C2p36 CHASSIS
/9.4_4.D5 /9.4_4.D5
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B -E4370 B
-X050f -X050m -XE4370-1 -XE4370-2
9968-BK:8 9968-BK-H1 6 6 0506 1 2
/11.5_2.D5
Search light
-X050f -X050m
CHASSIS 0507 7 7 0507
/11.5_2.C7
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-S1600
/9.6_1.B5
HORN -XS1600-31b -X056m -X056f -XD7902-5

31b 31b 0561 1 1 7902-510 10 C5:10 Dig In
A -D7902 A
/0.0_2.C5
/9.6_1.C5
Sw. horn
7902-309A D7902-309-24V
/7.5_1.B1
-S1490
B B
-XS8150-1f -XS8150-1m -XS1490f -XS1490f -XS8150-1m -XS8150-1f -XD7902-4
D7902-309-24V 7902-309 7 7 8150-17A 1 1 2 2 8150-115 15 15 7902-408 8 C4:8 Dig In
/11.5_5.A4 -D7902
/7.1_1A.C8
HORN
Sw. horn
8150-17C D7902-309-24V
/7.9_1.C2
8150-17D D7902-309-24V
/7.1_3.B2
8150-17B -XSP8150-17 8150-17E D7902-309-24V
/7.1_2.A2
8150-17F D7902-309-24V
/7.1_2.B2
8150-17G D7902-309-24V
/7.10_1.C2
C 8150-17H D7902-309-24V
/2.1.D3 C
-XD7901-2 -X032f -X032m -H8500-1

3A C2:12 12 7901-212A 3 3 0323 + +
-D7901
/0.0_1.C5 -
-

Horn
Horn
-X032m -X032f
0324 4 4 9937-00101 CHASSIS
/11.5_6.A5
D D
secuted.
7901-212B D7902-212-24V
/9.7_1.E1
-X099m
7901-212C 21 To chassi mounted horn
1
-K3016
-X029f -X029m
D7902-212-24V 7901-212B 7 7 0297 86 86 85 85 3016-85 CHASSIS
E /9.7_1.D4 /11.5_6.C8 E
-X029m -X029f -X032f -X032m

9968-RD:8 9968-RD-H1 30 30 87 87 3016-87 8 8 0298 5 5 0325
/11.5_2.B5
87A
-M8500-2
Compressor horn
Compressor horn
-X032m -X032f
+ + - - 0326A 6 6 9937-00102 CHASSIS
M /11.5_6.A5
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Signalhorn DCG,DRG 9.7_1 1
Name
R
Konstr/Design

Wiring Horn A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-H4282
ROT. BEACON
-XD7901-2 -X049f -X049m -X090Lf -X090Lm -XH4282+ -XH4282- -X090Lm -X090Lf
3A C2:13 13 7901-213A 9 9 0499 7 7 0907 + + - - 0908 8 8 0454A CHASSIS
-D7901 M /9.6_1.F7
/0.0_1.C5
Rotating beacon
B B
-X099m
7901-213B 22
See circuit
chassi
ROT. BEACON
TILT SUSPENSION
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Varningsljus DCG,DRG 9.7_2 1
Name
R
Konstr/Design

Wiring Beacon Light A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
VDO 24V
-X9002Am -X9002Bm -H9020R

-X9002Af 1/8 1/8 BK/WH-R +
24V_Mute 90022 2 2/8 2/8 -X9002Bf BK-R -
/9.8_2.B7
-X048f -X048m -X9002Af 3/8 3/8 3
Speaker Right
9968-BK:4 9968-BK-D1 1 1 0481 4 4/8 4/8 4
/11.5_2.C5
5/8 5/8 5
B 6/8 6/8 6 B
9968-RD:4 9968-RD-D1 2 2 0482 7 7/8 7/8
/11.5_2.A5 -H9020L
CHASSIS 9937-00304 3 3 0483 8 8/8 8/8
/11.5_6.B6 BK/WH-L +
BK-L -
Speaker Left
PK
-R9030 -XW9030m -XW9030f

24V -A9002
1 2 1 1 90301
150 Ohm 2 2 90302

Gnd
-W9030
1 2
C C
Antenna

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Radio DCG,DRG 9.8_1 1
Name
R
Konstr/Design

Wiring Radio A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1047
C
A
-XS1047 -XS1047-4 -X060m -X060f -X035m -X035f -X045f -X045m
D7902-401-24V 7902-401B 3 3 4 4 06011 11 11 0353 3 3 0455 5 5 90022 24V_Mute
/7.9_1.A2 /9.8_1.B3
10473 6 6 1 1
Mute
B B
7902-302I D7902-302-0VRef
/7.9_1.B8
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets strömställare tystnad DCG,DRG 9.8_2 1
Name
R
Konstr/Design

Wiring Mute Switch A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
12V 0464 -X038f -X038m -X083L-12

/11.5_2.E7
3 3 0383 1
B 0329B -X032f -X032m -X083R-12 B

9 9 0329 1
-U9010
-XU9010.1 -XU9010.4
9968-GN:3 9968-GN-C1 24V 24V 12V 12V 0329A
/11.5_2.E5 12V -X033f -X033m -X083R-GND-12
-XU9010.3 9937-0016B 9 9 0339 1
GND GND 9937-0016A
-XU9010.2
24V COM COM 9937-00106 CHASSIS
/11.5_6.A5
C Converter12/24V C
-X038f -X038m -X083L-GND-12

4 4 1
0384 0384

D D
secuted.
-X031f -X031m -X083R-24

9968-BK:6 9968-BK-F1A 9 9 0319 1
/11.5_2.D7
-X038f -X038m -X083L-24

9968-BK-F1B 5 5 0385 1
E E
-X038f -X038m -X083R-GND-24
6 6 1
CHASSIS 0466B 0386

/11.5_2.D7
-X038f -X038m -X083L-GND-24

0466C 7 7 0387 1
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Omvandlare 12/24V DCG,DRG 9.8_3 1
Name
R
Konstr/Design

Wiring Converter 12/24V A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
-X091Lf -X091Lm
0703A 1 1 orange(out)
0702 2 2 yellow(in)
-XSP0703 0703B 3 3 brown(down)
0704 4 4 green(up) LEFT
099-18A 5 5 red(heater + )
0708A 6 6 black(heater -)
MIRROR
-XS1230-1m -XS1230-1f -X099-18
C
Orange 1 1 1 099-18 -XSP099-181
C
+
81A LH left/right (white) 2 2
82A Left Common (Lt Blue) 3 3 0708 -XSP0708
88A LH up/down (Yellow) 4 4
88B RH up/down (yellow/black) 5 5 0706 -XSP0706

-X091Rf -X091Rm
0706A 1 1 orange(out)
82B Right Common (blue/black) 6 6 0707 2 2 yellow(in)
0703
0706B 3 3 green(down)
81B RH left/right (white/black) 0705 4 4 brown(up) RIGHT
7 7
D 099-18B 5 5 red(heater + ) MIRROR D
-S1230 Black 8 8 0708B 6 6 black(heater -)
Mirror Mini Joystick -
12301
12302
12303
12304
12305
12306
12307
12308
-X057m
4
3
5
6
7
8
1
E E
-X057f
1
2
3
4
5
6
7
8
0571
0572
0573
0574
0575
0576
0577
0578
9968-BK:6 9968-BK-F2
/11.5_2.C5

-X070m -X070f
1 1
2 2
F 3 3 F
secuted.
4 4
5 5
6 6
7 7
8 8
CHASSIS 9937-00406
/11.5_6.B8
G G
H H

Sign.
Ruta
Krets ställbara Backspeglar DCG,DRG 9.9_1 1
E³ DRAWING
Design change
Sq.
Name
R

Wiring adjustable Rear Mirrors A55040.0100 04
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8
A A
-S1046
C
A
-XS1046 -XS1046 -XS8150-4m -XS8150-4f -XD7902-3
D7902-309-24V 8150-47J 3 3 4 4 8150-414 14 14 7902-320 20 C3:20 Dig In
/1.3_1.B2 -D7902
1 1 8150-42J /0.0_2.E3
Rear window and mirror heater Sw. window heater & mirror heater
B B
D7902-302-0VRef
/1.3_1.B7
C C
-K8881
CHASSIS
-XD7901-2 -X029f -X029m
0,5A C2:6 6 7901-206 5 5 3991-86 86 86 85 85 3991-85 CHASSIS
-D7901 /11.5_6.B8
/0.0_1.B5
Rear window heater
-XE8881-1 -E8881 -XE8881-2
9968-GN:1 9968-GN-A1 30 30 87 87 3991-87 1 1 2 2 9937-00402 CHASSIS
/11.5_2.D5 /11.5_6.C8
Heated window Window heater


K8881-87
D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Värme Bakruta & Backspeglar DCG,DRG 9.9_2 1
Name
R
Konstr/Design

Wiring Heat Rear Window & Mirrors A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XR8020-2LEf
-X099-18 09918A 1 1/2
1 09918 -XSP071-1 2 2/2
9937-0502B
B -R8020-2LE B
-XR8020-2RIf
-X9937-005:2 09918B 1 1/2
1 9937-00502 -XSP071-2 9937-0502A 2 2/2
-X9937-005
-R8020-2RI
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120503 A55032.0900 Krets Värme Backspeglar DCG,DRG 9.9_3 1
Name
R
Konstr/Design

Wiring Heat Mirrors A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XD7902-4
7902-411 11 C4:11 Dig In
-D7902
-S1751 /0.0_2.A5
A Cab moving left/reverse
D7902-309-24V 8150-47E B
/8.2_3.A2 C
-XS1751 -XS8150-4m -XS8150-4f
D7902-309-24V 8150-47D -XS1751 4 4 8150-46 6 6
/9.10_2.C2 3 3 -XD7902-4
2 2 8150-48 8 8 7902-412 12 C4:12 Dig In
-XS8150-4f -XS8150-4m -D7902
D7902-310-24V 7902-310C 1 1 8150-41A 6 6 1 1 8150-42D /0.0_2.A5
/7.0_2.A1
Cab moving Cab moving right/forward
D7902-310-24V 8150-41B
/8.2_3.B2
B B
D7902-302-0VRef
/9.10_2.C8
8150-42E D7902-302-0VRef
/8.2_3.B8
-XD7902-4
7902-414 14 C4:14 Dig In
-D7902
-S1990-6/S1010/1690/1750 /0.0_2.A5
A Option 6
B
C Cabtilt up
D7902-309-24V 8150-47G -XS1990-6 -XS8150-4m -XS8150-4f
/7.5_3.B2 -XS1990-6 Turible seat C.C.W
4 4 8150-410 10 10
C D7902-309-24V 8150-47F 3 3 -XD7902-4 C
/8.2_3.A2 2 2 8150-411 11 11 7902-415 15 C4:15 Dig In
-D7902
D7902-310-24V 8150-41C 6 6 1 1 8150-42F /0.0_2.B5
/8.2_3.B2
Option 6/Cab tilt/Turnable seat/Up-Down Option 6
Cab tilt down
Turnible seat C.W
D7902-302-0VRef
/8.2_3.B8
8150-42G D7902-302-0VRef
/7.5_3.B7
D D
secuted.
-X099m -XD7901-1
16 7901-116 16 C1:16 Dig In
-D7901
-X099m /0.0_1.C2
D7901-205-24V 7901-205C 23
See circuit
/5.2_2.E4 chassi Cab in upper position (tilt)
-X099m -XD7901-1
See circuit 17 7901-131 31 C1:31 Dig In / Ana In
-D7901
/0.0_1.D2
chassi
Cab lower pos (tilt)
-X099m -XD7901-1
25 7901-132 32 C1:32 Dig In / Ana In
E -D7901 E
/0.0_1.D2
Cab moving damp sensor

-X099m
24 9937-00202 CHASSIS
/11.5_6.A8
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Hytt Förflyttning DCG,DRG 9.10_1 1
Name
R
Konstr/Design

Wiring Cab Moving A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1260
C
A
3 4
6 1
Diffrential lock
-S1990-4/S1010-2
B C B
A
-XS1990-4 -XS1990-4 -XS8150-4m -XS8150-4f -XD7902-3
D7902-309-24V 8150-47C 3 3 4 4 8150-45 5 5 7902-317 17 C3:17 Dig In
/8.2_2.B2 -D7902
1 1 8150-42C /0.0_2.D3
1990-436
Option 4 Aut cab tilt on/off
Diffrential Lock
Aut. cab tilt on/off
D7902-302-0VRef
/8.2_2.C8
D7902-309-24V 8150-47D 6
/9.10_1.B2
8150-42D D7902-302-0VRef
/9.10_1.B7
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Hytt Förflyttning DCG,DRG 9.10_2 1
Name
R
Konstr/Design

Wiring Cab Moving A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-S2500
A -XS2500-1 -XS2500-2 -XD7902-5 A

D7902-801-24V 7902-801 1 1 2 2 7902-511 11 C5:11 Dig In
/11.5_5.A3 -D7902
/0.0_2.C5
Operating switch Operating switch
B B
-D7901
-XD7901:C3
09815 09815B 24V -XD7901:C4
-XD7901-2 GND W09831C CHASSIS
Ground /11.5_6.E4
9968-RD:2 9968-RD-B1 38 C2:38
/11.5_2.A5 CPU POWER
/0.0_1.E5
CPU Power
C C
-D7902

KPU
-X034f -X034m -X060f -X060m -XD7902-1 Power -XD7902-1 -X060m -X060f -X034m -X034f
9968-BK:1 9968-BK-A1 5 5 0605 5 5 7902-101A 7902-101 1 C1:1 Main power Ground C1:2 2 7902-102 4 4 0604 4 4 9937-00201 CHASSIS
/11.5_2.B5 /11.5_6.A8
-XSP7
9968-BK:1 7902-101B /0.0_2.A3
D /11.6_1.B5 D
9968-BK:1 7902-101C
secuted.
/2.1.E3
-X050f
E 7901-211 8 E
-XD7901-2 -X099m
See circuit
1,5A C2:11 11 7901-211A 13

-D7901
/0.0_1.C5 chassi
Main relay ignition K3150
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets el-distribution DCG,DRG 11.5_1 1
Name
R
Konstr/Design

Wiring distribution of electricity A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-F9968-RD 9968-RD:1
-XF9968-RD-AB /11.5_3.D1
5A A:1 9968-RD-A1
1:1 A:1 /9.2_1.A3
1:2 A:2 A:2 RD,RD 9968-RD:1
-F9968-RD /9.2_1.D3
A 1 Startup / Inter lock device 15A B:1 9968-RD-B1 9968-RD:2
A
2:1 B:1 /11.5_1.C1
2 KCU, D7901 2:2 B:2
3
4 Radio 3:1 C:1
5 Service / RMI 3:2 C:2
6 Customer 5A D:1 9968-RD-D1 9968-RD:4
7 4:1 D:1 /9.8_1.B1
4:2 D:2
8 Compressor horn
10A E:1 9968-RD-E1
/11.5_2.B4 5:1 E:1
5:2 E:2
10A F:1 9968-RD-F1
6:1 F:1
6:2 F:2
-X039f
5A
7:1 G:1 0393 3 9968-BK-B:1
7:2 G:2 /8.2_4.D7
B 10A H:1 9968-RD-H1 9968-RD:8
B
8:1 H:1 /9.7_1.E1 0394 4
Moved to RD-3:1 when 8:2 H:2
X098-30 BATTERY /11.5_2.B1

5
battery power to converter 09830A
-XF9968:RDX:RD CHASSIS
/8.2_4.D7
is wanted.
-F9968-BK 9968-BK:1
-XF9968-BK-AB /11.5_1.D1
A:1 9968-BK-A1 9937-0036A CHASSIS
1:1
10A
A:1
/11.5_6.B6
/9.2_1.B3
1:2 A:2 A:2 BU,GN 9968-BK:1
-F9968-BK /9.2_1.D3
1 KPU, D7900-4 10A B:1 9968-BK-B1
2:1 B:1
2 Service / RMI 2:2 B:2 0507 CHASSIS
3 Display/Camera system
/9.6_5.C3
9968-BK-31 3:1 10A -X050f
4 Radio 3:1 C:1
5 Seat functions 9968-BK-32 3:2 3:2 C:2 0395 5
C 6 Customer 5A D:1 9968-BK-D1 9968-BK:4 C
7 Work light opt. 4:1 D:1 /9.8_1.B1 4
-XF9968-BK-5:1 4:2 D:2
8 Opt Search light
9968-BK-51 5:1 10A(25A) E:1 9968-BK-E1 9968-BK:5 3
/11.5_2.D4 5:1 E:1 /9.3_1.A1
5:2 E:2
10A F:1 9968-BK-F1
6:1 F:1 -X046f
6:2 F:2 F:2 9968-BK-F2 9968-BK:6
/9.9_1.E5 2
15A G:1 9968-BK-G1 9968-BK:7
/9.6_4.C1
7:1 G:1 9968-BK-F1A 9968-BK:6

9968-BK-32
/9.8_3.D2
7:2 G:2
1
10A H:1 9968-BK-H1 9968-BK:8
8:1 H:1 /9.6_5.B3 4
8:2 H:2
3
Dedicated for
-X098-15-1 IGNITION /11.5_2.C1 use of customer
-XF9968:BK X:BK
09815A 0465 5
D X098-15 D
09815B 09815
/11.5_1.B1 0466A 6
secuted.
09815C 098-15
/11.5_2.F3
-X098-15-3 -F9968-GN
-XF9968-GN-AB -XF9968-GN-AB 0466B CHASSIS
1:1 25A A:1 9968-GN-A1 9968-GN:1 /9.8_3.E2
1:1 A:1 /9.9_2.D2
-F9968-GN 1:2 A:2
-XF9968-GN-AB -XF9968-GN-AB
1 Rear window heater 2:1 B:1 9968-GN-B1 9968-GN:2
10A
2 Double front wipers 2:1 B:1 /9.5_2.B1
3 Converter 12/24V 2:2 B:2
4 3:1 10A C:1 9968-GN-C1 9968-GN:3 9937-0036B CHASSIS
5 Turnible seat 30 deg 3:1 C:1 /9.8_3.C2 /11.5_6.B6
3:2 C:2
6 Motor left armrest
7 4:1 D:1
8 4:2 D:2 -XF9968-GN-EF
/11.5_2.F4 E:1 9968-GN-E1 9968-GN:5
E 5:1
5A
E:1 /9.3_5.B4 E
5:2 E:2 -XF9968-GN-EF
F:1
5A 3461-330 9968-GN:6
6:1 F:1 /9.3_9.C1
6:2 F:2
7:1 G:1
1
7:2 G:2
12V
/9.8_3.B2
8:1 H:1
8:2 H:2
Option/ /11.5_2.E1
-XF9968:GN X:GN
098-15 Ignition
/11.5_2.D4
F F

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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets el-distribution DCG,DRG 11.5_2 1
Name
R
Konstr/Design

Wiring distribution of electricity A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-S1500
A -X056f -X056m -XS1500-1 -XS1500-1 -X056m -X056f -X060m -X060f -X035m -X035f -XD7901-1 A
3 3 0563 1 1 2 2 0564 4 4 0609 9 9 0351 1 1 7901-149 49 C1:49 Dig In Start up
-D7901
/0.0_1.E2
3 4
Ignition key
24V-D7900-1/10:9 3461-386
1
Switch ignition key /9.3_9.D1
ONLY IF MOTORIZED LEFT ARMREST
B B
-X037f -X037m -XS2660-LE-1 -S2660-LE -XS2660LE-2 -X037m -X037f -XD7901-1

0357B 1 1 0371 1 1 2 2 0372 2 2 7901-146 46 C1:46 Dig In Start up
-D7901
/0.0_1.E2
Braking cab door left
Door switch left
-X036f -X036m -XS2660RI-1 -S2660-RI -XS2660RI-2 -X036m -X036f -XD7901-1

0357A 1 1 0361 1 1 2 2 0362 2 2 7901-145 45 C1:45 Dig In Start up
-D7901
/0.0_1.E2
Braking cab door right
Door switch right
C C
0613B
Silicon panel

Hazard
-X035f -X035m -X061m -X061f -XD7902-1 -XD7902-1 -X061f -X061m -X035m -X035f -XD7901-1
9968-RD:1 9968-RD-A1 7 7 0357 3 3 0613 -XSP2 0613A 12 C1:12 Supply +30 In(Sw. Hazard) C1:11 11 7902-111 4 4 0614 8 8 7901-147 47 C1:47 Dig In Start up
/11.5_2.A5 -D7902 -D7902 -D7901
/0.0_2.A3 /0.0_2.A3 /0.0_1.E2
Supply +30 Sw. hazard S1090 Startup hazard
D D
secuted.
Interior light
0613C
-XD7902-1 -X061f -X061m -X035m -X035f -XD7901-1

In (Sw Inside light) C1:10 10 7902-110 5 5 0615 9 9 7901-148 48 C1:48 Dig In Start up
-D7902 -D7901
/0.0_2.A3 /0.0_1.E2
Sw interior light S1160 Interior light
9968-RD:1
/9.3_1.E3
E E
F F

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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets el-distribution Startup DCG,DRG 11.5_3 1
Name
R
Konstr/Design

Wiring distribution of electricity Star A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X035f -X035m -X061m -X061f -X056f -X056m -XS1440-2m -XS1440-2s -S1440-2 -XS1440-2s -XS1440-2m
5 5 0611 1 1 0565 5 5 14401 1 1 1 2 2 2 558B CHASSIS
/5.2_1.C7
B El. main switch Jord B
C C
CPU Power out -K3750

-X029m -XK3750 -XK3750
D7901-235-24V 6 0296 86 86 85 85 3750-85 CHASSIS
/11.6_1.C4 /11.5_6.B8
-X029f -X029m
9 9 30 87
0355 0299 30 87 3750-87 CHASSIS

/11.5_6.B8
Relay main switch

(holding circuit)
D D
secuted.
85 på spole huvudrelä i ram

-X099m
See circuit 14 09914
chassi
E E
F F

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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets el-distribution el. huvudbrytare DCG,DRG 11.5_4 1
Name
R
Konstr/Design

Wiring distribution of electricity el. A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XD7902-3
0,5A C3:9 9 7902-309 D7902-309-24V
-D7902 /9.7_1.B2
/7.1_1A.B2
24V Supply Island 1
-XD7902-8
0,5A C8:1 1 7902-801 D7902-801-24V
A -D7902 /11.5_1.A1 A
/0.0_2.D5
24V Supply Island 2
-XD7902-4
0,5A C4:1 1 7902-401 D7902-401-24V
-D7902 /8.2_1.B1
/0.0_2.E3
24V Supply Island 3 -XD7902-3
D7902-302-0VRef 7902-302A 2 C3:2 0V Ref
-XD7902-5 /7.1_1A.C7 -D7902
0,5A C5:1 1 7902-501 D7902-501-24V /0.0_2.B3
-D7902 /2.1.B2
/0.0_2.C5 Lever/Joystick
24V Supply Island 4 -XD7902-2
D7902-202-0VRef 7902-202A 2 C2:2 0V Ref
-XD7901-2 /9.3_6.B7 -D7902
0,5A C2:5 5 7901-205 D7901-205-24V /0.0_2.B3
-D7901 /5.2_2.D2
/0.0_1.B5 Motors Console/Seat
B 24V Supply Lever/Micro steering B
-XD7901-1
-XD7902-3 0V Ref
D7901-109-0VRef 7901-109 9 C1:9
PWM 1,5A C3:10 10 7902-310A D7902-310-24V /9.4_1.A1 -D7901
-D7902 /7.5_1.B1 /0.0_1.B2
/0.0_2.C3
Ref Sensors
Lever/Joystick
-XD7902-8
5V Ref C8:4 4 7902-804 D7902-804-5VRef
C -D7902 /1.1_1.C2 C
/0.0_2.D5
Supply pedals
-XD7902-3
5V Ref C3:1 1 7902-301A D7902-301-5VRef
-D7902 /7.1_1A.C2
/0.0_2.B3
Lever/Joystick
-X7950

Sensor supply 5V C1:8 8 7950-08 D7902-804-5VRef

-D7950 /8.1_1.B2
/11.6_1.B2
Toggle wheel
D D
secuted.
-XD7901-1
5V Ref C1:8 8 7901-108 D7901-108-5VRef
-D7901 /9.4_2.A1
/0.0_1.B2
Ref Air distr. / heat valve
E E
F F

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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets el-distribution Ref DCG,DRG 11.5_5 1
Name
R
Konstr/Design

Wiring distribution of electricity Ref A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
9937-00108 CHASSIS 9937-00208 CHASSIS

/5.2_1.B8 /7.9_2.B7
9937-00107 CHASSIS 9937-00207 CHASSIS
/11.6_1.F6 /9.4_2.D4
A 9937-00106 CHASSIS 9937-00206 CHASSIS
CHASSIS CHASSIS CHASSIS /9.8_3.C4 /9.5_1.C8 A
/9.3_1.B6 /9.3_1.B7 /9.3_1.B8 9937-00105 CHASSIS 9937-00205 CHASSIS
/9.5_2.D7 /9.6_1.E7
9937-00104 CHASSIS 9937-00204 CHASSIS
/9.4_2.C3 /9.3_1.C8
9937-00103 CHASSIS 9937-00203 CHASSIS
/9.5_1.D7 /5.2_2.D12
-X9937-025 -X9937-026 -X9937-027 9937-00102 CHASSIS 9937-00202 CHASSIS
/9.7_1.F8 /9.10_1.E7
9937-00101 CHASSIS 9937-00201 CHASSIS
/9.7_1.D7 /11.5_1.D8
-X9937-001 -X9937-002
9937-00408 CHASSIS
/9.4_5.E2
9937-00308 CHASSIS 9937-0047A CHASSIS
B /9.6_3.D8 /9.5_2.A4 B
3017-1-85 CHASSIS 9937-0047B CHASSIS
/9.6_4.C3 /9.5_2.C4
9937-0036A CHASSIS 9937-0047C CHASSIS
/11.5_2.C8 /9.5_2.C3
9937-0036B CHASSIS 9937-00406 CHASSIS
/11.5_2.E7 /9.9_1.G5
9937-00305 CHASSIS 3750-85 CHASSIS
/9.3_4.B8 /11.5_4.C6
/9.8_1.B1 /11.5_4.D6
/9.6_4.E8 /9.9_2.C5
9937-00302 CHASSIS 9937-00403 CHASSIS
/9.6_4.A8 /9.3_2.C7
9937-00301A CHASSIS 9937-00402 CHASSIS
/9.6_2.B8 /9.9_2.D7
9937-00301B CHASSIS 3016-85 CHASSIS
/9.6_2.C8 /9.7_1.E6
C -X9937-003 -X9937-004 C

3460-85 CHASSIS
/9.3_5.C4
9937-00508 CHASSIS
/9.3_5.D5
D D
secuted.
-X9937-005
-X9937-006
W09831A
E W09831B -X9937-000 Chassi cab E

W09831C CHASSIS
/11.5_1.B8
-098-31
F X098-31 F

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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets el-distribution Gnd DCG,DRG 11.5_6 1
Name
R
Konstr/Design

Wiring distribution of electricity Gnd A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X099m
0391 30 19
0392 20
See circuit
chassi
A A
7902-604 30
7902-603 -X039f -XD7901-1
CAN+ 1 7901-126 30 26 C1:26
/8.2_4.D7 + CAN
CAN- 2 7901-127 27 C1:27 CAN OPT.
/8.2_4.D7 -
-D7950
-XD7901-1
C2:1 Device
-X7950 -X060m -X060f -X034m -X034f 7901-103 30 3 C1:3
VBUS L+
C2:2 C1:3 3 30 0601 1 1 30 0341 1 1 30 7901-106 7901-104 4 C1:4 Normal CAN L
Data - Normal+ L-
C2:3 CAN C1:4 4 0602 2 2 0342 2 2 7901-107
Data + Normal-
C2:4 -D7901
Gnd -XD7901-1
30 6 C1:6 /0.0_1.B2
B C2:5 Host C1:6 6 7902-603 R+ B
Gnd Red+ 7 C1:7 RED CAN R
C2:6 CAN C1:7 7 7902-604 R-
Data- Red-
C2:7
Data+ C1:2 2 7902-101B 9968-BK:1
C2:8 Ign.Pwr /11.5_1.D2 CAN
VBUS C1:9 9 0603 3 3 0343 3 3 7902-135A
CAN Shield CPU Pwr
C1:1 1
/11.5_5.D1 5V Ref Gnd
5V Dig In
/8.1_1.B8 5V Dig In
7902-135B -XD7901-2
/8.1_1.B8 5V Dig In -XSP15 Dig Out CPU Power
7902-135 35 C2:35
KID 7902-135C -D7901
/0.0_1.D5
-X029f
C 6 D7901-235-24V
C
/11.5_4.C1 -X099m
30 2
1
7902-135E 6
See circuit
chassi
0347A 30 4
0346A 3
-X050f
7902-135D 9
30 0347B 2
D D
0346B 1
secuted.
-XD7902-1
7902-603 30 3 C1:3
L+
7902-604 4 C1:4 CAN
L- -D7902
E -X060f -X060m /0.0_2.A3 E
8 8 0348 8 8 7902-107 7 C1:7
+ CPU
-X034f -X034m -X060f -X060m

6 6 30 0346 6 6 7902-105 30 5 C1:5 CAN-BUS
R+
7 7 0347 7 7 7902-106 6 C1:6 CAN
R-
-X060m -X060f -X035m -X035f

06010 10 10 0352 2 2 9937-00107 CHASSIS
/11.5_6.A5
F F

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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 KretsCAN-BUS DCG,DRG 11.6_1 1
Name
R
Konstr/Design

Wiring CAN-BUS A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-X7950Bm -X7950Bf
1 020A1 1
2 020A2 2
3 30 020A3 3
4 020A4 4
6 30 020A6 6
7 020A7 7
8 020A8 8
C 9 020A9 9 C
10 020A10 10
11 020A11 11
-X7950Am -X7950Af
1 020B1 1
2 020B2 2
3 30 020B3 3
4 020B4 4
6 30 020B6 6
7 020B7 7
8 020B8 8
D 9 020B9 9 D
secuted.
10 020B10 10
11 020B11 11
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn RSO 120416 A55032.0900 Krets Display förlängning DCG,DRG 11.6_2 1
Name
R
Konstr/Design
Wiring Display extenstion A55040.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
C DRG450 C
Kretsar / Wiring

D D
secuted.
Attachment E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn MLG 120601 A56402.0100 Kretsar Agg DRG450 DRG450 0
Name
2 Added Combi 130273 MLG 130703 H.Grp:
R
Konstr/Design

Wiring Diagram DRG A56400.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
1
-D7911
B B
1:1 /7.9_4.B2 Elme front legs down Digital Output 1.5A 2:1 Digital Output 6A
1:2 /11.5_1.B4 Power Supply 2:2 Digital Output 6A
1:3 /11.6_1.C7 CAN 2:3 /9.6_5.B1 Work light attachment left opt Digital Output 6A
1:4 See pin K1:3 2:4 /9.6_5.C1 Work light attachment right opt Digital Output 6A
1:5 Analog Input 2:5 /9.6_4.B1 Work light attachment left Digital Output 6A
1:6 See pin K1:3 2:6 /9.6_4.C1 Work light attachment right Digital Output 6A
1:7 See pin K1:3 2:7 /7.6_1.D8 Rotation stop Dig/Ana Input
1:8 /7.9_19.B1 5V Analogue Ref 2:8 /7.5_1.E8 Damp spreading Dig/Ana Input
1:9 /7.9_19.B1 0V Analogue Ref 2:9 /7.5_1.E8 Damp spreading Dig/Ana Input
1:10 /11.5_3.A1 Ground Valves Digital Output NPN 2:10 /7.5_3.C8 30 stop left Dig/Ana Input
1:11 /7.9_4.B2 ELME rear legs down Digital Output 1.5A 2:11 /7.5_3.D8 30 stop right Dig/Ana Input
1:12 /7.9_2.B1 Unlocked twistlock (RD) Digital Out/In 1.5A 2:12 Dig/Ana/Freq Input
1:13 /7.9_2.C1 Locked twistlock (GN) Digital Out/In 1.5A 2:13 /7.9_1.C8 Alignment rear Dig/Ana Input
C 1:14 /7.9_5.B1 Lock twistlock Digital Output 1.5A 2:14 /7.9_1.F8 Alignment rear Dig/Ana Input C
1:15 /7.9_5.A1 Unlock twistlock Digital Output 1.5A 2:15 Dig/Ana Input
KFU7970, Main K1 connector pinout

1:16 /7.9_2.B1 Alignment (YE) Digital Out/In 1.5A 2:16 /7.9_1.B8 Alignment front Dig/Ana Input
1:17 /7.9_4.D2 Valve overhight up / Elme unclamp Digital Output 1.5A 1 2:17 /7.9_1.D8 Alignment front Dig/Ana Input
1:18 /7.9_4.D2 Valve overhight down / Elme clamp Digital Output 1.5A 2:18 /7.9_1.B8 Unlocked twistlock Dig/Ana Input
1:19 Elme front legs down Digital Out/In 1.5A 2:19 /7.9_1.E8 Unlocked twistlock Dig/Ana Input
1:20 /7.9_2.D1 Over Height leg upper pos Digital Out/In 1.5A 2:20 /9.14_1.D8 Central Lube feedback sensor Dig/Ana/Freq Input
1
1:21 /7.8_1.D1 Unlock levelling Digital Output 1.5A 2:21 /7.9_1.C8 Locked twistlock Dig/Ana/Freq Input
1:22 /7.8_1.E1 Unlock levelling Digital Output 1.5A 1 2:22 /9.14_1.B1 Central lubrication Attach pump 24V 2A Digital Output 6A
1:23 /7.7_1.D2 Unlock tilt Digital Output 1.5A

2:23 /7.9_1.E8 Locked twistlock Dig/Ana Input

1:24 /7.7_1.E2 Unlock tilt Digital Output 1.5A 2:24 /7.9_4.B7 Sensor overhight left leg upper pos / Elme clamped left Ana/Temp/Rheo Input
1:25 Digital Input D+ 2:25 /7.9_4.C7 Sensor overhight right leg upper pos / Elme clamped right Ana/Temp/Rheo Input
1:26 /7.9_4.C7 Elme first foot seated/Align. RR OHC Digital Out/In 1.5A 2:26 Digital Output 0.5A
1:27 /7.6_1.A1 Rotation c.w PWM Output Group1 2:27 Digital Output 0.5A
1:28 /7.6_1.C1 Rotation c.c.w PWM Output Group1 2:28 /7.9_4.E7 Sensor Alignment front left OHC Dig/Ana/Freq Input
1:29 /7.5_1.A1 Spreading out 20-40 PWM Output Group1 2:29 /7.9_4.E7 External attachment connected 1 Ana/Temp/Rheo Input
D 1:30 /7.9_4.A7 Valves ground group 2 Digital Output NPN 2:30 /7.9_4.C2 Elme rear legs up Digital Output 1.5A D
secuted.
1:31 See pin K1:3 2:31 /7.9_4.C2 ELME front legs up Digital Output 1.5A
1:32 See pin K1:3 2:32 /11.5_2.A1 Power supply sensors left Digital Output 0.5A
1:33 /7.5_1.B1 Spreading in 40-20 PWM Output Group1 2:33 /11.5_2.C1 Power supply sensors right Digital Output 0.5A
1:34 /7.5_1.C1 Spreading out 20-40 right DigOut 6A 2:34 /7.9_4.A2 Power Elme Digital Output 6A
1:35 /7.5_1.C1 Spreading in 40-20 right PWM Output Group1 2:35 /7.9_2.C8 Ground Indication light PWM 15A
1:36 /7.7_1.B2 Tilt in PWM Output Group1 2:36 Digital Output 6A
1 1:37 /7.7_1.A2 Tilt out PWM Output Group1 2:37 PWM 15A
1:38 /7.4_1.A1 Sideshift left PWM Output Group1 2:38 Digital Output 6A
1:39 /7.4_1.B1 Sideshift right PWM Output Group1
1:40 /7.8_1.A1 Levelling c.c.w PWM Output Group1 24V See pin K1:2
1 GND See pin K1:2
1:41 /7.8_1.B1 Levelling c.w PWM Output Group1
1:42 /7.9_4.D7 Elme all feet seated/Align. RL OHC Digital Out/In 1.5A
1:43 /7.5_2.B1 Buzzer auto spreading Digital Output 3A
E 1:44 Digital Output 3A E
1:45 /9.6_3.B1 Rotating warninglight Digital Output 3A
1:46 /7.9_4.D7 Sensor Alignment front right OHC Digital Out/In 6A
1:47 /7.9_7.A1 Valve rear leg up right (Combi) PWM Output Group2
1:48 /7.9_7.B1 Valve rear leg down right (Combi) PWM Output Group2
1:49 External attchment connected 2 Digital Out/In 6A
1:50 Ground Indication light PWM Output Group2
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn MLG 120601 A56402.0100 Kretsar Agg DRG450 DRG450 0.0_1
Name
R
Konstr/Design

Wiring Cross References std A56400.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-D7912
1:1 /7.9_8.C1 Valve Driving position left Digital Output 1.5A 2:1 Digital Output 6A
1:2 /11.5_1.C4 CPU power startup from KCU Power Supply 2:2 Digital Output 6A
1:3 /11.6_1.D7 CAN 2:3 /9.6_5.E1 Work light left front leg OPT Digital Output 6A
1:4 See pin K1:3 2:4 /9.6_5.F1 Work light right front leg OPT Digital Output 6A
1:5 Analog Input 2:5 /9.6_4.D1 Work light left rear leg STD Digital Output 6A
B 1:6 See pin K1:3 2:6 /9.6_4.E1 Work light right rear leg STD Digital Output 6A B
1:7 See pin K1:3 2:7 /7.9_10.A8 Sensor driving pos. Left Dig/Ana Input
1:8 5V sensor supply 5V Analogue Ref 2:8 /7.9_11.A8 Sensor driving pos. Right Dig/Ana Input
1:9 0V sensor supply 0V Analogue Ref 2:9 /7.9_10.C8 Sensor front knee left Dig/Ana Input
1:10 /7.9_6.A8 Valves ground Left side legs Digital Output NPN 2:10 /7.9_10.D8 Sensor front leg left Dig/Ana Input
1:11 /7.9_8.E1 Valve Driving position right Digital Output 1.5A 2:11 /7.9_10.C8 Sensor clamp front leg left Dig/Ana Input
1:12 /7.9_3.A1 Indication light alignment left front Digital Out/In 1.5A 2:12 /7.9_10.B8 Sensor alignment front leg left Dig/Ana/Freq Input
1:13 /7.9_3.B1 Indication light alignment right front Digital Out/In 1.5A 2:13 /7.9_12.C8 Sensor front knee right Dig/Ana Input
1:14 Digital Output 1.5A 2:14 /7.9_12.D8 Sensor front leg right Dig/Ana Input
1:15 Digital Output 1.5A 2:15 /7.9_12.C8 Sensor clamp front leg right Dig/Ana Input

1:16 /7.9_3.C1 Indication light alignment left rear Digital Out/In 1.5A 2:16 /7.9_12.B8 Sensor alignment front leg right Dig/Ana Input
1:17 Digital Output 1.5A 2:17 /7.9_9.C8 Sensor rear knee left Dig/Ana Input
1:18 Digital Output 1.5A 2:18 /7.9_9.D8 Sensor rear leg left Dig/Ana Input
1:19 /7.9_3.D1 Indication light alignment right rear Digital Out/In 1.5A 2:19 /7.9_9.C8 Sensor clamp rear leg left Dig/Ana Input
1:20 /7.9_3.C1 Indication light front legs upper pos Digital Out/In 1.5A 2:20 /7.9_9.B8 Sensor alignment rear leg left Dig/Ana/Freq Input
C /7.9_8.A1 Valve Clamp in left Digital Output 1.5A
C
1:21 2:21 /7.9_11.C8 Sensor rear knee right Dig/Ana/Freq Input
1:22 /7.9_8.B1 Valve Clamp out left Digital Output 1.5A 2:22 Digital Output 6A
1:23 /7.9_8.D1 Valve Clamp in right Digital Output 1.5A 2:23 /7.9_11.D8 Sensor rear leg right Dig/Ana Input
1:24 /7.9_8.E1 Valve Clamp out right Digital Output 1.5A 2:24 Ana/Temp/Rheo Input
1:25 Digital Input D+ 2:25 Ana/Temp/Rheo Input
1:26 /7.9_3.E1 Indication light front legs lower pos Digital Out/In 1.5A 2:26 /7.9_9.A1 Power supply sensors Left rear Digital Output 0.5A
1:27 /7.9_6.D1 Valve front knee in left PWM Output Group1 2:27 /7.9_11.A1 Power supply sensors Right rear Digital Output 0.5A
1:28 /7.9_6.D1 Valve front knee out left PWM Output Group1 2:28 /7.9_11.C8 Sensor clamp rear leg right Dig/Ana/Freq Input
1:29 /7.9_6.A1 Valve front leg up left PWM Output Group1 2:29 Ana/Temp/Rheo Input
1:30 /7.9_7.B8 Valves ground Right side legs Digital Output NPN 2:30 Digital Output 1.5A
1:31 See pin K1:3 2:31 Digital Output 1.5A

1:32 See pin K1:3 2:32 /7.9_10.A1 Power supply sensors Left front Digital Output 0.5A
1:33 /7.9_6.B1 Valve front leg down left PWM Output Group1 2:33 /7.9_12.A1 Power supply sensors Right front Digital Output 0.5A
1:34 /7.9_7.D1 Valve front knee in right PWM Output Group1 2:34 Digital Output 6A
1:35 /7.9_7.D1 Valve front knee out right PWM Output Group1 2:35 /7.9_3.A8 Indication light ground PWM 15A
D 1:36 /7.9_7.B1 Valve front leg up right PWM Output Group1 2:36 Digital Output 6A D
secuted.
1:37 /7.9_7.C1 Valve front leg down right PWM Output Group1 2:37 /7.9_8.A8 Valves ground Clamp/Drive pos. Valves PWM 15A
1:38 /7.9_6.E1 Valve rear knee in left PWM Output Group1 2:38 Digital Output 6A
1:39 /7.9_6.F1 Valve rear knee out left PWM Output Group1
1:40 /7.9_6.B1 Valve rear leg up left PWM Output Group1 24V See pin K1:2
GND See pin K1:2
1:41 /7.9_6.C1 Valve rear leg down left PWM Output Group1
1:42 /7.9_3.B1 Indication light clamp pos front legs Digital Out/In 1.5A
1:46 /7.9_3.E1 Indication light clamp pos rear legs Digital Out/In 6A
1:47 /7.9_7.E1 Valve rear knee in right PWM Output Group2
1:48 /7.9_7.F1 Valve rear knee out right PWM Output Group2
1:49 /7.9_11.B8 Sensor alignment rear leg right Digital Out/In 6A
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn MLG 120601 A56402.0100 Kretsar Agg DRG450 DRG450 0.0_2 1
Name
R
Konstr/Design

Wiring Cross References combi A56400.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6020
-XD7911-1 -XY6020 -XY6020
PWM Output Group1 C1:38 38 7911-138 WH 0.75 1 1 2 2 56007 WH 0.75 D7910-1_1:10_0V
-D7911 /11.5_3.C4
/0.0_1.E3
Sideshift left
Sideshift left
-Y6021
B -XD7911-1 -XY6021 -XY6021 B
-D7911 /11.5_3.C4
/0.0_1.E3
Sideshift right
Sideshift right
C C

D D
secuted.
E E
Circuit manouver see

F cab 7.1_1 F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

Wiring Side shift A56400.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-Y6018/-Y6018-LE
-XD7911-1 -XY6018/-XY6018-LE -XY6018/-XY6018-LE
A -D7911 /11.5_3.C4 A
/0.0_1.D3
Spreading out 20-40
Spreading out 20-40
-Y6019/-Y6019-LE
-XD7911-1 -XY6019/-XY6019-LE -XY6019/-XY6019-LE
-D7911 /11.5_3.C4
/0.0_1.D3
Spreading in 40-20
Spreading in 40-20
B B
1
-Y6018-RI
-XD7911-1 -XY6018-RI -XY6018-RI
DigOut 6A C1:34 34 7911-134 WH 0.75 1 1 2 2 56011 WH 0.75 D7910-1_1:10_0V
-D7911 /11.5_3.B4
/0.0_1.D3
Spreading out 20-40 right
Spreading out 20-40 DRG100
C C
-Y6019-RI
-XD7911-1 -XY6019-RI -XY6019-RI
-D7911 /11.5_3.B4
/0.0_1.D3
Spreading in 40-20 right
Spreading in 40-20 DRG100

D 1 D
secuted.
-XB7690f/-XB7690-LEf -XB7690m/-XB7690-LEm
D7910-1_2:32_24V 57103 WH 0.75 A A
/11.5_2.B4
BN
-B7690/-B7690-LE -XB7690m/-XB7690-LEm -XB7690f/-XB7690-LEf
-D7911
/0.0_1.C5
Damp spreading
BU Damp spreading
-XB7690m/-XB7690-LEm -XB7690f/-XB7690-LEf
B B 56703 BK 0.75 CHASSIS
/11.5_2.C7
E E
-XB7690-RIf -XB7690-RIm
A A
D7910-1_2:33_24V 57202 WH 0.75

/11.5_2.D4
BN
-B7690-RI -XB7690-RIm -XB7690-RIf -X503Am -X503Af
BK C C 50307 WH 0.75 7 7 7911-209 WH 0.75 9 C2:9 Dig/Ana Input
-D7911
/0.0_1.C5
DRG100
Damp spreading
BU Damp spreading
-XB7690-RIm -XB7690-RIf
/11.5_2.B7
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

Wiring Spreading 20-40 A56400.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-H9003
B B
-XD7911-1 -XH9003 -XH9003
Digital Output 3A C1:43 43 7911-143 WH 0.75 1 1 2 2 56906 BK 0.75 CHASSIS
-D7911 /11.5_2.D7
/0.0_1.E3
Buzzer auto spreading
Buzzer auto spreading
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

Wiring Automatic Spreading A56400.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-XB7770f/-XB7770-LEf -XB7770m/-XB7770-LEm
D7910-1_2:32_24V 57102 WH 0.75 A A
/11.5_2.B4
BN
-B7770/-B7770-LE -XB7770m/-XB7770-LEm -XB7770f/-XB7770-LEf
C 1 BK C C 7911-210 WH 0.75 10 C2:10 Dig/Ana Input C
-D7911
/0.0_1.C5
30 stop
BU 30 stop left
-XB7770m/-XB7770-LEm -XB7770f/-XB7770-LEf
/11.5_2.C7

D D7910-1_2:33_24V 57204 WH 0.75 A A D
/11.5_2.D4
secuted.
BN
-B7770-RI -XB7770-RIm -XB7770-RIf -X503Am -X503Af
BK C C 50308 WH 0.75 8 8 7911-211 WH 0.75 11 C2:11 Dig/Ana Input
-D7911
DRG 100 30 stop
/0.0_1.C5
BU 30 stop right
-XB7770-RIm -XB7770-RIf
/11.5_2.B7
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

Wiring 30-35 Stop A56400.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6008
-XD7911-1 -XY6008 -XY6008
-D7911 /11.5_3.D4
/0.0_1.D3
Rotation c.w
Rotation c.w
B B
-Y6009
-XD7911-1 -XY6009 -XY6009
-D7911 /11.5_3.D4
/0.0_1.D3
Rotation c.c.w
Rotation c.c.w
C C

-XB7225f/-XB7202-DLf -XB7225m/-XB7202-DLm
D7910-1_2:32_24V 56102 WH 0.75 A A
/11.5_2.C2
D D
BN
-XB7225m/-XB7202-DLm -XB7225f/-XB7202-DLf
secuted.
-B7225/-B7202-DL
1 -D7911
/0.0_1.C5
Rotation stop
BU Rotation stop
-XB7225m/-XB7202-DLm -XB7225f/-XB7202-DLf
/11.5_2.D7
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

Wiring Rotation A56400.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-Y6010
A -XD7911-1 -XY6010 -XY6010 A
-D7911 /11.5_3.C7
/0.0_1.E3
Tilt out
Tilt out
-Y6011
-XD7911-1 -XY6011 -XY6011
-D7911 /11.5_3.C7
/0.0_1.D3
Tilt in
B B
Tilt in
C C
1
-Y6012-1
-XD7911-1 -X507Af -X507Am -XY6012-1 -XY6012-1
Digital Output 1.5A C1:23 23 7911-123 WH 0.75 3 3 507A3 WH 0.75 1 1 2 2 5002A BK 0.75 CHASSIS
-D7911 /11.5_1.B7
/0.0_1.D3
D D
Unlock tilt
secuted.
Unlock tilt
1
-Y6012-2
-XD7911-1 -X507Bm -X507Bf -XY6012-2 -XY6012-2
Digital Output 1.5A C1:24 24 7911-124 WH 0.75 3 3 507B3 WH 0.75 1 1 2 2 5002B BK 0.75 CHASSIS
-D7911 /11.5_1.B7
/0.0_1.D3
Unlock tilt
Unlock tilt
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

Wiring Tilt A56400.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6035
-XD7911-1 -XY6035 -XY6035
-D7911 /11.5_3.C7
/0.0_1.E3
Levelling c.c.w
Levelling c.c.w
B -Y6036 B
-XD7911-1 -XY6036 -XY6036
-D7911 /11.5_3.C7
/0.0_1.E3
Levelling c.w
Levelling c.w
C C

D D
secuted.
-Y6034-1
-XD7911-1 -XY6034-1 -XY6034-1
Digital Output 1.5A C1:21 21 7911-121 WH 0.75 1 1 2 2 56903 BK 0.75 CHASSIS
-D7911 /11.5_2.D7
/0.0_1.C3
Unlock levelling
Unlock levelling
-Y6034-2
E -XD7911-1 -XY6034-2 -XY6034-2 E
Digital Output 1.5A C1:22 22 7911-122 WH 0.75 1 1 2 2 56904 BK 0.75 CHASSIS
-D7911 /11.5_2.D7
/0.0_1.D3
Unlock levelling
Unlock levelling
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

Wiring Levelling A56400.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X503Bm -X503Bf
-X503Bf -X503Bm -X563f -X563m_BB 2 2 56602 BK 0.75
D7910-1_2:33_24V 57203 WH 0.75 1 1 5031 WH 0.75 1 1
/11.5_2.D4
56302 WH 0.75 2 2 -X573f -X573m_BB
56303 WH 0.75 3 3 BK 0.75 5032 1 1
A 56304 WH 0.75 4 4 57302 2 2 A
56305 WH 0.75 5 5 57303 3 3
6 6 57304 4 4
1 57305 5 5
CHASSIS
-XB7202FRf/-XB7202URf -XB7202FRm/-XB7202URm 6 6 /11.5_2.B7
A A
BN
-B7202-FR/-B7202-UR -XB7202FRm/-XB7202URm -XB7202FRf/-XB7202URf -X503Bm -X503Bf -X503Am -X503Af
BK C C WH 0.75 5033 3 3 50303 3 3 7911-216 16 C2:16 Dig/Ana Input
-D7911
B B BK 0.75 /0.0_1.C5
Alignment front
BU Alignment front
A A
BN
B -B7204-RI -XB7204-RIm -XB7204-RIf -X503Bm -X503Bf -X503Am -X503Af B
-D7911
B B BK 0.75 /0.0_1.C5
Unlocked twistlock
BU Unlocked twistlock
A A
BN
-B7205-RI -XB7205-RIm -XB7205-RIf -X503Bm -X503Bf -X503Am -X503Af
BK C C WH 0.75 5035 5 5 50305 5 5 7911-221 21 C2:21 Dig/Ana/Freq Input
-D7911
B B BK 0.75 /0.0_1.C5
Locked twistlock
BU Locked twistlock
-XB7202-RRf/-XB7272-RIf -XB7202-RRm/-XB7202-RIm
A A
BN
C -B7202-RR/-B7202-RI -XB7202-RRm/-XB7202-RIm -XB7202-RRf/-XB7272-RIf -X503Bm -X503Bf -X503Am -X503Af C
-D7911
B B BK 0.75 /0.0_1.C5
Alignment rear
BU Alignment rear
1
-X504m -X504f
-X504f -X504m -X564f -X564m_BB 2 2 56702
D7910-1_2: 1 1 5041 1 1
/11.5_2.B4
56402 2 2
-X574f -X574m_BB
56403 3 3 5042 1 1
56404 4 4 57402 2 2
56405 5 5 57403 3 3
6 6 57404 4 4
D 1 57405 5 5 CHASSIS D
-XB7202-FLf/-XB7202-ULf -XB7202-FLm/-XB7202-ULm /11.5_2.C7
secuted.
6 6
A A
BN
-B7202-FL/-B7202-UL -XB7202-FLm/-XB7202-ULm -XB7202-FLf/-XB7202-ULf -X504m -X504f
BK C C 5043 3 3 7911-217 17 C2:17 Dig/Ana Input
-D7911
B B /0.0_1.C5
Alignment front
BU Alignment front
-XB7204-LEf -XB7204-LEm
A A
BN
-B7204-LE -XB7204-LEm -XB7204-LEf -X504m -X504f
-D7911
B B /0.0_1.C5
Unlocked twistlock
BU Unlocked twistlock
E E
-XB7205-LEf -XB7205-LEm
A A
BN
-B7205-LE -XB7205-LEm -XB7205-LEf -X504m -X504f
-D7911
B B /0.0_1.D5
Locked twistlock
BU Locked twistlock
-XB7202-RLf/-XB7202-LEf -XB7202-RLm/-XB7202-LEm
A A
BN
-B7202-RL/B7202-LE -XB7202-RLm/-XB7202-LEm -XB7202-RLf/-XB7202-LEf -X504m -X504f
F -D7911 F
1 B B /0.0_1.C5
Alignment rear
BU Alignment rear

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

Wiring Twistlock A56400.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
1
1
-H5620-1
-XD7911-1 -X507Af -X507Am -X505f -X505m
Digital Out/In 1.5A C1:12 12 7911-112 1 1 507A1 1 1 1 2
-D7911
/0.0_1.C3
B B
Unlocked twistlock (RD) Unlocked twistlock (RD)
-H5640-1
-XD7911-1 -X507Af -X507Am -X505f -X505m
Digital Out/In 1.5A C1:16 16 7911-116 2 2 507A2 2 2 1 2
-D7911
/0.0_1.C3
Alignment (YE) Alignment (YE)
1
1
1
-H5630-1
-XD7911-1 -X507Bm -X507Bf -X505f -X505m -X507Bf -X507Bm -XD7911-2
Digital Out/In 1.5A C1:13 13 7911-113 1 1 507B1 3 3 1 2 507B4 4 4 7911-235 35 C2:35 PWM 15A
-D7911 -D7911
/0.0_1.C3 /0.0_1.D5
C -X511f -X511m_BB C
Locked twistlock (GN) Locked twistlock (GN) 1 1 Ground Indication light
-X505m -X505f
4 4 51102 2 2
51103 3 3
4 4
-H5001
-XD7911-1 -X507Bm -X507Bf -X508f -X508m -X508m -X508f
Digital Out/In 1.5A C1:20 20 7911-120 2 2 507B2 1 1 1 2 2 2
-D7911
/0.0_1.C3
Over Height leg upper pos

Over Height leg upper pos

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
R
Konstr/Design

Wiring Indication Lamps A56400.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Green
-H5760-LF
A -X527Bm -X527Bf -X546f -X546m A
Digital Out/In 1.5A C1:12 12 7912-112 WH 0.75 1 1 527B01 WH 0.75 1 1 1 2 -X527Bf -X527Bm -XD7912-2
-D7912 5 5 7912-235 WH 2.5 35 C2:35 PWM 15A
/0.0_2.B2 -D7912
/0.0_2.D5
Indication light alignment left front Indication light alignment left front
Indication light ground
Green
-H5760-RF
-X527Bm -X527Bf -X546f -X546m -X546m -X546f
Digital Out/In 1.5A C1:13 13 7912-113 WH 0.75 2 2 527B02 WH 0.75 2 2 1 2 4 4
-D7912

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Reachstackers 42-45 tonnes

9 Frame, body, cab and accessories

G Terminology and index

Workshop Manual DRG 420–450 VDRG01.01GB

VDRG01.01GB Workshop Manual DRG 420–450

Cargotec will not accept any responsibility in the event of a modification

About machine version

Cargotec reserves the right to make changes to specifications and

All duplication by any means, such as copying, printing, etc., is

Workshop Manual DRG 420–450 VDRG01.01GB

Read operator's manual

Read the operator's manual

Read the Maintenance manual

refers to important information in the Maintenance manual.

Read the Maintenance manual

VDRG01.01GB Workshop Manual DRG 420–450

The workshop manual's contents

The workshop manual is divided into the following sections.

Workshop Manual DRG 420–450 VDRG01.01GB

Function group structure

The function groups are intended to be used as search terms in

The maintenance manual and the workshop manual contain different

References are indicated by either section and group numbers, e.g.

References between sections in the same manual are indicated with

References between Maintenance manual and Workshop manual

VDRG01.01GB Workshop Manual DRG 420–450

References between different information types

The basic rule of searching for information is to use the function

Function descriptions Hydraulic diagrams

Diagnostics Wiring diagrams

• From Function description to Component description, to enable

Workshop Manual DRG 420–450 VDRG01.01GB

Product alternatives and optional equipment

Special equipment is not described in the manual. If uncertain as

Equivalent information for different product alternatives is described

Optional equipment refers to options that can be added to standard

Information on auxiliary equipment is described in separate segments

VDRG01.01GB Workshop Manual DRG 420–450

The machine card indicates which drawings the machine is

If the information on the machine card is inadequate, contact Cargotec.

Workshop Manual DRG 420–450 VDRG01.01GB

The function descriptions describe the function in a logical flow from

The function descriptions use symbols to illustrate components such as

7:14 7 La s tha nte ring – Lyft och s ä nk

Lyft och sän k, fu n ktio n s b e s krivn in g

9 Pos Fö rkla rin g S ig n a lb e s krivn in g Hän vis n in g

VDRG01 .01SE Verkstad s ma nua l DRG 420–450

Example of function description

VDRG01.01GB Workshop Manual DRG 420–450

Symbol explanation function descriptions

Symbol explanation function descriptions

11 12 10. Valve block

25 Pa 26 Pa 23. Temperature sensor

D7901 26. Pressure sensor

Workshop Manual DRG 420–450 VDRG01.01GB

About the documentation

Always indicate publication number when ordering.

For publication number, see machine card.

Your feedback is important to be able to improve the information.

VDRG01.01GB Workshop Manual DRG 420–450

Workshop Manual DRG 420–450 VDRG01.01GB

VDRG01.01GB Workshop Manual DRG 420–450

In this publication Cargotec has documented and warned for situations