DRF450-65A5X Werkstattbuch

Reachstackers 40-45 tonnes
Publ. no VDRF03.02GB
Workshop Manual in original WORKSHOP MANUAL
DRF 400-450
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Workshop
manual 2 Transmission
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
G Terminologi och Index

A Foreword 1
A Foreword
Table of Contents A Foreword

mm mm mm mm mm mm
Foreword......................................................................................................... 3
About the Workshop Manual ...................................................................... 3
General ............................................................................................................. 3
Conditions ......................................................................................................... 3
Storage .............................................................................................................. 3
About the machine version ................................................................................ 3
Copyright ........................................................................................................... 3
Reading instructions ................................................................................... 4
Warning information .......................................................................................... 4
Important information ........................................................................................ 4
Read the Operator’s Manual ............................................................................. 4
Read the Maintenance Manual ......................................................................... 4
Workshop manual contents ............................................................................... 5
Function group structure ................................................................................... 6
References between different information types ............................................... 7
Product alternatives and optional equipment .................................................... 8
Machine card ..................................................................................................... 8
Function descriptions ........................................................................................ 9
About the documentation ......................................................................... 12
Documentation sections .................................................................................. 12
Ordering of documentation .............................................................................. 12
Feedback .................................................................................................. 13
Form for copying ............................................................................................. 13
Workshop manual DRF 400-450 VDRF03.02GB

2 A Foreword
VDRF03.02GB Workshop manual DRF 400-450

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

General
page
–
Thank you for choosing Cargotec as your machine supplier. We hope

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

tools. All lifting devices, such as slings, straps and ratchet blocks, must
meet governing national standards and regulations for lifting devices.
Cargotec will not accept any responsibility for modifications performed
without permission from Cargotec, or in the event of the use of lifting
devices, tools or work methods other than those described in this
manual.
Storage
page
–
NOTE
The workshop manual should be accessible to service personnel.
About the machine version

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

sign and appearance at the time of delivery from Cargotec. Due to cus-
tomisations, there may be variations and/or deviations.
Cargotec reserves the right to modify specifications and equipment
without prior notice. All information and data in this manual are valid at
the time of publication.
D ANGER
External equipment must only be used if it is
approved by Cargotec.
Danger to life and property!
Only use equipment approved by Cargotec.
Copyright
page
–
Cargotec Sweden AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Cargotec Sweden AB.
Duplication by any means such as copying, printing, etc., is prohibited.

4 A Foreword – Reading instructions
Reading instructions
Warning information
page
–
Warnings inform on potential dangers which can, if the warnings are

not heeded, result in personal injury or product damage.
D ANGER
Situation that may result in serious personal injury,
possible death, if the instruction is not followed.
WARN IN G
Situation that may result in serious personal injury if
the instruction is not followed.
C AUTION
Situation that may result in damage to the product if
the instruction is not followed.
Important information
page
–
Important information marked with NOTE facilitates the work process,

operation/handling or increases understanding of the information.
NOTE
Information that is important without being safety related.
Read the Operator’s Manual

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

page
–
The symbol to the left is sometimes found on the machine. It refers to

001128
important information in the Maintenance Manual.
Read the Maintenance Manual

A Foreword – Reading instructions 5
Workshop manual contents

page
–
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. If possible, the Workshop Manual
provides reference to supplier documentation instead of printing the
same information twice. Methods for preventive maintenance and cer-
tain checks are found in the Maintenance Manual, no references are
given. Use the function groups to locate the information in the Mainte-
nance 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 function are described under each subfunction.
Consequently, common components are described in several places, but in general
6 Suspension under the first function to use the component.
7 Load handling Together with the general description is a detailed description of what is unique
about the specific subfunction. The next subfunction to use the same component
8 Control system
only has a description what is unique for the new function.
9 Frame, body, cab and
Work instructions for corrective maintenance (replacement of components).
accessories
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

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

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

References between different information types

page
–
The maintenance manual and workshop manual are mainly divided

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

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

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

Product alternatives and optional equipment

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

ternative or optional equipment is 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 de-
termine which information is relevant. See Machine card page 8.
Product alternative
Product alternative describes options that are fitted instead of a spe-
cific piece of standard equipment (e.g. engine alternative).
Equivalent information for different product alternatives are described
consecutively in separate segments within the same function group.
To indicate that there are different alternatives, "Product alternative" is
added to the heading together with a simple description of the alterna-
tive, e.g. "(Product alternative Climate control system ECC)". In addi-
tion, the alternative that is an option is marked with the symbol for
optional equipment.
Optional equipment
000264
Optional equipment refers to options that can be added to standard

equipment for more or improved functions.
Symbol for optional equipment
Information on auxiliary equipment is described in separate segments
together with the standard equipment. The optional equipment de-
scription covers how the equipment affects standard function and what
components are added.
Machine card
page
–
NOTE
If the machine has been modified after delivery, information on
the machine card may be incomplete or incorrect.
The machine card indicates of which drawings the machine consists,
in many cases these can be associated options and product alterna-
tives. For more information about handling of product alternatives and
optional equipment, see Product alternatives and optional equipment
page 8. The machine card is delivered with the parts catalogue.
The machine card is divided into the same function groups as the
spare parts catalogue, maintenance manual and workshop manual.
For reasons of practicality, the machine card only uses the first and
second level of the function group register. The function groups are
written in groups of four characters, e.g. group 0107 refers to group 1.7
Cooling system in the manual.
For more information on how the machine card is used to order spare
parts, see the foreword of the spare parts catalogue.
If the information on the card machine does not help, contact
Cargotec.

NOTE
All documents that accompany the machine are non-registered
documents. No notification is made regarding changes.
Function descriptions
page
–
Function descriptions are schematic overviews that describe how a

function works as well as which components and signals work
together.
Function descriptions describe the function in a logical flow from input
signal to desired output signal. Most functions require that preset con-
ditions are fulfilled for the function to be activated. In these cases, the
conditions are listed above the illustration.
Function descriptions use symbols to illustrate components such as
valves, sensors, etc.
10
2
3
9
4
8
5
7
6
000520

Example of function description

1. Hydraulic force (solid double line)
2. Flag pressure check connection (Check point), indicates that
there is pressure check connection for checking pressure signal
3. Flag diagnostic test, indicates that the signal can be checked with
diagnostic test, see section 8 Control system, group 8.4
Diagnostics
4. Illustration of function, (apply brake)
5. Reference to description of component
6. Signal description, reference value for signal out from component
7. Description of component's function
8. Position number, reference to position in illustration
9. Position number in illustration, reference to row in table
10. Electric power (solid single line)

Symbol explanation function descriptions

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

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

12 A Foreword – About the documentation
About the documentation

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

Always specify the publication number when ordering.
See the machine card for publication number.

A Foreword – Feedback 13
Feedback
Form for copying
page
–
Cargotec’s ambition is that you who work with maintenance of a Ka-

lmar machine shall have access to correct information.
Your feedback is important to be able to improve the information.
Copy this form, write down your views and send it to us. Thank you for
your participation!
To: Cargotec Sweden AB

Technical Documentation
Torggatan 3
SE-340 10 Lidhult
SWEDEN
Fax: +46 372 263 93
From:
Company / Sender: ..........................................................................................................................................
Telephone:
..........................................................................................................................................................
E-mail:
.................................................................................................................................................................
Date: .................................... - .................. - ..................
Manual
information Name / Publication number: .............................................................................................................................
Section / page number: ......................................................................................................................................
Sugges-
tions, ...........................................................................................................................................................................
views,
remarks,
etc. ...........................................................................................................................................................................
...........................................................................................................................................................................
...........................................................................................................................................................................
...........................................................................................................................................................................
...........................................................................................................................................................................

14 A Foreword – Feedback

B Safety 1
B Safety
Table of Contents B Safety

mm mm mm mm mm mm
Safety .............................................................................................................. 3
General safety information ......................................................................... 3
Safety concerns everyone! ................................................................................ 3
A near accident is a warning! ............................................................................ 3
Safety instructions ...................................................................................... 4
General ............................................................................................................. 4
Service position ................................................................................................. 4
Hydraulic and brake systems, depressurising ................................................... 5
Oils .................................................................................................................... 6
Fuel system ....................................................................................................... 7
Clothing, etc. ..................................................................................................... 8
Several mechanics on the same machine ......................................................... 9
Working under machine .................................................................................... 9
Lifting heavy components ............................................................................... 10
Vibrations ........................................................................................................ 10
Noise ............................................................................................................... 11
Solvents .......................................................................................................... 11
Fire and explosion risks ................................................................................... 12
Fluid or gas under pressure ............................................................................ 13
Coolant ............................................................................................................ 14
Refrigerant ...................................................................................................... 14
Air pollution ..................................................................................................... 15
Tensioned springs ........................................................................................... 16
Electric motors ................................................................................................. 16
Rotating components and tools ....................................................................... 17
Tyres and rims ................................................................................................. 18
Lifting equipment ............................................................................................. 18
Spare parts ...................................................................................................... 19
Non-ionised radiation ...................................................................................... 20
Environment ............................................................................................. 21
General ........................................................................................................... 21

2 B Safety

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

Safety concerns everyone!
page
–
The safety information concerns everyone who works with the ma-
chine! Persons who do not follow the safety instructions given in this
manual must make absolutely sure that the work is performed without
risks of personal injury and without risk of damage to machine or ma-
chine property!
Remember to:
• follow the instructions in this manual
• be trained for the work in question
• follow local laws, safety rules and regulations
• use the correct equipment and tools for the job
• wear the correct clothes
• use common sense and work carefully. Do not take any risks!
Cargotec has in this publication documented and warned for situations
and risks that may occur in connection with using as well as service or
repairs of the machine during normal circumstances.
That is why it is important that all who work with the machine, or repair
or service the machine, read and follow the information in the Work-
shop Manual and Operator’s Manual.
A near accident is a warning!

page
–
A near-accident is an unexpected event where neither persons, ma-

chine or property are injured or damaged. However, a near-accident
indicates that there is an injury risk and actions must be taken to avoid
the risk of injuries.

4 B Safety – Safety instructions
Safety instructions
General
page
–
Read, consider and follow the safety instructions below before starting
to work in the machine:
• Service position page 4
• Hydraulic and brake systems, depressurising page 5
• Oils page 6
• Fuel system page 7
• Clothing, etc. page 8
• Several mechanics on the same machine page 9
• Working under machine page 9
• Lifting heavy components page 10
• Vibrations page 10
• Noise page 11
• Solvents page 11
• Fire and explosion risks page 12
• Fluid or gas under pressure page 13
• Coolant page 14
• Refrigerant page 14
• Air pollution page 15
• Tensioned springs page 16
• Electric motors page 16
• Rotating components and tools page 17
• Tyres and rims page 18
• Lifting equipment page 18
• Spare parts page 19
• Non-ionised radiation page 20
Service position
page
–
General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
Service position means:
• Machine parked, that is, parking brake applied.
• Boom fully retracted and lowered to horizontal position.
• Engine off.
• Main electric power off (with battery disconnector).
003603
Machine with a fully retracted and lowered boom

B Safety – Safety instructions 5
Hydraulic and brake systems, depressurising

page
–
1 Machine in service position.

2 Depressurise the hydraulic system.
Turn the start key to position I and activate extension out, a
strong hissing sound 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 and turn off the main electric
power.
4 Depressurise the attachment.

Open the relief valve for top lift.
C AUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
Check that the relief valve top lift is closed before the
engine is started after the completion of work.
002269
The illustration above shows closed 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.
NOTE
After work is finished, close drain valve and tighten the lock
ring.
Oils
page
–
The following safety instructions shall be followed for work when han-
dling oils.
WARN IN G
Warm and pressurised oil.
Always depressurise hydraulic and brake systems

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

Warm oil can cause burn injuries, rashes and
irritation! The oil may also be corrosive to mucous
membranes in, e.g., the eyes, skin and throat.
I M P OR TA NT
Always clean the area around components and
connections before they are loosened. Dirt in oil
systems causes increased wear, resulting in
subsequent material damages.
Always take action to avoid spills. In places where

drain containers cannot be used, use a pump or hose
for safe handling.
Always check that plugs seal tight before collection

containers are moved.
Handle all oil as environmentally hazardous waste.
Oils freely released cause damage to the environment
and may also cause fires. Waste oils/fluids shall
always be handled by an authorised company.

Fuel system
page
–
The following safety instructions shall be followed for work when han-
dling fuel.
D ANGER
Pay attention to the risk of fire when working on the
fuel system.
Work on the fuel system shall be avoided when the

engine is warm since fuel can spill on hot surfaces
and may ignite.
Ensure that naked flames, sparks or glowing objects

have been removed before work begins on or near the
fuel system.
Do not smoke in the vicinity of the machine when
working on the fuel system.
WARN IN G
Use protective gloves and protective goggles. If a
component is to be disconnected, hold a rag over the
connection as protection and to collect fuel. The
engine’s fuel system operates at very high pressure.
The pressure is so high that the jet can injure the skin,
resulting in severe injuries. Risk of personal injuries.
Avoid skin contact with fuel, use protective gloves.

Fuel is corrosive to mucous membranes in, e.g., eyes,
skin and throat.
C AUTION
Always clean the area around components and
connections before they are loosened. Dirt in the fuel
may cause malfunctions and engine stop in
undesirable situations as well as increase wear,
resulting in subsequent material damages.

I M P OR TA NT
Always take action to avoid spills. In places where
drain containers cannot be used, use a pump or hose
for safe handling.
Always check that plugs and connections seal tight
before moving collection containers.
Handle the fuel as environmentally hazardous waste.

Fuel freely released causes damage to the environ-
ment and may also cause fires. Fuel shall always be
handled by an authorised company.
Clothing, etc.
page
–
Clothes should be in good condition. Remove loosely hanging clothing

(tie, scarf, etc.). Do not wear clothes with wide sleeves, wide trouser
legs, etc.
Remove jewellery as it may conduct electricity and get caught in mov-
ing parts.
Long hair should be adequately gathered since it can easily get caught
in moving parts. Be careful when working with welding or an open
flame since hair easily catches on fire.

Several mechanics on the same machine

page
–
WARN IN G
If several mechanics are working on the same vehicle,
take extra care so that unintentional movements do
not injury another person. Communicate so that eve-
ryone knows where all are and what they are doing.
Risks
Work with wheels or axle suspension, mountings, etc. may result in
components on the other side moving and causing damage/injury.
Movements performed from the operator’s station, e.g., movement of
lifting equipment, may cause severe personal injuries.
Safety precautions
• Make sure that the machine's lifting equipment is completely low-
ered or secured in another way.
• Move battery disconnector to position zero, remove the key.
• Be aware of the risks when several persons work around the
vehicle.
• Make your co-workers aware of what you’re working with.
• Do not work with drive wheels on the machine's both sides at the
same time.
Working under machine

page
–
Working under cab

On machines with liftable cab, the cab must be secured in the raised
position with the locks designed for this purpose.
Working under the frame

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

Lifting heavy components

page
–
WARN IN G
Careless handling of heavy components can lead to
serious personal injury and material damage.
Use type approved lifting tools or other devices to

move heavy components. Make sure that the device is
stable and intact.
Risks
Unsuitable lift slings, straps, etc. may break or slip.
The centre of gravity (balance point) of the component can change
during the course of the work, and the component may then make un-
expected movements which may cause severe personal injuries and
material damage.
A component lifted with lifting equipment can start to turn if the equilib-
rium is upset.
A component lifted using an overhead crane may start to swing back
and forth, which can cause severe crushing injuries or material
damage.
Safety precautions
Lifting with lifting device. Use lifting tools or other tools, especially
when there are such adapted for certain work. See workshop manual
for methods.
If lifting must be performed without lifting device:
• Lift near the body.
• Keep your back vertical. Raise and lower with legs and arms, do
not bend your back. Do not rotate your body while lifting. Ask for
assistance in advance.
• Wear gloves. They're good protection against minor crushing in-
juries and cuts to fingers.
• Always use protective shoes.
Vibrations
page
–
In case of long-term use of vibrating tools, for example, impact nut run-
ners or grinders, injuries may be sustained as vibrations can be trans-
mitted from tools to hands. Especially when fingers are cold.
Safety precautions
Use heavy gloves to protect against cold and somewhat against
vibrations.
Switch between work duties to give the body time to rest.
Vary work position and grip so that the body is not stressed in only one
position by the vibrations.

Noise
page
–
Noise louder than 85 dB (A) that lasts for longer than 8 hours is con-
sidered harmful to hearing. (Limit values may vary between different
countries.) High tones (high frequencies) are more damaging than low
tones at the same sound level. Impact noise can also be hazardous,
e.g. hammer blows.
Risks
At noise levels higher than the limits hearing damage can occur. In
more severe cases, hearing damage can become permanent.
Safety precautions
Use hearing protection. Make sure that it is tested and protects against
the noise level in question.
Limit noise with noise-absorbing dividers, for example, noise-absorb-
ing materials in roof and on walls.
Solvents
page
–
Fluids that (as opposed to water) dissolve grease, paint, lacquer, wax,
oil, adhesive, rubber, etc. are called organic solvents. Examples:
White (petroleum) spirits, gasoline, thinner, alcohols, diesel, xylene,
trichloroethylene, toluene. Many solvents are flammable and consti-
tute a fire hazard.
Risks
Products containing solvents produce vapours that can cause dizzi-
ness, headaches and nausea. They may also irritate mucous mem-
branes in the throat and respiratory tracts.
If the solvent ends up directly on the skin it may dry out and crack. Risk
of skin allergies increases. Solvents may also cause injury if they pen-
etrate through the skin and are absorbed by the blood.
If the body is continuously exposed to solvents, the nervous system
may be damaged. Symptoms include sleep disorders, depressions,
nervousness, poor memory or general tiredness and fatigue. Continu-
ous inhalation of gasoline and diesel fumes is suspected to cause
cancer.
Safety precautions
Avoid inhaling solvent fumes by providing good ventilation, or wearing
a fresh-air mask or respiratory device with a suitable filter for the toxic
gases.
Never leave a solvent container without tight-sealing lid.
Use solvents with a low content of aromatic substances. It reduces the
risk of injury.
Avoid skin contact.
Use protective gloves.
Make sure that work clothes are solvent-resistant.

Fire and explosion risks

page
–
Examples of flammable and explosive substances are oils, gasoline,

diesel fuel oil, organic solvents (lacquer, plastics, cleaning agents),
rustproofing agents, welding gas, gas for heating (acetylene), high
concentration of dust particles consisting of combustible materials.
Rubber tyres are flammable and cause explosive fires.
Risks
Examples of cause of ignition is welding, cutting, smoking, sparks
when working with grinders, contact between hot machine parts and
flammable materials, heat development in rag drenched with oil or
paint (linseed oil) and oxygen. Oxygen cylinders, lines and valves shall
be kept free from oil and grease.
Fumes from, e.g., gasoline are heavier than air and may "run" down
into a sloping plane, or down in a grease pit, where welding flames,
grinding sparks or cigarette embers may cause an explosion. Evapo-
rated gasoline explodes very forcefully.
Special cases
Diesel fuel oil with added gasoline has a lower ignition point. Risk of
explosion already at room temperature. The explosion risk for warmed
diesel fuel oil is higher than for gasoline.
When changing oil in the engine, hydraulic system and transmission,
keep in mind that the oil may be hot and can cause burn injuries.
Welding on or near machine. If diesel and or other oils have leaked out
and been absorbed by rags, absorbent agents, paper or other porous
material, hot welding sparks can cause ignition and explosive fires.
When a battery is charged, the battery fluid is divided into oxygen and
hydrogen gas. This mixture is very explosive. The risk of explosion is
especially high when using a booster battery or quick-charger, as this
increases the risk of sparks.
Today’s machines contain a lot of electronic equipment. When weld-
ing, the control units must be disconnected and the electric power
must be turned off with the battery disconnector. Powerful welding cur-
rents may otherwise short-circuit the electronics, destroy expensive
equipment or cause an explosion or fire.
Never weld on painted surfaces (remove paint, by blasting at least 10
cm around the welding or cutting point). Use gloves, breathing protec-
tion and protective glasses. Also, welding work may not be done near
plastic or rubber materials without first protecting them from the heat.
Paints, plastics, and rubber develop a number of substances that may
be hazardous to health when heated. Be careful with machines that
have been exposed to intense heat or fire.

Safety precautions
Store hazardous substance in approved and sealed container.
Make sure that there is no ignition source near flammable or explosive
substances.
Make sure that ventilation is adequate or there is an air extraction unit
when handling flammable substances.
Fluid or gas under pressure

page
–
High-pressure lines can be damaged during work, and fluid or gas can
stream out.
There may be high pressure in a line even if the pump has stopped.
Therefore, gas or fluid can leak out when the connection to the hose
is loosened.
A gas cylinder subjected to careless handling can explode, for exam-
ple, if it falls onto a hard surface. Gas can stream out through dam-
aged valves.
Risks
Risk of damage/injuries in connection with work on:
• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Tyre repairs.
• Air conditioning.
Safety precautions
• Use safety glasses and protective gloves.
• Never work on a pressurised system.
• Never adjust a pressure limiting valve to a higher pressure than
recommended by the manufacturer.
• A hydraulic hose that swells, for example, at a connection, is
about to rupture. Replace it as soon as possible! Check connec-
tions thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• Discarded pressure accumulator shall first be depressurised and
then punctured before it is discarded (to avoid risk of explosion).
Carefully, drill a hole with 3 mm diameter after depressurising.
• Never use your hands directly to detect a leak. A fine high-pres-
sure stream from a hydraulic hose can easily penetrate a hand
and causes very severe injuries.

Coolant
page
–
The coolant in the machine’s cooling system consists of water, anti-

corrosion compound and (when needed) 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 operates at high pressure when the engine is
warm. Hot coolant can jet out and cause scalding in case of a leak or
when the expansion tank cap (filler cap) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.
Safety precautions
• Use protective gloves and safety glasses if there is a risk of
splashing or spraying.
• Open the filler cap first, to release the excess pressure. Open
carefully. Hot steam and coolant can stream out.
• If possible, avoid working on the cooling system when the coolant
is hot.
Refrigerant
page
–
Refrigerant is used in the machine’s air conditioning system.

Work on the air conditioning system must be performed by accredited/
authorised and trained personnel according to national legislation and
local regulations.
Risks
The air conditioning operates at high pressure. Escaping refrigerant
can cause frostbite.
Refrigerant that is heated (e.g., when repairing leaking climate/AC
system), generates gases that are very dangerous to inhale.
Safety precautions
• Use special instructions and equipment for refrigerant according
to the manual when working on the air conditioning system. Spe-
cial certification and authorisation is often required of the person
who may do the work. (Note national legislation and local
regulations!)
• Use protective gloves and safety glasses if there’s a risk of leaks.
• Make sure that heat-producing sources or objects are not close by
(cigarette glow, welding flame).

Air pollution
page
–
Air pollution is the impurities in the air around us and which are regard-
ed as hazardous to health. Certain pollution is more prominent in cer-
tain environments.
The following health-hazardous air pollution is especially prominent in
workshops:
• Carbon monoxide (fumes) is present in exhaust fumes. Odour-
less and therefore especially dangerous.
• Nitrogen oxides (nitrous gases) are present in exhaust fumes.
• Welding smoke especially hazardous to health when welding on
oily surfaces, galvanised or lacquered materials.
• Oil mist for example, when applying anti-corrosion agent.
• Grinding dust and gases generated when grinding and heating
plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.
• Isocyanates are present in certain paints, fillers, adhesives and
foam plastics used on machines.
Risks
Sulphuric acid mist is corrosive and injures the respiratory tracts.
(Generated when heating certain plastics and paints.)
Isocyanates can be released in the form of steam, dust (or may be
present in aerosols) when cutting, grinding or welding. Can irritate mu-
cous membranes producing symptoms similar to asthma and impair-
ing lung function. Even brief exposure to high concentrations can give
problems with persistent high sensitivity.
Safety precautions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are
generated.
• Use suitable protective gloves and breathing protection when
there is a risk of oil mist. Make sure that the protection is oil-proof.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eye-wash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine inside the workshop.
Connect an air extractor to the exhaust pipe so that the exhaust
fumes are removed from the workshop.

Tensioned springs
page
–
Examples of tensioned springs:

1. Torque springs in pedals for example
2. Return spring (cup springs) in parking brake cylinder.
3. Lock rings
4. Gas springs
Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries.
Parking brake springs are tensioned with high force and can cause
very severe accidents if they are accidentally released in an uncon-
trolled manner.
Gas springs and gas-charged shock absorbers are tensioned with
high force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety precautions
• Use safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manual when performing
maintenance and changing parts and components.
• Always use recommended tools.
Electric motors
page
–
Safety precautions
Always turn off the battery disconnector when working on electric
motors.
Always block the machine’s wheels and make sure that the parking
brake is activated and that the gear selector is in neutral position be-
fore starting any work on the machine.

Rotating components and tools

page
–
Examples of rotating components and tools:

• Cooling fan
• Drive belts
• Propeller shafts
• Drills
• Grinders
Risks
Rotating components, for example, fans or shafts, can cause severe
injuries if touched.
Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothes or hair get caught and are wound up in the
machine.
Safety precautions
• Do not use gloves when working with a drill.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or trouser legs.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair-net or similar.
• Remove large or loose hanging jewellery from hands, arms and
neck.

Tyres and rims

page
–
D ANGER
Tires shall be regarded as pressure reservoirs. If han-
dled incorrectly, they constitute a fatal danger
Parts can be thrown with explosive force and may

cause severe injuries.
Never repair damaged tyres, rims or lock rings. Tyre
changes shall be performed by authorised personnel.
Risks
Dismantling wheels: Tyres, rims or lock rings can be thrown.
Inflating of wheels: Tires, rims or lock rings may be ejected.
Safety precautions
• Always deflate the tyre before starting to work on the wheel.
• Check that tyres, rims and lock rings aren’t damaged. Never re-
pair damaged rims or lock rings.
• Wheels shall be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
• Use protective screen and safety glasses.
Lifting equipment
page
–
When working on the machine in general, and with the machine’s lift-
ing equipment in particular, the greatest caution must be exercised
with respect to securing the boom and attachment.
For this reason, always be in the habit of having the boom fully lowered
and fully retracted during work on the machine.
Risks
Risk of crushing if the machine’s lifting equipment is not lowered or
secured.
Risk of crushing is extra high when depressurising the hydraulic sys-
tem, see Hydraulic and brake systems, depressurising page 5.
Safety precautions
• Do not start work until the boom is lowered and fully retracted if
possible.

Spare parts
page
–
WARN IN G
The following parts must, for safety reasons, only be
replaced with original spare parts:
• Brake valve
• Drive axle
• Valve for mini-wheel/lever steering
• Steering valve (Orbitrol)

• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Rims
• Lift boom
• Boom nose extension
• Lift cylinder
• Valve block lift
• Extension cylinder
• Valve block extension
• Rotation motor unit
• Tilt cylinder
• Twistlocks, lifting shoe
• Safety switch (for hydraulic function)
• Emergency switch
• Frame
• Accumulator
• Main valve load handling
• Accumulator charging valve
• All control units

Non-ionised radiation
page
–
WARN IN G
Extra equipment such as communication radio, RMI,
phone, etc. can emit non-ionised radiation.
Danger of disruption to active or inactive medical

products.
Use communication radio, RMI, phone, etc. when
there are no people with active or inactive medical
products in the vicinity.
NOTE
When there are no people with active or inactive products in the
vicinity the phone and communication radio in the cab may be
used.
Equipment should not be used during operation or load handling
as your concentration as operator is reduced.
Cargotec accepts no responsibility for equipment not installed by
Cargotec or with Cargotec approved installation.

B Safety – Environment 21
Environment
General
page
–
Ever-increasing industrialisation of our world is having a significant im-

pact on our global environment. Nature, animals and man are subject-
ed daily to risks in connection with various forms of chemical handling.
There are still no environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle, perform
service on or repair machines must use the tools, assisting devices
and methods necessary to protect the environment in an environmen-
tally sound manner.
By following the simple rules below, you will contribute to protecting
our environment.
Recycling
Well-thought out recycling of the machine is the cornerstone of ending
its life cycle and being able to re-use materials in new products. Ac-
cording to calculations by Cargotec, the machine can be recycled to
more than 90% by weight.
Environmentally hazardous waste

Components such as batteries, plastics, and other materials that may
be considered as environmentally hazardous waste must be handled
in an environmentally correct manner.
Discarded batteries contain substances hazardous to personal health
and the environment. Therefore, handle batteries in an environmental-
ly safe manner and according to national regulations.
Oils and fluids

Oils freely discharged 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 must always be taken care of by an authorised
disposal company.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal the leaks.
Air conditioning unit

The refrigerant in the air conditioning unit for the cab contributes to the
greenhouse effect and may not be intentionally released into the open
air. Special training is required for all service work on the air condition-
ing unit. Many countries demand certification by a governing authority
for such work.
Working in a contaminated area

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

22 B Safety – Environment
Declarations
The machine does not contain asbestos.
The machines contains lead in batteries and in electric cabling. In cer-
tain models, there are lead castings as counterweight.
If the machine is equipped with air conditioning, then refrigerant of the
type R134a is used, in an amount between 1-3 kg.

C Preventive maintenance – C Preventive maintenance 1
mm mm mm mm mm mm
The information is found in the

page
–
Maintenance Manual
The information is found in the Maintenance Manual.
For information on how to order the Maintenance Manual, see the
section A Foreword.
Workshop manual DRF 400–450 VDRF03.02GB

2 C Preventive maintenance – C Preventive maintenance
VDRF03.02GB Workshop manual DRF 400–450

0 Complete machine 1
0 Complete machine
Table of Contents 0 Complete machine

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

Complete machine, description ............................................................................. 3
Troubleshooting, general work instructions ............................................................ 4
Troubleshooting without an error code, example ................................................... 5
Troubleshooting with error code, example ............................................................. 5
Troubleshooting cable harness .............................................................................. 7
Troubleshooting hydraulic hoses ............................................................................ 8

2 0 Complete machine

0 Complete machine – Complete machine 3
Complete machine
mm mm mm mm mm mm
Complete machine, description

page
–
The Kalmar DRF 400–450 is a "Reachstacker" for container handling.

The machine a lifting capacity of 40–45 tonnes depending on version.
The drive source is a six-cylinder, four-stroke diesel engine with direct
injection.
The transmission is hydromechanical, with constant mesh gears. It
has four speeds forwards and four speeds in reverse. Engine power is
transmitted by a torque converter.
The driveline/axle comprises a propeller shaft and a rigid drive axle
with hub reduction. Drive is via the front wheels.
The service brake is of wet disc type, built together with drive wheel
hubs. The parking brake is a disc brake and acts on the drive axle in-
put shaft.
Steering is via the rear wheels and a double acting hydraulic cylinder.
The steering axle is pendulum-suspended in the frame.
The wheels are mounted on the hubs with clamps. Twin wheels are
mounted on the drive axle, while the steering axle has single wheels.
Load handling comprises components and functions for managing
loads. Loads are lifted with and attachment that is fitted on a liftable
telescopic boom. Load handling is divided into lifting/lowering, exten-
sion, side shift, spreading, rotation, tilt, levelling and load carrier func-
tions.
• Lifting/lowering is the function used to raise and lower the boom.
• Extension is the function to extend the boom in and out.
• Side shift is used to move the lift attachment laterally in relation to
the machine.
• Spreading is used to adjust the width between the attachment’s
lifting points.
• Rotation is rotating the load in relation to the machine.
• Tilt is angling the load in the longitudinal direction of the truck.
• Levelling is angling the load in the lateral direction of the truck.
• The load carriers are designed to hold a fixed load.
The control system is functions for warning the operator of dangerous
situations and machine faults. The control system has diagnostic re-
sources that simplify troubleshooting.
The frame supports the machine. Mounted in the frame are the engine,
transmission, drive axle and steering. The side of the frame houses
tanks for fuel, hydraulic oil and oil for the brake system. The cab is cen-
trally located and can be tilted longitudinally. As an option the cab is
available in a side-mounted version that can be raised and lowered.

4 0 Complete machine – Complete machine
Troubleshooting, general work

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

Troubleshooting without an error

page
–
code, example
1 Choose suitable section 0–12 to find the function and sub-func-
tion that have caused the symptom.
2 Read the function description for the function in question to get
an overall understanding of which components are affected and
how these interact.
3 Use the function description and check the signals for the func-
tion in question to find where in the function chain that signal or
reaction is incorrect.
4 The fault is probably between the two units where the signal is
failing. Start by checking the component that should send the
signal.
5 If the component that is to send the signal seems to be correct,
check transmission of the signal (electric wiring or hydraulic
hoses).
For electric cabling, see Troubleshooting cable harness page 7.
For hydraulic hoses,
see Troubleshooting hydraulic hoses page 8.
6 If the leads or hoses between the components seem in order,
then check the component that receives the signal.
Troubleshooting with error code,

page
–
example
Error codes are strong indicators of malfunctions detected by the con-
trol system. Many error codes are connected to electrical malfunctions
but there are also error codes that interpret associations between one
or several signals that indicate a non-electrical malfunction. It’s impor-
tant to not draw conclusions too fast based on an error code.
1 Read out error codes from the display, e.g., error code 34.
2 Use the error code lists and search information about the error
code, see "Example of error code information in error code list"
below.
Error code lists are found in section D Error codes.
For detailed instruction on reading out error code, see section D
Error codes.
3 Follow the instructions in the field “Action”.
4 Use diagnostic menus and circuit diagrams to determine if the in-
put signal to the control unit is correct; see section 8 Control
system , group 8.4 Diagnostics as well as section E Schematics.
5 Use the function group to find more information if needed.
In section 0–12 there is function description, the function's includ-
ed components and their position as well as, in certain cases,
work instructions for how components are checked, cleaned or
adjusted.

6 If possible, eliminate component fault by testing the component

individually.
Electric components can sometimes be checked with resistance
measurements using a multimeter.
Hydraulic components are often checked by measuring pressure
(then described in the function group and indicated in the
section C Preventive maintenance). Sometimes valves can be
activated mechanically to determine if the malfunction is electric
or hydraulic.
7 If the component’s measurement values are correct, continue by
troubleshooting electric cables and hydraulic hoses.
For electric cabling, see Troubleshooting cable harness page 7.
For hydraulic hoses, see Troubleshooting hydraulic hoses page
8.
8 If the cable is not defective, then connect the lead to the control
unit.
NOTE
The main electric power shall be turned off with the battery
disconnector!
9 Disconnect the cable from the component in question.
10 Turn on the main electric power with the battery disconnector.
11 Turn the ignition key to the operating position.
12 Check that voltage reaches the component.
Table 1. Example of error code information in error code list
Connections
Diagnos- Function
Code Description Limitation Action and
tic menu group
components
34 Signal error from Parking brake Check cabling D791-1/K8:5 - HYD, 4.1.2 Parking
parking brake cannot be between the control S107, K8:13 - menu 5 brake control
switch, indicates re- released. unit and the S107
leased and applied component with
at same time or diagnostic menu.
nothing at all. Check component.

Troubleshooting cable harness

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

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

ing using electronic cleaner 923836.0826 and re-
grease them with connector grease 923836.0552.
4 Check if there is 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 for the component
in the connector at the control unit or component.
b. The resistance must correspond with the component. Other-
wise there may be an open circuit or short circuit in cable har-
ness and/or component.
5 Check if there is short circuit to frame:
a. Unplug the connector at both the control unit and the compo-
nent in question.
b. Measure the resistance of one lead at a time. Measure be-
tween the lead and a frame-connected part of the machine.
c. The multimeter should show endless resistance.

Troubleshooting hydraulic hoses

page
–
WARN IN G
Oil under high pressure!
Personal injury!
Always depressurise hydraulic and brake systems
before starting to work on the systems.
1 Depressurise the hydraulic and brake systems; see section B

Safety.
2 Study the relevant hydraulic diagram, check between whichever
components the suspect hose is connected and correspondingly
where it is spliced.
3 Locate the hose on the machine.
Start at one component and follow the hose to the next
component.
4 Inspect the entire hose and splicing points with respect to chafing
damage, pinching damage and leaks.
Change damaged hoses. When removing a hydraulic hose,
change of O-ring is always recommended on the hoses that have
these (ORFS).

1 Engine 1
1 Engine
Table of Contents1 Engine

mm mm mm mm mm mm
1 Engine ............................................................................................................. 3
1.1 Controls and instruments ......................................................................... 23
1.1.1 Ignition switch ...................................................................................... 23
1.1.2 Accelerator pedal ................................................................................. 24
1.2 Fuel system .............................................................................................. 25
1.2.1 Fuel tank .............................................................................................. 25
1.2.2 Sensor, fuel level ................................................................................. 25
1.6 Air intake and exhaust outlet .................................................................... 26
1.6.1 Air cleaning system .............................................................................. 26
1.6.3 Exhaust system ................................................................................... 26
1.6.4 Intercooler ............................................................................................ 27
1.7 Cooling system ......................................................................................... 28
1.7.4 Radiator and expansion tank ............................................................... 29
1.7.5 Cooling fan ........................................................................................... 30
1.7.7 Coolant ................................................................................................ 32
1.7.10 Engine heater ...................................................................................... 35
1.9 Engine control system .............................................................................. 36
1.9.1 Control unit, engine .............................................................................. 36
1.11 Start/stop .................................................................................................. 37
1.11.1 Starter motor ........................................................................................ 37
1.11.2 Stopping device ................................................................................... 37

2 1 Engine

1 Engine 3
1 Engine
mm mm mm mm mm mm
Engine, general
page
–
Engine alternative
The machine can be equipped with one of the following engine
alternatives:
• Volvo TWD1240VE stage II as per Directive 97/68/EC
• Volvo TAD1250VE (stage III as per Directive 97/68/EC)
• Cummins QSM11 (stage III as per Directive 97/68/EC )
If there are differences between engine alternatives, this is written in
brackets after headings or under figures to clarify that which is shown.
Volvo engines have many similarities. Descriptions and instructions
that are the same for both engine alternatives are denominated "(en-
gine alternative Volvo)". If a description or set of instructions only ap-
plies to one engine alternative then the whole engine designation is
written out, for instance "(engine alternative Volvo TAD1250VE).
Component supplier documentation

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

4 1 Engine
Engine alternative Volvo, function

page
–
description
Condition Reference value Reference
Disconnected (when cable is in start lock-out is Engine heater, description page 35
Engine heater
activated)
˚C
0 . bar
P I
rpm
II kph
III D5
10 <˚ 1, 5
D10 D1
2, 11 6, 15 18, 21
D790-1 D790-2 D795
D793 D794 D797-R

20, 22 3, 7, 12 14, 23 17
D7
D14 D16
D19
19 D3
H2O 16
8 M SENSORS 13
4
008223
9
Pos Explanation Signal description Reference

1 The ignition key lock sends a voltage sig- U = 24 V Ignition switch, description page 23
nal to the cab control unit (D790-1) when D1: Diagnostic menu, see section 8 Control
the start key is turned to position 1 or the system , group 8.4.1.4 CAN/POWER,
preheating position. menu 4 and 8.4.6.4 ENGINE, menu 4
2 Cab control unit (D790-1) sends ignition on Checked by control sys- Section 11 Common electrics, group
via the CAN bus. If the key is turned to the tem, error shown with 11.5.3.1 Cab control unit
preheating position, then preheating is error code.
also sent on the CAN bus.
3 If preheating is activated with the start key U = 24 V D3: Diagnostic menu, see section 8 Control
then Control unit, engine (D794) supplies system , group 8.4.6.5 ENGINE, menu 5
power to the preheating element.
4 The preheating coil warms the engine - D3: Diagnostic menu, see section 8 Control
intake air. system , group 8.4.6.5 ENGINE, menu 5

1 Engine 5

5 The ignition key lock sends a voltage sig- U = 24 V Ignition switch, description page 23
nal to the Control unit KIT (D790-2) when D5: Diagnostic menu, see section 8 Control
the start key is turned to the start position. system , group 8.4.6.4 ENGINE, menu 4
6 Control unit KIT (D790-2) transmits a start Checked by control Section 11 Common electrics, group
signal on the CAN bus. system, error shown 11.5.3.11 Control unit KIT
with error code.
7 The engine control unit (D794) supplies U = 24 V Starter motor, description (engine alterna-
power to the starter motor. tive Volvo) page 37
D7: Diagnostic menu, see section 8 Control
system , group 8.4.6.5 ENGINE, menu 5
8 The starter motor cranks the engine. - Starter motor, description (engine alterna-
tive Volvo) page 37
9 The engine’s sensors send signals to the Checked by control sys- Section 11 Common electrics, group
engine control unit (D794), which regulates tem, error shown with 11.5.3.10 Engine control unit
the injectors so that the engine starts. error code.
10 The accelerator pedal sends the cab con- U = 0.5–4.5 V Section 9 Frame, body, cab and accesso-
trol unit (D790-1) a voltage signal propor- Lower voltage than 0.5 ries, group 9.1 Controls and instruments
tional to the downward press of the pedal. V and higher voltage D10: Diagnostic menu, see section 8 Con-
than 4.5 V used to de- trol system , group 8.4.6.1 ENGINE,
tect malfunction in cable menu 1
harnesses and controls.
11 The cab control unit (D790-1) transmits a Checked by control sys- Section 11 Common electrics, group
message with the rpm request on the CAN tem, error shown with 11.5.3.1 Cab control unit
bus error code.
12 The engine control unit (D794) increases - Section 11 Common electrics, group
engine speed. 11.5.3.10 Engine control unit
13 The NO switch for coolant level sends a U = 24 V Cooling system, description page 28
voltage signal to Control unit, engine
(D794) if the coolant level in the expansion
tank is low.
14 The engine control unit (D794) transmits Checked by control sys- Section 11 Common electrics, group
engine data and warning messages on the tem, error shown with 11.5.3.10 Engine control unit
CAN bus. error code. D14: Diagnostic menu, see section 8 Con-
trol system , group 8.4.6.6 ENGINE,
menu 6 and 8.4.6.7 ENGINE, menu 7
15 The KID control unit (D795) shows engine - Section 11 Common electrics, group
data via display figures. 11.5.3.12 KID control unit

6 1 Engine

16 The fuel level sensor (B757) sends a volt- U = 0.5–4.5 V Sensor, fuel level, description page 25
age signal to Control unit, frame rear Lower voltage than 0.5 D16: Diagnostic menu, see section 8
(D797-R) proportional to the fuel level in V and higher voltage Control system , group 8.4.3.7 CAB,
the tank. than 4.5 V used to de- menu 7
tect malfunction in cable
17 Control unit, frame rear (D797-R) transmits Checked by control sys- Section 11 Common electrics, group
fuel level on the CAN bus. tem, error shown with 11.5.3.3 Control unit, frame rear
error code.
18 The KID control unit (D795) displays the - Section 11 Common electrics, group
fuel level in the operating menu for engine. 11.5.3.12 KID control unit
19 The output shaft sensor (B758) sends the - D19: Diagnostic menu, see section 8
transmission control unit (D793) pulses Control system , group 8.4.7.6 TRANSM,
with frequency proportional to output shaft menu 6
rpm.
20 The transmission control unit (D793) Checked by control sys- Section 11 Common electrics, group
transmits speed on the CAN bus. tem, error shown with 11.5.3.9 Control unit, transmission
error code.
21 The KID control unit (D795) shows the ma- - Section 11 Common electrics, group
chine’s speed. 11.5.3.12 KID control unit
22 If output shaft rpm is so high that it reaches Checked by control sys- Section 11 Common electrics, group
the limit for the machine’s speed limitation, tem, error shown with 11.5.3.1 Cab control unit
the cab control unit (D790-1) transmits a error code.
reduce engine rpm request on the CAN
bus.
23 Control unit engine (D794) restricts engine - Section 11 Common electrics, group
rpm. 11.5.3.10 Engine control unit

1 Engine 7
Engine alternative Cummins QSM11,

page
–
function description
(model year-2008)
Engine heater
activated)
˚C
0 . bar
P I
rpm
II kph
III
1, 3
8 <˚
D8 D1 D3
2, 9 4, 13 16, 19
D790-1 D790-2 D795
D793 D794 D797-R

18, 20 12, 21 5, 10, 15
D14
D12
D17 D5
17
H2O SENSORS M 6
14
008224
11 7

1 The ignition switch sends a voltage sig- U = 24 V Ignition switch, description page 23
the ignition key is turned to position 1. system , group 8.4.1.4 CAN/POWER, menu 4
and 8.4.6.4 ENGINE, menu 4
2 The cab control unit (D790-1) transmits Checked by control Section 11 Common electrics, group
Ignition on as a start message on the system, error shown 11.5.3.1 Cab control unit
CAN bus. with error code.
nal to Control unit KIT (D790-2) when the D2: Diagnostic menu, see section 8 Control
start key is turned to the start position. system , group 8.4.6.4 ENGINE, menu 4
4 The KIT control unit (D790-2) transmits a Checked by control Section 11 Common electrics, group
start signal on the CAN bus. system, error shown 11.5.3.11 Control unit KIT
with error code.

8 1 Engine

5 Control unit, frame rear (D797-R) U = 24 V Starter motor, description (engine alternative
supplies power to the starter motor. Cummins) page 37
6 The starter motor cranks the engine. - Starter motor, description (engine alternative
Cummins) page 37
7 The engine’s sensors send signals to the - Section 11 Common electrics, group
engine control unit (D794), which 11.5.3.10 Engine control unit
regulates the injectors so that the engine
starts.
8 The accelerator pedal sends the cab U = 0.5–4.5 V Section 9 Frame, body, cab and accessories,
control unit (D790-1) a voltage signal Lower voltage than 0.5 group 9.1 Controls and instruments
proportional to the downward press of V and higher voltage D8: Diagnostic menu, see section 8 Control
the pedal. than 4.5 V used to de- system , group 8.4.6.1 ENGINE, menu 1
9 The cab control unit (D790-1) transmits a Checked by control Section 11 Common electrics, group
message with the rpm request on the system, error shown 11.5.3.1 Cab control unit
CAN bus with error code.
10 The engine control unit (D794) controls - Section 11 Common electrics, group
11 The NO switch for coolant level sends a U = 24 V Cooling system, description page 28
voltage signal to Control unit, engine
(D794) if the coolant level in the expan-
sion tank is low.
engine data and warning messages on tem, error shown with 11.5.3.10 Engine control unit
the CAN bus. error code. D12: Diagnostic menu, see section 8 Control
system , group 8.4.6.6 ENGINE, menu 6 and
8.4.6.7 ENGINE, menu 7
13 The KID control unit (D795) shows en- - Section 11 Common electrics, group
gine data via display figures. 11.5.3.12 KID control unit
14 The fuel level sensor (B757) sends a U = 0.5–4.5 V Sensor, fuel level, description page 25
voltage signal to Control unit, frame rear Lower voltage than 0.5 D14: Diagnostic menu, see section 8 Control
(D797-R) proportional to the fuel level in V and higher voltage system , group 8.4.3.7 CAB, menu 7
the tank. than 4.5 V used to de-
15 Control unit, frame rear (D797-R) Checked by control Section 11 Common electrics, group
transmits fuel level on the CAN bus. system, error shown 11.5.3.3 Control unit, frame rear
with error code.
fuel level in the operating menu for 11.5.3.12 KID control unit
engine.

1 Engine 9

17 The output shaft sensor (B758) sends - D17: Diagnostic menu, see section 8 Control
the transmission control unit (D793) system , group 8.4.7.6 TRANSM, menu 6
pulses with frequency proportional to
output shaft rpm.
18 The transmission control unit (D793) Checked by control Section 11 Common electrics, group
transmits speed information on the CAN system, error shown 11.5.3.9 Control unit, transmission
bus. with error code.
19 The KID control unit (D795) shows the - Section 11 Common electrics, group
machine’s speed. 11.5.3.12 KID control unit
20 If the speed is at the machine’s speed Checked by control Section 11 Common electrics, group
limitation limit, the cab control unit system, error shown 11.5.3.1 Cab control unit
(D790-1) transmits an engine speed with error code.
reduction request on the CAN bus.
21 Control unit engine (D794) restricts - Section 11 Common electrics, group

engine rpm. 11.5.3.10 Engine control unit

10 1 Engine

page
–
(model year 2009-)
Engine heater
activated)
0 . bar
P I
rpm
II kph
III
1, 3
8
D8 D1 D3
2, 9 4, 14 17, 20
D790-1 D790-2 D795
D793 D794 D797-R

19, 21 13, 22 5, 10, 16
12
D15
D13
D18 D5
18 H2O
SENSORS M 6
15
013025a
11
7

the ignition key is turned to position 1. system , group 8.4.1.4 CAN/POWER, menu 4
and 8.4.6.4 ENGINE, menu 4
2 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group
Ignition on as a start message on the tem, error shown with 11.5.3.1 Cab control unit
CAN bus. error code.
nal to Control unit KIT (D790-2) when the D2: Diagnostic menu, see section 8 Control
start key is turned to the start position. system , group 8.4.6.4 ENGINE, menu 4
4 The KIT control unit (D790-2) transmits a Checked by control sys- Section 11 Common electrics, group
start signal on the CAN bus. tem, error shown with 11.5.3.11 Control unit KIT
error code.

1 Engine 11

5 Control unit, frame rear (D797-R) sup- U = 24 V Starter motor, description (engine alternative
plies power to the starter motor. Cummins) page 37
6 The starter motor cranks the engine. - Starter motor, description (engine alternative
Cummins) page 37
7 The engine’s sensors send signals to the - Section 11 Common electrics, group
engine control unit (D794), which regu- 11.5.3.10 Engine control unit
lates the injectors so that the engine
starts.
8 The accelerator pedal sends the cab U = 0.5–4.5 V Section 9 Frame, body, cab and accessories,
control unit (D790-1) a voltage signal Lower voltage than 0.5 group 9.1 Controls and instruments
proportional to the downward press of V and higher voltage D8: Diagnostic menu, see section 8 Control
the pedal. than 4.5 V used to de- system , group 8.4.6.1 ENGINE, menu 1
9 The cab control unit (D790-1) transmits a Checked by control Section 11 Common electrics, group
message with the rpm request on the system, error shown 11.5.3.1 Cab control unit
CAN bus with error code.
10 The engine control unit (D794) controls - Section 11 Common electrics, group
11 The NO switch for coolant level grounds Low coolant level: U Cooling system, description page 28
the control terminal of the coolant level K322:85 = 0 V
relay (K322) if the coolant level is low in
the expansion tank.
12 Coolant level relay (K322) breaks the cir- - Cooling system, description page 28
cuit to Control unit, engine (D794) if the
coolant level is low in the expansion
tank.
engine data and warning messages on tem, error shown with 11.5.3.10 Engine control unit
the CAN bus. error code. D13: Diagnostic menu, see section 8 Control
system , group 8.4.6.6 ENGINE, menu 6 and
14 The KID control unit (D795) shows en- - Section 11 Common electrics, group
gine data via display figures. 11.5.3.12 KID control unit
15 The fuel level sensor (B757) sends a U = 0.5–4.5 V Sensor, fuel level, description page 25
voltage signal to Control unit, frame rear Lower voltage than 0.5 D15: Diagnostic menu, see section 8 Control
(D797-R) proportional to the fuel level in V and higher voltage system , group 8.4.3.7 CAB, menu 7
the tank. than 4.5 V used to de-

12 1 Engine

16 Control unit, frame rear (D797-R) Checked by control Section 11 Common electrics, group
transmits fuel level on the CAN bus. system, error shown 11.5.3.3 Control unit, frame rear
with error code.
fuel level in the operating menu for 11.5.3.12 KID control unit
engine.
18 The output shaft sensor (B758) sends - D18: Diagnostic menu, see section 8 Control
the transmission control unit (D793) system , group 8.4.7.6 TRANSM, menu 6
pulses with frequency proportional to
output shaft rpm.
19 The transmission control unit (D793) Checked by control Section 11 Common electrics, group
transmits speed information on the CAN system, error shown 11.5.3.9 Control unit, transmission
bus. with error code.
20 The KID control unit (D795) shows the - Section 11 Common electrics, group
machine’s speed. 11.5.3.12 KID control unit
21 If the speed is at the machine’s speed Checked by control Section 11 Common electrics, group
limitation limit, the cab control unit system, error shown 11.5.3.1 Cab control unit
(D790-1) transmits an engine speed with error code.
22 Control unit engine (D794) restricts - Section 11 Common electrics, group

engine rpm. 11.5.3.10 Engine control unit

1 Engine 13
Engine alternative Volvo

page
–
TWD1240VE, component location

1 2 3 4 5 6 7
20
19
8
18 9
10
17 11
16
001641
15 14 13 12
Engine alternative, Volvo TWD1240VE, right side (in machine’s

direction of travel)
1. Air nipple, cooling system 11. Sensor, engine speed

2. Charge air pressure and charge air temperature sensor 12. Fuel pre-filter
3. Engine control unit (D794) 13. Draining of condensation from fuel filter and water-in-fuel
4. Intercooler sensor
5. Coolant temperature sensor 14. NO switch, fuel pressure
6. Dipstick 15. Fuel filter
7. Engine oil filling point 16. Extra coolant pump
8. Fuel connection (intake) 17. Oil pressure and oil temperature sensor
9. Fuel connection (return) 18. Compressor, air conditioning
10. Starter motor 19. Alternator

20. Sensor camshaft rpm

14 1 Engine
1 2 3 4 5 6
10
003160
17 16 15 14 13 12 11
Engine alternative, Volvo TWD1240VE, left side (in machine’s
direction of travel)
1. Connection cab heat 9. Transmission oil cooler

2. Air cleaner connection 10. Thermostat, transmission oil cooler
3. Turbocharger 11. Radiator connection intake
4. Exhaust system connection 12. Coolant pump
5. Radiator connection outlet 13. Coolant filter
6. Expansion tank connection 14. Engine oil drain plug
7. Thermostat 15. Coolant shut-off cock
8. Water cooler 16. Oil filter (full flow)
17. Oil filter (bypass)

1 Engine 15
Engine alternative Volvo

page
–
TAD1250VE, component location
4 5
1 2 3 6
10
11
12
13
14
15
16
17
18
19
20
21
006446
Volvo TAD1250VE engine right side (in machine’s direction of travel)
1. Intercooler 12. Water separator

2. Water cooler 13. Sensor, water-in-fuel
3. Transmission oil cooler 14. Fuel filter
4. Preheating element 15. Engine control unit (D794)
5. Charge air pressure and charge air temperature sensor 16. Oil level sensor
6. Engine oil filling point 17. Crankcase pressure sensor
7. Coolant temperature sensor 18. Engine oil drain plug
8. Starter motor 19. Oil pressure and temperature sensor
9. Sensor, engine speed 20. Dipstick
10. NO switch, fuel pressure 21. Alternator
11. Fuel pre-filter

16 1 Engine
006400
10 9 8
Volvo TAD1250VE engine, left side (in machine’s direction of travel)
1. Connection cab heat 6. Coolant pump

2. Expansion tank 7. Coolant filter (behind console)
3. Sensor, coolant level 8. Oil filter (full flow)
4. Thermostat 9. Oil filter (bypass)
5. Turbocharger 10. Oil pressure sensor, piston cooling

1 Engine 17

page
–
component location
1 2 3
12
001643
11 10 9 8 7 6 5 4
Engine alternative, Cummins, right side (in machine’s direction of
travel)
1. Location for air conditioning compressor 7. Draining of condensation from fuel filter and water-in-fuel sensor
2. Fuel connection (outlet) 8. Fuel filter
3. Engine control unit (D794) 9. Sensor fuel pressure
4. Engine oil drain plug 10. Fuel pump
5. Starter motor 11. Oil pressure and oil temperature sensor
6. Fuel connection (intake) 12. Crankshaft position sensor

18 1 Engine
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15
16
25
17
24 18
003163
23 22 21 20 19
Engine alternative, Cummins, left side (in machine’s direction of travel)
1. Engine oil filling point 13. Radiator connection (outlet)

2. Dipstick 14. Intake, intercooler
3. Connection cab heat 15. Intercooler
4. Air cleaner connection 16. Water cooler
5. Turbocharger 17. Thermostat
6. Intercooler connection (outlet) 18. Transmission oil cooler
7. Intercooler connection (intake) 19. Radiator connection (intake)
8. Intake temperature sensor 20. Coolant pump
9. Exhaust system connection 21. Expansion tank connection
10. Boost pressure sensor 22. Thermostat housing
11. Expansion tank connection 23. Oil filter
12. Alternator (coolant temperature sensor behind alternator) 24. Coolant filter
25. Coolant shut-off cock

1 Engine 19
Engine and transmission,

page
–
separation (engine alternative

Volvo)
Separation
1 Machine in service position, see section B Safety.
2 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 plugs in front of the flywheel.

Use the outer hole to turn the engine round.
6 Remove the flex plate’s attaching bolt. Turn the engine until flex
plate’s attaching bolts are visible in the inner hole. The flex plate
has eight attachment points to be loosened.
7 Take up the slack in the hoisting equipment.
NOTE
Do not lift the engine or transmission.

20 1 Engine
8 Remove the bolts between the engine and the transmission.

9 Loosen the engine or transmission attachment brackets and sep-
arate the engine and transmission.
Assembly
10 Check that the holes for the flex plate’s mounting in the flywheel
are just in front of the flex plate’s retaining nuts.
The flex plate has eight attachment points to be connected with
the flywheel on the engine.
11 Fit the engine or transmission brackets.
Tighten to a torque of 168 Nm.
12 Connect the engine to the transmission.
13 Fit the bolts between the engine and transmission. Tighten to a

torque of 40 Nm.
14 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.
15 Fit the plugs in front of the flywheel.

16 Remove the hoisting equipment from the engine.
17 Remove the jack from underneath the transmission.
18 Connect the requisite hoses and cables for the engine and trans-
mission. Check and fill fluids as needed.
19 Bleed air from the engine’s fuel system before start.

1 Engine 21

page
–
separation (engine alternative

Cummins QSM11)
Separation
2 Attach hoisting equipment to the engine.
3 Disconnect the requisite hoses and cables before separating en-
gine and transmission.
NOTE
Drain and collect liquids before detaching hoses.
4 Use a jack to secure the transmission.
5 Remove the cover washer.

22 1 Engine
6 Rotate the engine for each bolt in the flex plate that has to be
removed.
7 Remove the screws of the flex plate through the hole under the
cover washer.
8 Take up the slack in the hoisting equipment.
NOTE
Do not lift the engine.
9 Remove the bolts between engine and transmission.
10 Loosen the engine and transmission brackets.
11 Withdraw the engine rearwards to separate it from the
transmission.
Assembly
12 Rotate the engine so that the holes in the flywheel are just in front
of the attachment points on the flex plate.
The flex plate has eight attachment points to be connected with
the flywheel on the engine.
13 Fit the bolts to the engine and transmission brackets. Tighten to
a torque of 168 Nm.
14 Connect the engine to the transmission.
15 Fit the bolts between engine and transmission. Tighten to a
torque of 52 Nm.
16 Fit the flex plate’s attaching bolts. Tighten to a torque of 40 Nm.
NOTE
The engine must be loosened from the engine mounts and
separated from the transmission to remove a dropped bolt.
Secure the bolt in the socket when installing.
17 Fit the plug in front of the flywheel.
18 Remove the hoisting equipment from the engine.
19 Remove the jack from underneath the transmission.
20 Connect the requisite hoses and cables for the engine and trans-
mission. Check and fill fluids as needed.

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

1.1.1 Ignition switch
Ignition switch, description
page
–
P No function.
0 Stop position. Everything switched off; key can be removed.
I Operating position.
Voltage to all electrical functions. Engine and transmission con-
trol units are now ready for start.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.1.4 CAN/POWER, menu 4.
II Preheating position.
In the preheating position the engine’s intake air is heated by the
electric heater to a suitable temperature. The preheating lamp il-
luminates during preheating.
0 8 Control system , group 8.4.6.4 ENGINE, menu 4.
III Start position.
P I
Engagement of starter motor for engine start.
II NOTE
The machine is equipped with an electric restart interlock,
which prevents engagement of the starter motor when the
engine is rotating.
000317
III
Conditions for starter motor engagement are that
transmission is in neutral position and the engine is not
already running.
8 Control system , group 8.4.6.4 ENGINE, menu 4.

24 1 Engine – 1.1.2 Accelerator pedal
1.1.2 Accelerator pedal

Accelerator pedal, replacement
page
–

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

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

1 Engine – 1.2 Fuel system 25
1.2 Fuel system

Fuel system, description
page
–
The fuel system distributes fuel between the cylinders and thereby
controls the engine output power and rpm.
When the engine is started, the fuel pump sucks fuel from the tank
through the fuel filter and forces it to the unit injections. The unit injec-
tors spray in the fuel and atomises the fuel to the engine’s combustion
chamber.
1.2.1 Fuel tank

Fuel tank, description
page
–
The fuel tank is located on the left-hand side of the machine behind the
brake fluid reservoir.
1.2.2 Sensor, fuel level

Sensor, fuel level, description
page
–
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.3.7 CAB, menu 7.
002289
1 2 3
1. Fuel filler orifice
2. Fuel tank
3. Sensor, fuel level (behind air filter)

26 1 Engine – 1.6 Air intake and exhaust outlet
1.6 Air intake and exhaust outlet

1.6.1 Air cleaning system
Air cleaning system, description
page
–
Combustion in the engine requires air. Free unobstructed flow for

1 2 3 4 5
fresh air and exhausts is essential for effective engine operation.
001357
Air cleaning system, overview

1. Intake hose
2. Filter indicator
3. Air cleaner
4. Intake
5. Dust reservoir
1.6.3 Exhaust system

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

1 2 3
stalled between the engine and the exhaust system to protect wiring,
etc. A flex-pipe between the turbo and silencer absorbs the engine’s
4
movements. On the outside of the machine, there is a heat shield fitted
over the exhaust system.
5
WARN IN G
001356
Hot exhaust system!
Exhaust system overview Risk of burn injuries!

1. Turbocharger
Never touch the turbo or muffler when the machine is
2. Flex pipe
running or just after it has been turned off!
3. Exhaust pipe
4. Tail pipe
5. Silencer

1 Engine – 1.6.4 Intercooler 27
1.6.4 Intercooler
Intercooler, description
page
–
Engine alternative Volvo TAD1250VE and Cummins

QSM11
The charge air is cooled by an air-air intercooler in the upper part of
1 the cooling unit.
Engine alternative Volvo TWD1240VE

The charge air is cooled by a water-air intercooler on the engine, see
engine supplier documentation.
Also refer to Cooling system, description page 28.
3
003215
Cooling unit, engine alternative Volvo TAD1250VE

and Cummins QSM11
1. Intercooler
2. Engine cooler
3. Transmission oil cooler
4. Transmission oil thermostat
5. Condenser mounting (to AC)

28 1 Engine – 1.7 Cooling system
1.7 Cooling system

Cooling system, description
page
–
The engine is water-cooled and has passages through which the cool-
ant from the radiator flows round a closed system.
Main parts of the cooling system:
• Coolant pump
• Expansion tank
• Thermostat
• Cooling fan
• Radiator
• Engine oil cooler
• Intercooler
• Coolant filter
How the engine cooling system works:
1. The coolant pump pumps coolant through the cylinder head, en-
gine block and oil cooler. On the engine alternative Volvo
TWD1240VE a separate coolant pump pumps coolant through the
intercooler.
2. The thermostat directs the heated coolant back to the coolant
pump or through the radiator.
3. When the coolant is colder than the thermostat opening tempera-
ture it is pumped back to the engine.
When the coolant is warmer than the thermostat opening temper-
ature it is pumped through the radiator and then back to the cool-
ant pump.
4. The expansion tank allows the coolant to expand without escap-
ing from the engine.

1 Engine – 1.7.4 Radiator and expansion tank 29
1.7.4 Radiator and expansion tank

Radiator and expansion tank, description
page
–
Radiator for the engine is located in the cooling unit which is fitted be-
hind the engine.
The purpose of the cooler assembly is to cool:
1 • Engine coolant
• Transmission oil (cooled in the lower part of the cooling unit), see
also section 2 Transmission, group 2.6.3 Oil cooler.
• The charge air (engine alternative Volvo TAD1250VE and Cum-
mins QSM11) is cooled in the upper cooling unit), see also Inter-
cooler, description page 27.
Engine alternative Volvo TWD1240VE has water-air intercooler
mounted directly on the engine.
Also refer to Cooling system, description page 28.
For more information, see supplier documentation, engine.
4
1
3
003215
Cooling unit, engine alternative Volvo TAD1250VE

and Cummins QSM11
1. Intercooler
2. Engine cooler
5. Condenser mounting (to AC) 4
2
003214
Cooling unit, engine alternative Volvo TWD1240VE

1. Engine cooler

30 1 Engine – 1.7.5 Cooling fan
1.7.5 Cooling fan

Fan belt, replacement (engine alternative Volvo)
page
–
1 Position the cab in the front position.

3 Remove the cover plates over the engine and radiator.
4 Release the tension on the fan belt and release the fan belt from
belt pulley on the belt tensioner.
5 Remove the fan belt.
6 Fit the new fan belt as illustrated.
The figure shows engine without cooling fan.

1 Engine – 1.7.5 Cooling fan 31
Drive belt, extra water pump, replacement (engine

page
–
alternative Volvo TWD1240VE)

4 Release the tension on the fan belt.
5 Remove the drive belt.
6 Fit the new drive belt as illustrated.
The figure shows engine without cooling fan.

32 1 Engine – 1.7.7 Coolant
Fan belt, replacement (engine alternative Cummins)

page
–

4 Loosen the belt tensioner.
5 Remove the fan belt.
6 Fit a new fan belt.
7 Tension the fan belt with the belt tensioner.
1.7.7 Coolant
Coolant, changing (engine alternative Volvo)
page
–
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.

2 Remove the cap on the expansion tank.
3 Place a receptacle under the radiator and engine. (The cooling
system holds about 40 l.)
C
004851
A. Location, expansion tank

B. Filling point
C. Level marking

1 Engine – 1.7.7 Coolant 33
4 Drain the cooling system.

Open the drain cock on the bottom of the radiator. Collect the
coolant in the receptacle.
5 Open the drain cock on the engine.

6 Once all the coolant has drained out, close drain cocks.
7 Fill the new premixed coolant of the correct type in the expansion
tank. For volume and quality, see section F Technical data.
C AUTION
Different types of coolant cannot be mixed.
Risk of engine damage and damage to the

cooling system if different coolant types are mixed.
When changing and refilling the coolant the coolant

must be of the same type as was previously used.
8 Open the bleed nipple to release the air and speed up the filling.
Close the bleed nipple when clean coolant without air bubbles is
flowing out.
9 Turn on the main electric power and start the engine.
10 Turn on max. heat in the cab.
11 Run the engine to operating temperature so the thermostat
opens and coolant is pumped around the whole system.
12 Check the level in the expansion tank, fill if required.
13 Check the coolant level again after 10 operating hours.

34 1 Engine – 1.7.7 Coolant
Coolant, changing (engine alternative Cummins

page
–
QSM11)
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety

2 Remove the cap on the expansion tank.
3 Place a receptacle under the radiator and engine. (The cooling
system holds about 40 l.)
C
004851
A. Location, expansion tank

B. Filling point
C. Level marking
4 Drain the cooling system.
Open the drain cock on the bottom of the radiator. Collect the
coolant in the receptacle.

1 Engine – 1.7.10 Engine heater 35
5 Open the drain cock on the engine.

6 Once all the coolant has drained out, close drain cocks.
7 Fill the new premixed coolant of the correct type in the expansion
tank. For volume and quality, see section F Technical data.
C AUTION
Different types of coolant cannot be mixed.
Risk of engine damage and damage to the

cooling system if different coolant types are mixed.
When changing and refilling the coolant the coolant

must be of the same type as was previously used.

9 Turn on max. heat in the cab.
10 Run the engine to operating temperature so the thermostat
1. Coolant shut-off cock opens and coolant is pumped around the whole system.
2. Coolant filter
11 Check the level in the expansion tank, fill if required.
3. Oil filter
12 Check the coolant level again after 10 operating hours.
1.7.10 Engine heater

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

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

36 1 Engine – 1.9 Engine control system
1.9 Engine control system

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

unit and supplier documentation, engine.

1 Engine – 1.11 Start/stop 37
1.11 Start/stop
1.11.1 Starter motor
Starter motor, description (engine alternative Volvo)
page
–
The starter motor cranks the engine until fuel combustion begins and
the engine starts.
The starter motor is supplied with voltage directly from the start batter-
ies. A relay on the starter motor (solenoid) is activated by the engine
control unit (D794).
Starter motor, description (engine alternative

page
–
Cummins)
The starter motor cranks the engine until fuel combustion begins and
the engine starts.
The starter motor is supplied with voltage directly from the start batter-
ies. A relay on the starter motor (solenoid) is activated by Control unit,
frame rear (D797-R).
Control system , group 8.4.6.5 ENGINE, menu 5.
1.11.2 Stopping device

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

fuel when the voltage is cut off, which means that the engine stops.
The engine can only be stopped by turning off the ignition via the igni-
tion switch.
NOTE
The battery disconnect switch must not be used for emergency
stop!
Automatic engine shutdown is available as an option. This means

that the engine shuts off automatically after 3-30 minutes (depending
on customer setting) if the machine is stationary and idling.

38 1 Engine – 1.11.2 Stopping device

2 Transmission 1
2 Transmission
Table of Contents 2 Transmission

mm mm mm mm mm mm
2 Transmission.................................................................................................. 3
2.1 Controls and instruments ......................................................................... 21
2.1.1 Gear selector and multi-function lever ................................................. 21
2.2 Torque converter/Clutch system .............................................................. 22
2.2.1 Flex plates ........................................................................................... 22
2.6 Lubrication system ................................................................................... 26
2.6.3 Oil cooler .............................................................................................. 29
2.7 Cooling system ......................................................................................... 31
2.7.3 Oil cooler .............................................................................................. 31
2.8 Transmission control system .................................................................... 32
2.8.1 Control unit transmission ..................................................................... 32
2.8.2 Normally closed (NC) switch, disengagement ..................................... 32
2.8.3 Transmission cable harness ................................................................ 32

2 2 Transmission

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

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

4 2 Transmission – 2 Transmission
Transmission, function description

page
–
(transmission alternative Dana)
F
R
1
D1
22 5
D22
D5
6, 23 2, 7 19
D790-1 D790-2 D795
D793 D794 D797-F

10, 16, 18, 20, 26 21 25
D12 D13 D14 D24

D15
D9 9 Pa
D8 8 12 13 14 15 24
Pa
4 17
11
3
002212
1 The gear selector sends a voltage sig- Forward, Conn. F: Section 9 Frame, body, cab and accessories,
nal to the KIT control unit (D790-2). U = 24 V group 9.1 Controls and instruments
Reverse, Conn. R: D1: Diagnostic menu, see section 8 Control
U = 24 V system , group 8.4.7.2 TRANSM, menu 2
2 The KIT control unit (D790-2) trans- Checked by control sys- Section 11 Common electrics, group 11.5.3.11
mits the selected direction of travel tem, error shown with KIT control unit
(forward or reverse) on the CAN bus. error code.
3 The transmission’s oil pump pumps oil - -

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

oil from impurities.
5 The accelerator pedal transmits a sig- U = 0.5-4.5 V Section 1 Engine, group 1.1.2
nal to the cab control unit (D790-1). Accelerator pedal


6 The cab control unit (D790-1) trans- Checked by control sys- Section 11 Common electrics, group 11.5.3.1
mits the desired throttle application on tem, error shown with Cab control unit
the CAN bus. error code.
7 The KIT control unit (D790-2) trans- Checked by control sys- Section 11 Common electrics, group 11.5.3.11
mits the selected shifting program on tem, error shown with KIT control unit
8 The oil pressure sensor sends the Checked by Control unit D8: Diagnostic menu, see section 8 Control
transmission control unit (D793) a transmission, error system , group 8.4.7.10 TRANSM, menu 10
voltage signal proportional to oil pres- shown with error code.
sure.
9 The engine speed and oil temperature Checked by Control unit D9: Diagnostic menu, See Section 8 Control
sensor (B758/766) sends the trans- transmission, error system , group 8.4.7.6 TRANSM, menu 6 and
mission control unit (D793) a pulse shown with error code. 8.4.7.10 TRANSM, menu 10
signal with frequency proportional to
engine speed and a voltage signal
proportional to the transmission oil
temperature.
10 The transmission control unit (D793) Checked by Control unit Section 11 Common electrics, group 11.5.3.9
supplies voltage to valve block trans- transmission, error Transmission control unit
mission control to obtain desired func- shown with error code.
tion.
11 Solenoid valves for travel direction Checked by Control unit -

and gear position in valve block trans- transmission, error
mission control activate gears in the shown with error code.
transmission and the engine’s power
is transmitted to the transmission’s
output shaft.
12 The turbine speed sensor (B751) Checked by Control unit D12: Diagnostic menu, see section 8 Control
sends the transmission control unit transmission, error system , group 8.4.7.6 TRANS, menu 6
(D793) a pulse signal with frequency shown with error code.
proportional to turbine speed.
13 The drum sensor (B752) sends the Checked by Control unit D13: Diagnostic menu, see section 8 Control
transmission control unit (D793) a transmission, error system , group 8.4.7.6 TRANSM, menu 6
pulse signal with frequency propor- shown with error code.
tional to drum speed.
14 The output shaft speed sensor (B758) Checked by Control unit D14: Diagnostic menu, see section 8 Control
sends the transmission control unit transmission, error system , group 8.4.7.6 TRANSM, menu 6
(D793) a pulse signal with frequency shown with error code.
proportional to output shaft speed.
15 The torque converter temperature Checked by Control unit D15: Diagnostic menu, see section 8 Control
switch (S221) sends the transmission transmission, error system , group 8.4.7.10 TRANSM, menu 10
control unit (D793) a voltage signal if shown with error code.
oil temperature in the torque converter
becomes too high.


controls gear shifting according to se- transmission, error Transmission control unit
lected shifting program. shown with error code.
17 The oil cooler cools the transmission - Oil cooler, description page 31
oil. A thermostat senses the oil’s tem-
perature and directs the oil back to the
transmission if the oil is cold.
18 The transmission control unit (D793) Checked by control sys- Section 11 Common electrics, group 11.5.3.9
transmits temperature and speed data tem, error shown with Transmission control unit
on the CAN bus. error code.
19 The KID control unit (D795) shows Checked by control sys- Section 11 Common electrics, group 11.5.3.12
transmission information in operating tem, error shown with KID control unit
menus. error code.
20 If the signal from the output shaft - D15: Diagnostic menu, see section 8 Control
speed sensor (B758) indicates that system , group 8.4.7.6 TRANSM, menu 6
machine speed exceeds the speed
limitation, the transmission control
unit (D793) transmits a engine speed
21 The engine control unit (D794) reduc- - Section 11 Common electrics, group 11.5.3.10
es engine speed. Engine control unit
22 If the clutch pedal (S220-1) is de- U = 24 V Section 9 Frame, body, cab and accessories,
pressed, it sends a voltage signal to group 9.1 Controls and instruments
the cab control unit (D790-1). D22: Diagnostic menu, see section 8 Control
system , group 8.4.7.1 TRANSM, menu 1
mits disengage drive on CAN bus. tem, error shown with Cab control unit
error code.
24 Normally closed (NC) switch, disen- Brake pressure above Normally closed (NC) switch, disengagement,
gagement (S220-2) sends the Control 0.2 MPa: description page 32
unit, frame front (D797-F) a voltage Conn 1, U = 24 V D24: Diagnostic menu, see section 8 Control
signal if brake pressure is high system , group 8.4.7.1 TRANSM, menu 1
Conn 2, U = 24 V
enough to allow drive disengagement.
Brake pressure below
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
25 Control unit, frame front (D797-F) Checked by control sys- Section 11 Common electrics, group 11.5.3.2
transmits disengagement approved tem, error shown with Control unit, frame front
on the CAN bus. error code.
supplies voltage to valve block trans- transmission, error Transmission control unit
mission control so that drive is disen- shown with error code.
gaged.

Transmission, function description

page
–
(transmission alternative Dana full

flow)
F
R
1
D1
30 5 D1
D30 D5
6, 31 2, 7 27
D790-1 D790-2 D795
D793 D794 D797-F

12, 24, 26, 28, 34 29 33
D13 D8 D10
8 9 10 20 21 22 D32
Pa
Pa Pa
23
D11 32
4 19
18 11
17
3 16
15 25
14
010494
13

1 The gear selector sends a voltage sig- Forward, Conn. F: U = 24 V Section 9 Frame, body, cab and accesso-
nal to the KIT control unit (D790-2). Reverse, Conn. R: U = 24 V ries, group 9.1 Controls and instruments
2 The KIT control unit (D790-2) transmits Checked by control system, Section 11 Common electrics, group
the selected direction of travel (forward error shown with error code. 11.5.3.11 KIT control unit
or reverse) on the CAN bus. D1: Diagnostic menu, see section 8 Control
3 The transmission’s oil pump pumps oil - -

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

oil from impurities.
5 The accelerator pedal transmits a sig- U = 0.5-4.5 V Section 1 Engine, group 1.1.2 Accelerator
nal to the cab control unit (D790-1). pedal


6 The cab control unit (D790-1) transmits Checked by control system, Section 11 Common electrics, group
the desired throttle application on the error shown with error code. 11.5.3.1 Cab control unit
CAN bus.
7 The KIT control unit (D790-2) transmits Checked by control system, Section 11 Common electrics, group
the selected shifting program on the error shown with error code. 11.5.3.11 KIT control unit
CAN bus.
8 Pressure sensor gear 1/3 (B6067) Checked by Control unit D8: Diagnostic menu, see section 8 Control
sends the transmission control unit transmission, error shown system , group 8.4.7.10 TRANSM,
(D793) a voltage signal proportional to with error code. menu 10
oil pressure.
9 Pressure sensor gear 2/4 (B6069) Checked by Control unit D8: Diagnostic menu, see section 8 Control
sends the transmission control unit transmission, error shown system , group 8.4.7.10 TRANSM,
oil pressure.
10 Sensor, engine speed (B7530) sends a Checked by Control unit D10: Diagnostic menu, see section 8 Con-
pulse signal with frequency proportion- transmission, error shown trol system , group 8.4.7.6 TRANSM,
al to the engine speed to Control unit, with error code. menu 6
transmission (D793).
11 The oil temperature sensor (B7660) Checked by Control unit D11: Diagnostic menu, see section 8 Con-
sends the transmission control unit transmission, error shown trol system , group 8.4.7.10 TRANSM,
transmission oil temperature.
12 The transmission control unit (D793) Checked by Control unit Section 11 Common electrics, group
supplies voltage to the solenoid and transmission, error shown 11.5.3.9 Transmission control unit
servo valves to obtain the desired func- with error code.
tion.
13 Solenoid valve drive forward (Y6066F) Checked by Control unit D13: Diagnostic menu, See Section 8 Con-
14 or Solenoid valve drive reverse transmission, error shown trol system , group 8.4.7.7 TRANSM, menu
(Y6066R) and Servo valve gear for- with error code. 7 , 8.4.7.8 TRANSM, menu 8 and 8.4.7.9
15
ward/reverse (Y6300) are activated to TRANSM, menu 9
16 select the direction of travel.
17 Solenoid valve gear selection 1/3
18 (Y6075) and Servo valve gear 1/3
(Y6067) or Solenoid valve gear selec-
19
tion 2/4 (Y6074) and Servo valve gear
2/4 (Y6069) are activated to select gear
position.
The engine’s power is transferred to
the transmission’s output shaft.
20 The turbine speed sensor (B7510) Checked by Control unit D10: Diagnostic menu, see section 8 Con-
sends the transmission control unit transmission, error shown trol system , group 8.4.7.6 TRANS, menu 6
(D793) a pulse signal with frequency with error code.
proportional to turbine speed.


21 The drum sensor (B7520) sends the Checked by Control unit D10: Diagnostic menu, see section 8 Con-
transmission control unit (D793) a transmission, error shown trol system , group 8.4.7.6 TRANSM,
pulse signal with frequency proportion- with error code. menu 6
al to drum speed.
22 The output shaft speed sensor (B7580) Checked by Control unit D10: Diagnostic menu, see section 8 Con-
sends the transmission control unit transmission, error shown trol system , group 8.4.7.6 TRANSM,
(D793) a pulse signal with frequency with error code. menu 6
proportional to output shaft speed.
23 The torque converter temperature Checked by Control unit D11: Diagnostic menu, see section 8 Con-
switch (S2210) sends the transmission transmission, error shown trol system , group 8.4.7.10 TRANSM,
control unit (D793) a voltage signal if oil with error code. menu 10
temperature in the torque converter be-
comes too high.
controls gear shifting according to se- transmission, error shown 11.5.3.9 Transmission control unit
lected shifting program. with error code.
25 The oil cooler cools the transmission - Oil cooler, description page 31
oil. A thermostat senses the oil’s tem-
perature and directs the oil back to the
transmission if the oil is cold.
26 The transmission control unit (D793) Checked by control system, Section 11 Common electrics, group
transmits temperature and speed data error shown with error code. 11.5.3.9 Transmission control unit
on the CAN bus.
27 The KID control unit (D795) shows Checked by control system, Section 11 Common electrics, group
transmission information in operating error shown with error code. 11.5.3.12 KID control unit
menus.
28 If the signal from the output shaft speed - D10: Diagnostic menu, see section 8 Con-
sensor (B7580) indicates that machine trol system , group 8.4.7.6 TRANSM,
speed exceeds the speed limitation, menu 6
the transmission control unit (D793)
transmits a engine speed reduction re-
quest on the CAN bus.
29 The engine control unit (D794) reduces - Section 11 Common electrics, group
30 If the clutch pedal (S220-1) is de- U = 24 V Section 9 Frame, body, cab and accesso-
pressed, it sends a voltage signal to the ries, group 9.1 Controls and instruments
cab control unit (D790-1). D30: Diagnostic menu, see section 8 Con-
trol system , group 8.4.7.1 TRANSM,
menu 1
disengage drive on CAN bus. error shown with error code. 11.5.3.1 Cab control unit


32 Normally closed (NC) switch, disen- Brake pressure above Normally closed (NC) switch, disengage-
gagement (S220-2) sends the Control 0.2 MPa: ment, description page 32
unit, frame front (D797-F) a voltage sig- Conn 1, U = 24 V D32: Diagnostic menu, see section 8 Con-
nal if brake pressure is high enough to trol system , group 8.4.7.1 TRANSM,
Conn 2, U = 24 V
allow drive disengagement. menu 1
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
33 Control unit, frame front (D797-F) Checked by control system, Section 11 Common electrics, group
transmits disengagement approved on error shown with error code. 11.5.3.2 Control unit, frame front
the CAN bus.
supplies voltage to valve block trans- transmission, error shown 11.5.3.9 Transmission control unit
mission control so that drive is disen- with error code.
gaged.

Transmission shifting, function

page
–
description (transmission
alternative Dana)
Fwd 2/4 Rev 1/3
9 11 13 15
7
RSP
38 6
8
10 12 14 16
5
37 39
18
36 17
19 20 21 22
Rev Fwd VFS 2/4 VFS 1/3
34 35 3 4
23 24 25 26
1/3 2/4
33 2
Fwd 2:nd 4:th Rev 1:st 3:rd
1
27 28 29 30 31 32
008210
1. Bottom strainer oil sump, separates particles - -
from the oil before the pumps.
2. The transmission’s oil pump 1 feeds the trans- 100.5 l/min at 1973 rpm -
mission with control pressure for control of the
transmission.
3. The oil filter cleans the oil. - -
4. The bypass valve in the filter bracket leads the oil Opening pressure: 410-450 -
past the filter if the resistance through the filter kPa
becomes too high.
5. The pressure governor releases pressure to the Opening pressure: 2200 -

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

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


8. Valve spool neutral position opens or closes to - -
allow control pressure to the transmission.
9. Solenoid valve drive forward (Y630) controls 0-600 kPa Diagnostic menu, see section 8
Pressure booster drive forward. Control system , group 8.4.7.8
TRANSM, menu 8 and 8.4.7.9
TRANSM, menu 9
10. Pressure booster forward increases the pressure 0-2000 kPa -

and pressurises Drive clutch forward.
11. Solenoid valve gear 2/4 (Y6069) controls Pres- 0-600 kPa Diagnostic menu, see section 8
sure booster gear 2/4. Control system , group 8.4.7.8
TRANSM, menu 9
12. Pressure booster gear 2/4 increases the pres- 0-2000 kPa -
sure and feeds Valve slide gear selection 2/4 as
well as Valve slide gear 2/4 control.
13. Solenoid valve drive reverse controls Pressure 0-600 kPa Diagnostic menu, see section 8
booster drive reverse. Control system , group 8.4.7.8
TRANSM, menu 9
14. Pressure booster reverse increases the pressure 0-2000 kPa -

and pressurises Drive clutch reverse.
15. Solenoid valve 1/3 (Y6067) controls Pressure 0-600 kPa Diagnostic menu, see section 8
booster gear 1/3. Control system , group 8.4.7.8
TRANSM, menu 9
16. Pressure booster gear 1/3 increases the pres- 0-2000 kPa -
sure and feeds Valve slide gear selection 1/3 as
well as Valve slide gear 1/3 control.
17. Contact drive sends signal to the control unit to -

verify that drive clutches for travel direction and
gear selection are activated when solenoid valve
neutral position (RSP) (Y6066) is activated.
18. The drive control valve compares pressure sig- - -

nals from drive clutches for direction of travel and
gear selection and sends the pressure signal on
to the drive contact.
19. The valve spool for reverse drive control opens 0-2000 kPa
when the reverse drive clutch is pressurised and
leads a pressure signal to the drive control valve.
20. The valve spool for forward drive control opens 0-2000 kPa -
when the forward drive clutch is pressurised and
21. Solenoid valve VFS 2/4 (Y6074) controls servo 1200 kPa Diagnostic menu, see section 8
pressure to Valve slide gear selection 2/4. Control system , group 8.4.7.7
TRANSM, menu 7


22. Solenoid valve VFS 1/3 (Y6075) controls servo 1200 kPa Diagnostic menu, see section 8
pressure to Valve spool gear selection 1/3. Control system , group 8.4.7.7
TRANSM, menu 7
23. The valve slide for gear 1/3 control opens when 0-2000 kPa -
valve slide gear selection 1/3 is pressurised and
24. The valve slide for gear 2/4 control opens when 0-2000 kPa -
valve slide gear selection 2/4 is pressurised and
25. Valve slide gear selection 2/4 pressurises drive 0-2000 kPa -
clutch gear 2 or drive clutch gear 4.
26. Valve spool gear selection 1/3 pressurises Drive 0-2000 kPa -
clutch gear 1 or Drive clutch gear 3.
27. Drive clutch forward locks the transmission in for- - -

ward drive when the clutch is pressurised.
28. Drive clutch gear 2 locks the transmission in gear - -

position 2 when the clutch is pressurised.

30. Drive clutch reverse locks the transmission in re- - -

verse drive when the clutch is pressurised..


33. The transmission oil pump pumps oil through the 85.1 l/min at 1973 rpm -
cooler and supplies the torque converter with oil
pressure to run the machine.
34. The oil filter cleans the oil. - -
35. The bypass valve in the filter bracket leads the oil - -
past the filter if the resistance through the filter
becomes too high.
36. The oil is distributed to different lubrication points - -

in the transmission.
37. The transmission oil cooler cools the oil. - -
38. The torque converter transmits the engine’s - -

power to the transmission.
39. The safety valve leads the oil back to the sump if Opening pressure: 900 kPa -
the pressure in the torque converter becomes
too high.

Transmission shifting, function

page
–
description (transmission
alternative Dana full flow)
30
28
5
6 11 17
16 22
27 Pa Pa
29
7 12 18
26 8 13 19
24 25 3 4
31
Rev Fwd 1st 3rd 2nd 4th
23 2
9 10 14 15 20 21
1
013040
1 Bottom strainer oil sump, separates particles - -
from the oil before the pumps.
2 The transmission’s oil pump 1 feeds the trans- 30.4 l/min at 685 rpm -
mission with control pressure for control of the
transmission.
3 The oil filter cleans the oil. - -
4 The bypass valve in the filter bracket leads the Opening pressure: 410-450 kPa -
oil past the filter if the resistance through the
filter becomes too high.
5 The pressure governor releases pressure to Opening pressure: 2200 kPa -

the torque converter if the pressure becomes
too high.
6 Servo valve front/rear (Y6300) controls pres- - Diagnostic menu, see section 8
sure to Valve travel direction, proportional to Control system , group 8.4.7.7
the desired traction. TRANSM, menu 7
7 Solenoid valve drive forward (Y6066F) or So- - Diagnostic menu, see section 8
lenoid valve drive reverse (Y6066R) controls Control system , group 8.4.7.8
Valve travel direction for drive forward or re- TRANSM, menu 8 and 8.4.7.9
verse. TRANSM, menu 9
Depending on the solenoid valve activated,
Valve travel direction controls pressure to
drive clutch forward or drive clutch reverse.


8 The accumulator evens out the pressure. - -
9 Drive clutch reverse locks the transmission in Drive reverse: 2200-2600 kPa -
reverse drive when the clutch is pressurised..
10 Drive clutch forward locks the transmission in Drive forward: 2200-2600 kPa -
forward drive when the clutch is pressurised.
11 Servo Valve 1/3 (Y6067) controls pressure to - Diagnostic menu, see section 8
Solenoid valve gear selection gear 1/3 Control system , group 8.4.7.8
(Y6075) proportional to the desired engage- TRANSM, menu 8 and 8.4.7.9
ment force. TRANSM, menu 9
12 Solenoid valve gear selection gear 1/3 - Diagnostic menu, see section 8
(Y6075) pressurises Drive clutch gear 1 or Control system , group 8.4.7.7
Drive clutch gear 3. TRANSM, menu 7
14 Drive clutch gear 1 locks the transmission in Gear selected: 2200-2600 kPa -
gear position 1 when the clutch is pressurised.
16 Pressure sensor gear 1/3 (B6067) sends the - Diagnostic menu, see section 8
transmission control unit (D793) a voltage sig- Control system , group 8.4.7.10
nal proportional to engagement pressure. TRANSM, menu 10
17 Servo Valve 2/4 (Y6069) controls pressure to - Diagnostic menu, see section 8
Solenoid valve gear selection gear 1/3 Control system , group 8.4.7.8
(Y6075) proportional to the desired engage- TRANSM, menu 8 and 8.4.7.9
ment force. TRANSM, menu 9
18 Solenoid valve gear selection gear 2/4 - Diagnostic menu, see section 8
(Y6074) pressurises Drive clutch gear 1 or Control system , group 8.4.7.7
Drive clutch gear 3. TRANSM, menu 7
22 Pressure sensor gear 2/4 (B6069) sends the - Diagnostic menu, see section 8
nal proportional to engagement pressure. TRANSM, menu 10
23 The transmission oil pump pumps oil through 15.8 l/min at 685 rpm -
the cooler and supplies the torque converter
with oil pressure to run the machine.
24 The oil filter cleans the oil. - -
25 The bypass valve in the filter bracket leads the - -

oil past the filter if the resistance through the
filter becomes too high.


26 The oil is distributed to different lubrication - -
points in the transmission.
27 The transmission oil cooler cools the oil. - -
28 The torque converter transmits the engine’s - -

power to the transmission.
29 The safety valve leads the oil back to the Opening pressure: 900 kPa -
sump if the pressure in the torque converter
becomes too high.
30 The torque converter temperature switch - Diagnostic menu, see section 8

(S2210) sends the transmission control unit Control system , group 8.4.7.10
(D793) a voltage signal if oil temperature in TRANSM, menu 10
the torque converter becomes too high.
31 The oil temperature sensor (B7660) sends the - Diagnostic menu, see section 8
nal proportional to oil temperature. TRANSM, menu 10

Transmission, component location

page
–
2
1
6
5
3 4
9
10
11 8
12
006768
15 14 13 7
1. Power take-off 9. Engine rpm and oil temperature sensor (B758/766)

(from radiator to sump)
2. Transmission oil dipstick and filler orifice 10. Temperature switch, torque converter (S221)
3. Thermostat 11. Turbine speed sensor (B751)
4. Transmission oil cooler 12. Sensor, drum rpm (B752)
5. Oil pump transmission 13. Oil filter transmission
6. Gearbox 14. Sensor rpm output shaft (B758)
7. Valve block transmission control 15. Output shaft
8. Torque converter

1 2 3 4 5
11
6
10 7
006752
1. Accelerator pedal (B690) 7. Transmission control unit (D793)
2. Control unit KIT (D790-2) 8. Diagnostic socket, transmission
3. Control unit KID (D795) 9. Declutch pedal (S220-1)
4. Multi-function lever (S162) 10. NO switch, declutch (S220-2)
5. Control unit cab (D790-1) 11. Control unit frame front (D797-F)
6. Control unit frame rear (D797-R)

Transmission, component location

page
–
(transmission alternative Dana full

flow)
3 7
2 6
4 5
18
19
20
21
22 17 8
9
013433
25 23 10
24 16 15 14 13 12 11
1. Power take-off 14. Servo valve gear 2/4 (Y6069)

2. Dipstick 15. Solenoid valve gear selection 2/4 (Y6074)
3. Filling of transmission oil 16. Solenoid valve drive reverse (Y6066R)
4. Thermostat 17. Torque converter
5. Transmission oil cooler 18. Sensor engine speed (B7530)
6. Oil pump transmission 19. Temperature switch, torque converter (S2210)
7. Gearbox 20. Turbine speed sensor (B7510)
8. Solenoid valve drive forward (Y6066F) 21. Sensor, drum rpm (B7520)
9. Servo valve gear forward/reverse (Y6300) 22. Oil filter transmission
10. Servo valve gear 1/3 (Y6067) 23. Sensor rpm output shaft (B7580)
11. Solenoid valve gear selection 1/3 (Y6075) 24. Sensor oil temperature (B7660) (from radiator to sump)
12. Pressure sensor gear 1/3 (B6067) 25. Output shaft
13. Pressure sensor gear 2/4 (B6069)

1 2 3 4 5
11
6
10 7
006752
1. Accelerator pedal (B690) 7. Transmission control unit (D793)
2. Control unit KIT (D790-2) 8. Diagnostic socket, transmission
3. Control unit KID (D795) 9. Declutch pedal (S220-1)
4. Multi-function lever (S162) 10. NO switch, declutch (S220-2)
5. Control unit cab (D790-1) 11. Control unit frame front (D797-F)
6. Control unit frame rear (D797-R)

page
–
separation
Engine alternative Volvo: see section 1 Engine , group 1 Engine and
transmission separation (Engine alternative Volvo).
Engine alternative Cummins: see section 1 Engine , group 1 Engine
and transmission separation (Engine alternative Cummins).

2 Transmission – 2.1 Controls and instruments 21

2.1.1 Gear selector and multi-function
lever
Gear and multi-function lever, description
page
–
Travel direction is selected with the gear and multi-function lever.

F
Selection of travel direction:
• F – Forward
• N – Neutral
• R – Reverse
The switch is supplied voltage by and sends signals to the KIT control
unit (D790-2).
002209
R
Control system , group 8.4.7.2 TRANSM, menu 2.

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

system
2.2.1 Flex plates
Flex plates, replacement (engine alternative Volvo)
page
–

2 Remove the cover plate for the flywheel.
3 Remove the bolts for the flex plate.

2 Transmission – 2.2.1 Flex plates 23
4 Turn the engine for each bolt to be removed from the flex plate.
5 Attach the transmission to an overhead crane.
6 Remove the bolts holding together the transmission and engine.
7 Carefully separate the transmission and engine.

24 2 Transmission – 2.2.1 Flex plates
8 Remove the bolts holding the flex plate to the transmission.

9 Replace the flex plate.
10 Fit in the reverse order. Fit the attaching bolts with 40 Nm.
11 Before the machine is put into operation, the transmission must
be calibrated; see Transmission, calibration page 32.
Flex plate attachment.
Flex plates, replacement (engine alternative

page
–
Cummins QSM11)
2 Remove the cover plate.
3 Remove the bolts for the flex plate.
4 Turn the engine for each bolt to be removed from the flex plate.
5 Attach the transmission to an overhead crane.
6 Remove the bolts holding together the transmission and engine.

2 Transmission – 2.2.1 Flex plates 25
7 Carefully separate the transmission and engine.
8 Remove the bolts holding the flex plate to the transmission.

9 Replace the flex plate.
10 Fit in the reverse order. Fit the attaching bolts with 40 Nm.
11 Before the machine is put into operation, the transmission must
be calibrated; see Transmission, calibration page 32.
Flex plate attachment.

26 2 Transmission – 2.6 Lubrication system
2.6 Lubrication system

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

• Lubricate gear wheel and bearings
• Apply the clutches in the transmission
• Cool down the torque converter and the transmission
• Clean the oil of any impurities with two oil filters.
During operation of the engine, the oil pump draws oil from the trans-
mission’s oil sump through a strainer, and it then pumps it through two
oil filters to a control valve.
The control valve supplies oil at the correct pressure to the transmis-
sion’s valve housing to activate the clutch plates for FORWARD or
REVERSE and gear 1, 2, 3 or 4. The clutch plates require just a small
amount of the oil flow supplied by the pump. The remainder of the oil
is pumped through the torque converter circuit to the oil cooler and re-
turns to the transmission for lubrication.
See also supplier documentation, transmission.
Oil and oil filter, changing

page
–
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
The transmission must not be over filled!
1 Operate and warm up the transmission oil.
3 Remove the drain plug for transmission oil and let the oil drain
into the receptacle.
Draining transmission oil

2 Transmission – 2.6 Lubrication system 27
4 Change oil filter.

Moisten the O-ring of the new oil filters with transmission oil.
Tighten until it makes contact and then another two-thirds of a
turn.
5 When the transmission oil has drained, fit the drain plug.
Make sure that the washer for the oil plug is included.
Oil filter transmission

6 Fill with new transmission oil through the filler orifice (position B).
B C
For volume and grade, see section F Technical data.
7 Start the engine and allow it to idle for at least two minutes.
8 Check that the transmission oil drain plug is airtight.
9 Check the transmission oil level with the engine running at idle
and top up to the marking for low level.
A
013334
A. Location of filler orifice and level control

B. Filling
C. Dipstick
10 Warm up the transmission so that the display shows an oil tem-
perature between 60-65 °C. Use the oil temperature operating
menu to check transmission oil temperature.
a
11 Check the oil level. Fill to the MAX mark.
000356
Operating menu, oil temperature

a. Transmission oil temperature
b. Hydraulic oil temperature

28 2 Transmission – 2.6 Lubrication system
Oil level, check

page
–
B C NOTE
Safety.
The transmission’s oil filler pipe and dipstick (position B) are located
under the service hatch in front of the cab.
1 Check the oil level with the engine at idle, transmission in neutral
position and at operating temperature (approx. 60-65 °C in the
display). The dipstick has two markings, MAX and MIN. The oil
level should be at MAX.
Wipe off the dipstick before checking.
A NOTE
The oil dipstick is long. Wear gloves.
2 Fill transmission oil (position B) if required (for volume and grade,
see section F Technical data).
013334
Fill – wait a moment – check the dipstick.
A. Location of filler orifice and level control

B. Filling
NOTE
C. Dipstick Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil, which means
risk of transmission damage.

2 Transmission – 2.6.3 Oil cooler 29
2.6.3 Oil cooler

Oil cooler, description
page
–
The transmission oil is cooled in the lower section of the cooling unit.
A temperature-controlled bypass valve, which only acts on the trans-
mission oil cooling circuit, is located in a pipe on the underside of the
1 cooler (engine side). The valve closes when the oil starts to reach
working temperature. This means that the oil reaches normal working
temperature more quickly.
For more detailed information, see supplier documentation, transmis-
sion.
3
003215
4
Cooling unit, engine alternative Cummins QSM11 and
Volvo TAD1250VE 3
1. Intercooler
2. Radiator, engine
2
003214
Cooling unit, engine alternative Volvo TWD1240VE

1. Radiator, engine

30 2 Transmission – 2.6.3 Oil cooler
Thermostat transmission oil cooler, changing

page
–
NOTE
Safety.

2 Drain the oil from the transmission, see Oil and oil filter, changing
page 26.
3 Loosen the cover plug and remove the thermostat.
4 Check the O-ring and the spring in the bottom, change as need-
ed.
5 Install the new thermostat, and the cover plug.
I M P OR TA NT
007447
It is very important that the thermostat is used with

the temperature bulb facing out as shown.
6 Fill with transmission oil; see Oil and oil filter, changing page 26.
7 Start the engine and check for leaks.
8 Check the transmission oil level; see Oil level, check page 28.

2 Transmission – 2.7 Cooling system 31
2.7 Cooling system

2.7.3 Oil cooler
page
–
See Oil cooler, description page 29.

32 2 Transmission – 2.8 Transmission control system
2.8 Transmission control system

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

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

trol unit and Supplier documentation.
2.8.2 Normally closed (NC) switch,

disengagement
Normally closed (NC) switch, disengagement,
page
–
description
The NC switch for disengagement detects if the wheel brakes are
1 pressurised. The NC switch is located on the distribution block for the
10
2 brake system, above the drive axle’s differential.
1
3 The sensor can be checked from the diagnostic menu, see section 8
3 Control system , group 8.4.7.1 TRANSM, menu 1.
4
5
5
9 6
8 7
000439
1. Brake cooling connection, return from wheel brake

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

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

3 Driveline/axle 1
3 Driveline/axle
Table of Contents 3 Driveline/Axle

mm mm mm mm mm mm
3 Driveline/axle .................................................................................................. 3
3.2 Propeller shaft ............................................................................................ 3
3.3 Drive axle ................................................................................................... 4

2 3 Driveline/axle

3 Driveline/axle 3
3 Driveline/axle
mm mm mm mm mm mm
3.2 Propeller shaft

Propeller shaft, description
page
–
The propeller shaft transfers engine power from the transmission to

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

page
–

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

4 Fit the propeller shaft attaching bolts.
Tightening torque 156 Nm. Retighten the attaching bolts after
50 hours of operation.

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

Drive axle, general
page
–

The workshop manual only describes components and work descrip-
tions related to installation in the machine. Please refer to the compo-
nent supplier documentation for descriptions and instructions of drive
axle components and systems.
References to supplier documentation are only used in exceptional
cases. If information about a component is missing, use the supplier
documentation.
Drive axle, replacement

page
–
D ANGER
Drive axle and machine are very heavy.
Risk of pinch injury!
Do go under a machine which has been lifted by a jack

etc under any circumstances. For machine weights,
please refer to section F Technical data
1 Park the machine with blocks behind the steering wheels.

2 Depressurise the brake and hydraulic systems, see section
B Safety.
power.
4 Install wedges between the steering axle and frame.

3 Driveline/axle – 3.3 Drive axle 5
5 Disconnect hydraulic hoses (position 1) and cabling (position 2)

from the distribution block.
NOTE
Plug all unions at once to protect the hydraulic system from
contamination.
004501
2
1. Hydraulic hoses
2. Cables
6 Remove the casing (position 3) on the parking brake.
3
004505
3. Casing 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. Reinstall the casing on
6 the parking brake (position 3).
8 Disconnect the hydraulic hose (position 6) from the parking
brake.
5
NOTE
4 Plug all unions at once to protect the hydraulic system from
contamination.
004506
4. Lock nut
5. Release screw
6. Hydraulic hose, parking brake

9 Disconnect the propeller shaft from the drive axle. Secure the
propeller shaft, otherwise there is a risk that it will be pulled apart.
Securing propeller shaft.

10 Lift the machine so that the wheels are off the ground.
11 Remove the drive wheels from the drive axle.
12 Block up the drive axle under the hubs.
C AUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away when
not under control.
Lifting the machine
13 Remove the bolts that secure the drive axle in the frame.
14 Lift away the drive axle.
C AUTION
Crushing injury!
not under control.
15 Transfer parts from the old drive axle to the new one.
Attaching bolts, drive axle
NOTE
contamination.
16 Clean the contact surfaces on the drive axle and frame. Also
clean the bolts’ contact surface on the underside of the drive axle.

3 Driveline/axle – 3.3 Drive axle 7
17 Remove the nuts for attaching the drive axle, blow clean and re-
install the nuts.
18 Transfer the guide pins from the old axle to the new axle.
19 Lift the drive axle into place under the frame.
C AUTION
Crushing injury!
not under control.
20 Lower the frame toward the drive axle. Check that the guide pins
fit in the frame.
21 Fit the new bolts that secure the drive axle in the frame. Tighten
the bolts to a torque of 2820 Nm.
22 Install the drive wheels on the new axle.
23 Rustproof the bolts with suitable paint.
24 Connect hydraulic hoses (position 1) and cabling (position 2) to

the distribution block on the drive axle.
25 Connect the hydraulic hose to the parking brake, adjust the park-
ing brake.
26 Connect the drive shaft to the drive axle, tighten the bolts to a
torque of 156 Nm. (Retighten the attaching bolts after 50 hr oper-
ating time).
27 Check the oil level in the drive axle.
1 28 Start the machine and bleed the brakes; see section 4 Brakes,
group 4.3.9 Wheel brake.
29 Check for leaks.
004501


4 Brakes 1
4 Brakes
Table of Contents 4 Brakes

mm mm mm mm mm mm
4 Brakes ............................................................................................................. 3
4.1 Controls and instruments ........................................................................... 3
4.1.1 Brake pedal ............................................................................................ 3
4.3 Power-assisted brake system .................................................................... 5
4.3.1 Brake fluid pump .................................................................................... 7
4.3.2 Brake fluid filter .................................................................................... 12
4.3.3 Accumulator charging valve ................................................................. 13
4.3.4 Accumulator ......................................................................................... 16
4.3.5 Brake valve .......................................................................................... 20
4.3.6 Drive axle block ................................................................................... 24
4.3.7 NC switch, brake fluid pressure ........................................................... 25
4.3.8 NO (normally open) switch, brake lights .............................................. 26
4.3.9 Wheel brake ......................................................................................... 28
4.3.10 Pipes and hoses .................................................................................. 30
4.5 Parking brake system ............................................................................... 31
4.5.1 Brake fluid pump .................................................................................. 32
4.5.3 M-valve parking brake ......................................................................... 33
4.5.4 Parking brake unit ................................................................................ 34
4.5.5 Parking brake NC switch ..................................................................... 37
4.5.6 Pipes and hoses .................................................................................. 37
4.8 Temperature control, cleaning and brake oil ............................................ 38
4.8.1 Brake fluid tank .................................................................................... 39
4.8.2 Tank heater .......................................................................................... 40
4.8.3 Brake fluid pump .................................................................................. 40
4.8.4 Accumulator charging valve ................................................................. 40
4.8.5 Drive axle block ................................................................................... 40
4.8.6 Wheel brake ......................................................................................... 40
4.8.7 Oil cooler .............................................................................................. 41
4.8.8 Cooling fan ........................................................................................... 42
4.8.9 Thermal bypass valve .......................................................................... 42
4.8.10 Sensor brake oil temperature .............................................................. 43
4.8.11 Breather filter ....................................................................................... 44
4.8.13 Pipes and hoses .................................................................................. 46
4.8.14 Brake system fluid ............................................................................... 46

2 4 Brakes

4 Brakes 3
4 Brakes
mm mm mm mm mm mm

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

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

shows a loose brake pedal.)
Brake pedal, replacement

page
–
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Turn off the engine and the main electrical power.
B Safety.
3 Detach the brake valve from the brake pedal.
Secure the brake valve on the cab’s underside and remove the
brake valve attaching bolt.

4 4 Brakes – 4.1.1 Brake pedal
4 Remove the panel around the steering wheel shaft.
NOTE
There is a variant available with adjustable steering wheel
shaft.
5 Detach the steering valve from the pedal bracket.

Secure the steering valve on the cab’s underside. Remove the
steering valve’s attaching bolts. Pull down the valve slightly so
that the steering axle releases from the steering valve.
6 Detach the steering wheel shaft from the brake pedal.
Undo the bolts and pull the steering wheel shaft up slightly so that
the brake pedal can be removed.
7 Detach the clutch-release pedal from the brake pedal.
8 Remove the brake pedal.
Remove the brake pedal’s attaching bolt and lift away the brake
pedal.
Mounting of steering wheel shaft and steering valve in 9 Transfer the pedal rubber to the new pedal.
pedal bracket.
10 Fit the new brake pedal.
Fit the pedal and fit the pedal’s attaching bolts.
11 Connect the steering valve to the brake pedal.
12 Connect the brake valve to the brake pedal.
13 Fit the clutch pedal to the brake pedal.
14 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
15 Grease and adjust the brake pedal, see Brake pedal, checking
and adjusting page 3.

4 Brakes – 4.3 Power-assisted brake system 5
4.3 Power-assisted brake system

Power assisted brake system, function
page
–
description
13
D790-2 5
B
P
T
D10 D797-R D797-F
10 9, 12 8 C5
Pa
D11 D8
C3
4 11
Pa
7
B
ACC 6
C1
3
P
006401
1 The brake fluid pump pumps fluid from P = 20.5 ±1.0 MPa Brake fluid tank, description page 39
the brake fluid tank. Brake fluid pump, description page 7
2 The brake oil filter cleans the oil. - Brake fluid filter, description page 45
3 The accumulator charging valve directs - Accumulator charging valve, description

oil to charging of accumulators or page 13
through the brake system's cooling
circuit.
4 The accumulators store oil pressure. See the pressure plate, Ac- Accumulator, description page 16
cumulator pressure brake
system, on the left-hand
frame member.
5 The brake valve directs pressure from - Brake valve, description page 20
the accumulators to the brake cylinders
proportional to pressing of the pedal.

6 4 Brakes – 4.3 Power-assisted brake system

6 The brake cylinders compress the discs See the pressure plate, Wheel brake, description page 28
in the brake unit. Brake pressure, on left-
hand frame member.
7 The wheel brakes brake the machine. - Wheel brake, description page 28
8 The brake light NO switch (S216) closes Brake pressure above Switch normally open (NO), brake lights,
the circuit when the brake cylinders are 0.2 MPa: description page 26
pressurised. Conn 1, U = 24 V D8: Diagnostic menu, see section 8 Con-
Conn 2, U = 24 V trol system , group 8.4.5.4 HYD, menu 4

0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
9 Control unit, frame front (D797-F) trans- Checked by control system, Section 11 Common electrics, group
mits the brake light request on the CAN error shown with error code. 11.5.3.2 Control unit, frame front
bus.
10 The brake lights are activated by Control U = 24 V Section 9 Frame, body, cab and accesso-
unit, frame rear (D797-R). ries, group 9.6.4 Brake lights
D10: Diagnostic menu, see section 8
Control system , group 8.4.2.11 LIGHTS,
menu 11
11 NC switch, brake oil pressure (S204) Brake pressure above NC switch, brake oil pressure, description
opens the circuit if the pressure in the 11.5 MPa: page 25
accumulators is low. Conn 1, U = 24 V D11: Diagnostic menu, see section
Conn 2, U = 24 V 8 Control system , group 8.4.5.4 HYD,
menu 4
11.5 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
12 Control unit, frame front (D797-F) trans- Checked by control system, Section 11 Common electrics, group
mits a warning about low brake pressure error shown with error code. 11.5.3.2 Control unit, frame front
on the CAN bus.
13 Control unit KIT (D790-2) activates Checked by control system, Section 11 Common electrics, group
Warning light brake pressure. error shown with error code. 11.5.3.11 Control unit KIT
Hydraulic diagram, basic machine

4 Brakes – 4.3.1 Brake fluid pump 7
4.3.1 Brake fluid pump

Brake fluid pump, description
page
–
The brake system has a gear pump with fixed displacement. The
brake oil pump is fitted at the front of the left-hand main pump. The
pump generates hydraulic power, which is stored in the accumulators
for brake force to the power-assisted brake and parking brake. It also
generates the oil flow used for cleaning and cooling. The switchover
between power generation and flow is regulated by the accumulator
charging valve, see Accumulator charging valve, description page 13.
The brake oil pump is driven by the main pump’s shaft from gearbox
power take-off. The brake oil pump’s speed is directly dependent on
engine speed. The pump flow rate increases with engine speed and
varies with the speed of the input shaft.
1
NOTE
2 It is very important that the clearance between the gears and be-
000006
tween the gear and the housing is correct. Clearance that is too
small creates wear damage. Clearance that is too large reduces
1. Brake fluid pump
the pump’s power output.
2. Pump cooling and filtering, working hydraulics
Brake fluid pump, check

page
–
NOTE
Safety.
Checking pump pressure

1 Operate and warm up the machine so that the oil in the brake sys-
tem reaches operating temperature, at least 50 °C.
2 Machine in service position, see section B Safety
B Safety.
4 Connect a pressure gauge (0–25 MPa) to the pump pressure
measuring outlet on the accumulator charging valve.
5 Start the engine and run it at idling speed.
Measuring outlet, pump pressure

8 4 Brakes – 4.3.1 Brake fluid pump
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. 1.0–1.5 MPa at max.
engine rpm.
8 Stop the engine
Close the accumulator charging valve
B Safety.
10 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
Checking accumulator charging

B Safety.
13 Connect a pressure gauge (0–25 MPa) to the measuring outlet
for accumulator pressure on the accumulator charging valve.
16 Check that the pressure increases slowly to 20.5 ±1.0 MPa.
17 Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve must switch to cooling at 15.5 ±0.5 MPa.
B Safety.
Measuring outlet, accumulator pressure
measuring outlet.
NOTE

Brake oil pump, replacement (hydraulic oil pump

page
–
alternative Rexroth)
NOTE
B Safety.
B Safety.
3 Mark up and detach the hydraulic hoses from the pump.
NOTE
Plug all connections immediately to protect the brake
system from impurities.
4 Remove the attaching bolts, pull the pump out backwards and lift
it away.
5 Transfer the connection adapters and the contact to the new
pump.
6 Remove the spacer ring from the brake pump or hydraulic oil
pump.
Clean the O-rings’ contact surfaces on the spacer ring.
7 Check the O-rings and replace as required. Install the O-rings on
the spacer ring. Brush sealing silicone on the sealing face against
the brake pump, see section F Technical data.
NOTE
Only use silicone on the side facing the brake pump.

8 Fit the spacer ring on the main pump.
9 Brush sealing silicone on the brake pump’s sealing face against

the spacer ring; see section F Technical data.
10 Fit the brake pump on the main pump.
Fir the pump and check that the gear engages in the shaft and
that the spacer ring is directly against the brake pump.
Fit the pump’s attaching bolts.
11 Connect the hydraulic hoses to the brake pump.
NOTE
Check that the O-rings are intact and are fitted correctly.
NOTE

14 Check that the hose connections and seal between the hydraulic
oil pump and brake pump are fully sealed.
Check the feed pressure from the brake pump, see Brake fluid
pump, check page 7.
15 Check the oil level in the brake system, fill as necessary.
NOTE
If the pump is replaced due to malfunction, change the oil
and filter in the brake system as well.
Brake oil pump, replacement (hydraulic oil pump

page
–
alternative Sauer-Danfoss)
NOTE
B Safety.
1 Machine in service position, section B Safety.
B Safety.
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
it away.
pump.

12 4 Brakes – 4.3.2 Brake fluid filter
6 Brush sealing silicone on the brake pump’s sealing face; see

section F Technical data.
Position the pump and check that the pump’s splines engage in
the shaft in the main pump.
NOTE
NOTE
11 Check that the hose connections and seal between the hydraulic
oil pump and brake pump are fully sealed.
Check the feed pressure from the brake pump, see Brake fluid
pump, check page 7.
NOTE
and filter in the brake system as well.
4.3.2 Brake fluid filter

Brake fluid filter, general
page
–
See Brake fluid filter, description page 45.

4 Brakes – 4.3.3 Accumulator charging valve 13
4.3.3 Accumulator charging valve

Accumulator charging valve, description
page
–
The accumulator charging valve distributes oil from the hydraulic oil
1 2
13 pump between pressure storage and cooling of the wheel brakes. The
accumulator charging valve is fitted on the beam in front of the gear-
12 3 box in the engine compartment.
The accumulator charging valve stores pressure by guiding the oil to
11 4
the accumulators. The wheel brakes are cooled by oil being guided to
the drive axle cooling circuit and then on to the brake system cooler.
10 5
The accumulator charging valve prioritises charging of the accumula-
6 tors above cooling. A restriction of the charging means that a small
9 quantity of oil also flows to cooling during accumulator charging. At
idling speed the flow from the pump is so small that all oil flows to pres-
8 sure storage.
The drain valve (position 11) is used to relieve the pressure in the ac-
7
cumulators to the tank. The valve opens a connection between the ac-
cumulators and the wheel brake’s cooling circuit. The oil is drained
through the wheel brake to the tank.
There is a measuring outlet for measuring the accumulator pressure
000431
(position 5) and pump pressure (position 4) on the accumulator charg-

ing valve. The pressures are individual to each machine and each are
1. Safety valve
specified on the pressure plate on the left-hand frame member, see
2. Connection from pump (P)
section 10 Common hydraulics. The accumulator charging valve also
3. Wheel brake connection (T)
houses the parking brake solenoid valve (position 6), brake fluid pres-
4. Measuring outlet, pump pressure (P)
sure NC switch (position 9) and parking brake NC switch (position 7).
5. Measuring outlet, accumulator pressure (M)
6. Solenoid valve parking brake (Y642) • Solenoid valve parking brake, description page 33
7. NC switch, parking brake (GHB) (S200) • NC switch, brake oil pressure, description page 25
8. Connection, accumulators (ACC)
• Parking brake NC switch, description page 37
9. NC switch, brake fluid pressure (LB) (S204)
10. Connection, parking brake caliper (HB)
11. Drain valve
12. Main valve, charging
13. Pressure limiting valve
Accumulator charging, checking and adjustment

page
–
NOTE
B Safety.

2 Check accumulator charging; see Brake fluid pump, check page
7.

14 4 Brakes – 4.3.3 Accumulator charging valve
3 If necessary, adjust the accumulator charging pressure on the

pressure limiting slide.
Undo the lock nut and adjust the pressure by turning the adjusting
screw.
Clockwise: reduce pressure.
Counter-clockwise: increase pressure.
4 Open the drain valve on the accumulator charging valve so that
the accumulators are drained and the valve switches to charging.
Close the valves and check the max. pressure again.
5 Repeat steps 3 and 4 until the pressure is correct.
Adjusting screw accumulator charging pressure

NOTE
Accumulator charging valve, replacement

page
–
NOTE
B Safety.
B Safety.
3 Mark up hydraulic hoses and electric cables.
4 Detach the wiring from the accumulator charging valve.
5 Detach and plug all hydraulic hoses from the accumulator
charging valve.
Remove the parking brake valve (C) for easier access.
NOTE

4 Brakes – 4.3.3 Accumulator charging valve 15
6 Remove the accumulator charging valve.

7 Transfer the connection adapters and sensors to the new accu-
mulator charging valve.
8 Fit the new valve.
9 Connect the hoses to the accumulator charging valve in accord-

ance with the marking.
NOTE
10 Fit the parking brake valve and NC switch parking brake.
11 Connect the wiring to the accumulator charging valve.
NOTE
Check that the hydraulic connections are sealed tightly.
14 Check the charging and changing function, see Accumulator
charging, checking and adjustment page 13.

16 4 Brakes – 4.3.4 Accumulator
4.3.4 Accumulator
Accumulator, description
page
–
The accumulators store pressure so that there is a pressure reserve

in the event of engine or brake system malfunction. The brake system
has 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 di-
vided into two spaces by a diaphragm. One side of the diaphragm is
pressurised by nitrogen gas. The other side is pressurised by the hy-
draulic oil, which compresses the nitrogen gas.
The accumulator has test outlets for checking the gas pressure on the
000001 opposite side to the pressure connection.
Accumulator, checking
page
–
NOTE
B Safety.

B Safety.
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.
• Check with test equipment: continue with step 4.
• Check in machine: continue with step 6.

4 Brakes – 4.3.4 Accumulator 17
Checking with test equipment

4 Remove the accumulators and test them with the intended test
equipment.
The accumulators’ gas pressure should match with the pressure
plate.
5 Continue with step 17.
MPa
MPa
MPa
MPa MPa MPa

MPa
MPa
MPa MPa
001031
920643.0024
Pressure plate, gas pressure brake accumulators

Checking in machine
6 Detach three of the accumulators from the distribution block. Plug
the distribution block connections with plugs that can withstand
high pressure. Plug the connections on the accumulators to pro-
tect against contamination.
for accumulator pressure on the accumulator charging valve.
charge the accumulator until the accumulator charging valve
changes to cooling.
10 Check that the plugs seal properly.
11 Stop the engine
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 shut off,
then the accumulator does not have any pre-charge pressure.
This indicates internal leakage and the accumulator must be
changed.
If the pressure can be reduced slowly to a pressure below
10 MPa then the precharge pressure is too low and the
accumulator must be replaced or given to authorised personnel
for maintenance.

18 4 Brakes – 4.3.4 Accumulator

B 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.
B Safety.
Installing and final checking

17 Connect all accumulators to the distribution blocks. If needed,
replace or fill defective accumulators.
NOTE
Check that the seals are intact and are fitted correctly.
NOTE
20 Check that the accumulators’ connections are sealed tightly.
21 When the accumulators are fully charged, shut off the engine and
turn the start key to position I.
22 Check that at least 8 brake applications (pedal depressions) can
be performed before the pressure drops to 10 MPa.
At 11.5 MPa the warning lamp for low brake pressure must come
on.
Accumulator, replacement
page
–
NOTE
B Safety.
B Safety.

4 Brakes – 4.3.4 Accumulator 19
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.
7 Fit the new accumulator.
NOTE
Check that the seal is intact and is fitted correctly.
8 Secure the accumulator’s clamp and tighten the bolt.

20 4 Brakes – 4.3.5 Brake valve
NOTE
11 Check that the accumulator's connection is sealed tightly.
12 Check precharging and function, see Accumulator, checking
page 16 steps 18-19.
4.3.5 Brake valve

Brake valve, description
page
–
The brake valve, which is located on the underside of the cab under-
neath the brake pedal, controls the hydraulic pressure to the brakes.
1 A lever transfers pedal force to the valve.
2 The brake valve is a mechanically activated proportional valve. This
means that the resistance in the brake valve increases in proportion to
3
brake pressure. This provides optimum pedal responsiveness and in-
creased safety as the operator senses if no brake pressure is being
built up (no resistance in the pedal).
000013
1. Inlet from accumulator [P]

2. Return connection [T]
3. Outlet to brake cylinders [B]
Brake valve, checking

page
–
NOTE
B Safety.
1 Operate and warm up the machine so that the brake fluid reaches
operating temperature, at least 50 °C.
B Safety.

4 Brakes – 4.3.5 Brake valve 21
4 Connect a pressure gauge (0-25 MPa) to the measuring outlet for

brake pressure on the distribution block on the front axle.
6 Start the machine and run it at idling speed until the accumulators
are charged and the accumulator charging valve changes to
cooling.
7 Press down the pedal completely and read off the pressure.
Compare to the pressure plate on the left frame member.
8 Stop the engine
9 Depress the pedal fully and keep it pressed down, check the
pressure.
The brake pressure must correspond with the value specified on
MPa the pressure plate and must not decrease from this value for
15 seconds.
10 Release the pedal, the brake pressure must decrease to 0 MPa
MPa
immediately. Otherwise the brake valve is not sealed and can
cause the brakes to remain applied and then overheat during
MPa
operation.
MPa MPa MPa
MPa Replace the brake valve if it is not sealed.
MPa
B Safety.
MPa MPa measuring outlet.
008214
NOTE

22 4 Brakes – 4.3.5 Brake valve
Brake valve, replacement

page
–
NOTE
B Safety.
1 Slide the cab forward slightly so that the brake valve is accessible
under the cab.
B Safety.
4 Mark up and detach the hydraulic hoses from the brake valve.
NOTE
Plug the connections immediately to protect the brake sys-
5 Secure the brake valve under the cab.
6 Remove the brake valve attaching bolt.

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

with the marking.
NOTE
11 Grease and adjust the brake pedal, see Brake pedal, checking
and adjusting page 3.

4 Brakes – 4.3.5 Brake valve 23
NOTE
13 On machines with manual sliding cab. Secure the cab in the rear-
most position with the cab locks.
14 Turn on the main electric power and start the engine. Run the en-
gine at idling speed.
15 Test the brakes a couple of times.
16 Check that the brake valve's connections are sealed tightly.
17 Bleed the wheel brakes' brake cylinders, see Wheel brakes,
A bleeding page 29.
000270
B C
A. Location, lock handle
B. Lock pin
C. Lock handle for securing cab

24 4 Brakes – 4.3.6 Drive axle block
4.3.6 Drive axle block

Drive axle block, description
page
–
The drive axle block distributes oil flow and brake pressure to the right
1 and left-hand wheel brakes. The drive axle block is located on a brack-
10
2 et above the drive axle differential.
1
3 The drive axle block has a measuring outlet for brake pressure and for
3 measuring back pressure in the disc brake’s cooling circuit.
4
The drive axle block has a bypass valve which guides oil directly from
5
5 the cooling circuit intake to the cooling circuit return if the resistance in
9 the axle becomes too great. This protects the wheel brake seals, e.g.
6 when the oil is cold.
8 7 The drive axle block houses two switches: brake light NO (normally
open) switch (S216), see Switch normally open (NO), brake lights, de-
scription page 26, and declutch NO switch (S220-2), see section 2
Transmission, group 2.8.2 Normally open (NO) switch, declutch.
000439
1. Brake cooling connection, return from wheel brake

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

4 Brakes – 4.3.7 NC switch, brake fluid pressure 25
4.3.7 NC switch, brake fluid pressure

NC switch, brake oil pressure, description
page
–
The brake oil pressure NC switch (S204) detects the pressure in the
accumulators. The NC switch is located on the accumulator charging
valve on the lifting beam in front of the gearbox in the engine
compartment.
When the pressure in the feed circuit is high enough to ensure braking
of the machine, the sensor closes an electric circuit. This is used to
warn for pressure-drop in the brake system. The sensor’s opening
pressure is chosen so that there is pressure for another eight brake
applications without additional feed from the pump after the light has
gone off.
The brake oil pressure NC switch (S204) is supplied voltage by Control
unit, frame front (D797-F). When the pressure increases above the
cut-off pressure, the voltage signal to Control unit, frame front
(D797-F) is cut off.
The signal can be checked from the diagnostic menu, see tab
8 Control system , group 8.4.5.4 HYD, menu 4.
000435
Brake oil pressure NC switch, adjustment

page
–
NOTE
B Safety.
1 Operate and warm up the machine until the oil reaches operating
temperature, at least 50 °C.
B Safety.
accumulator pressure on the accumulator charging valve.
6 Start the engine and fully charge the accumulators (the accumu-
lator charging valve changes to cooling).
7 Stop the engine and turn the starter key to position I.
8 Brake several times, stop when the warning lamp for low brake
pressure comes on.
9 Read off the accumulator pressure. The pressure should be
approx. 11.5 MPa.
10 If necessary, adjust the warning level by turning the adjusting
screw in the rear edge of the sensor, between the contact pins.
NOTE
The setting is very sensitive, turn max. 1/4 turn at a time.

26 4 Brakes – 4.3.8 NO (normally open) switch, brake lights
11 Repeat steps 6-10 until the warning lamp comes on at 11.5 MPa.
12 Seal the adjusting screw with locking fluid.
B Safety.
measuring outlet.
NOTE
4.3.8 NO (normally open) switch, brake

lights
Switch normally open (NO), brake lights, description
page
–
The brake light NO switch controls brake light activation when the ma-
chine brakes. The switch is located on the drive axle block which sits
on a bracket above the drive axle differential.
The brake light NO switch (S216) is supplied voltage by and sends a
voltage signal to Control unit, frame front (D797-F). When the pres-
sure increases above the closing pressure, a voltage signal is sent to
Control unit, frame front (D797-F).
The signal can be checked from the diagnostic menu, see tab 8 Con-
trol system , group 8.4.5.4 HYD, menu 4.
000439
Brake light NO switch, checking

page
–
NOTE
B Safety.
1 Operate and warm up the machine until the brake fluid reaches
operating temperature, at least 50 °C.
3 Brake and check that the brake light comes on.

4 Brakes – 4.3.8 NO (normally open) switch, brake lights 27

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

DIAG HYD 4(6) system , group 8.4.5.4 HYD, menu 4.
PRESSURE SWITCHES
BRAKE PRESSURE X BRAKE LIGHT PRESS. indicates status for the brake light con-
BRAKE LIGHT PRESS. X tact. 1 = Activated contact (brakes applied).
000144
DECLUTCH PRESSURE X 9 Press down the brake pedal slowly until the brake light is activat-
ed or the status of the input signal changes. Keep the pedal in this
position and check the pressure on the pressure gauge.
The status can be changed and the brake light should come on
when the pressure is approx. 0.2 MPa.
10 Stop the engine
B Safety.
measuring outlet.
NOTE

28 4 Brakes – 4.3.9 Wheel brake
4.3.9 Wheel brake

Wheel brake, description
page
–
The wheel brakes brake the machine during operation and are located
on the drive axle between the drive axle housing and hub reduction.
The wheel brake uses so-called wet disc brakes (WDB). Wet disc
brakes require minimal maintenance and have a long service life due
to effective cooling. Maintenance requirements are minimised since oil
circulates in the brake system and prevents corrosion.
000015
The wheel brakes have two main sections - disc assembly and brake
1 2
cylinder. The disc assembly performs the braking. The brake cylinder
presses the discs in the disc assembly together during braking.
000016
Wheel hub and brake, cross-section

1. Disc assembly
2. Brake cylinder

4 Brakes – 4.3.9 Wheel brake 29
Wheel brakes, bleeding

page
–
NOTE
B Safety.
I M P OR TA NT
Both the brake cylinder and disc brake must be bled
after work where the brake system is opened or after
work on the wheel brake.
Brake cylinder
2 Place a ring spanner on the bleed nipple and connect a transpar-
ent hose to the bleed nipple.
Lead the other end of the hose down into a collection container.
3 Start the machine and depress the brake pedal, keep the pedal
depressed.
4 Open the bleed nipple and allow oil to run out of it until the oil is
free of air bubbles.
NOTE
The hydraulic hose between the brake pedal and brake is
approx. 7 metres long. Therefore, allow at least two litres of
oil to pass through the air bleeder nipple when bleeding to
ensure that no air pockets remain in the system.
Bleed nipple, brake cylinder, on top of the drive axle at 5 Close the bleed nipple.
the wheel hub's inner short side (left-hand side).
6 Move the spanner and hose and repeat steps 1–4 on the other
side.
Disc brake
NOTE
Disc brake ventilation is vital to correct cooling of the discs.
1 Start the engine and allow it to idle. Wait until the brake accumu-
lators are fully loaded and the accumulating charging valve has
switched to brake cooling.
2 Remove the bleed screw of the disc brake and let oil flow out of
the hole until it is free of air bubbles. Refit the bleed screw.
3 Repeat steps 1-3 on the other wheel.
Bleed nipple, disc brake, on top of the drive axle at the

wheel hub’s inner short side (left-hand side).

30 4 Brakes – 4.3.9.1 Disc assembly
Wheel brake, replacement

page
–
See supplier documentation, drive axle.
4.3.9.1 Disc assembly

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

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

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

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

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

Parking brake system, function description
page
–
D5
5
6 12
D790-1 D790-2
D797-F
7 11
D8
D10
C3 8
4
Pa 10 9
ACC
C1 3
H
P
2 T
006402
1 The brake fluid pump pumps fluid from P = 19 ±0.5 MPa Brake fluid tank, description page 39
the brake fluid tank. Brake fluid pump, description page 7
2 The brake fluid filter cleans dirt from the - Brake fluid filter, description page 45
oil.
3 The accumulator charging valve directs Accumulator charging valve, description

circuit.
4 The accumulators store oil pressure. See pressure plate on left Accumulator, description page 16
frame beam.
5 Switch parking brake (S107) activates Switch activated: Section 9 Frame, body, cab and accesso-
parking brake. Conn 1, U = 22–28 V ries, group 9.1 Controls and instruments
The switch uses two signals - one for ap- Conn 7, U = 0 V D5: Diagnostic menu, see section 8 Control
plied and one for released parking system , group 8.4.5.5 HYD, menu 5
Switch in home position:
brake. Both signals must be correct to
enable release of the parking brake. Conn 1, U = 0 V
Conn 7, U = 22–28 V
release or apply parking brake on the tem, error shown with 11.5.3.1 Cab control unit


7 Control unit, frame front (D797-F) acti- U = 24 V Section 11 Common electrics, group
vates the parking brake solenoid valve 11.5.3.2 Control unit, frame front
(Y642). D8: Diagnostic menu, see section 8 Control
system , group 8.4.5.5 HYD, menu 5
8 Solenoid valve parking brake (Y642) af- Pump pressure. Solenoid valve parking brake, description
fects the valve slide which drains pres- page 33
sure in the parking brake calliper to tank. D8: Diagnostic menu, see section 8 Control
9 The brake calliper is drained of pressure 0 MPa Parking brake unit, description page 34
and the spring applies the parking
brake.
10 The parking brake NC switch (S200) Applied parking brake: Parking brake NC switch, description page
closes the circuit when the pressure de- Conn 1: U = 24 V 37
creases. D10: Diagnostic menu, see section 8 Control
Conn 2: U = 0 V
Released parking brake:
Conn 1: U = 24 V
Conn 2: U = 24 V
11 Control unit, frame front (D797-F) trans- Checked by control sys- Section 11 Common electrics, group
mits parking brake applied on the CAN tem, error shown with er- 11.5.3.2 Control unit, frame front
bus. ror code.
12 The KIT control unit (D790-2) activates Checked by control sys- Section 11 Common electrics, group
the parking brake indicator light (508). tem, error shown with er- 11.5.3.11 Control unit KIT
ror code.

Brake fluid pump, general
page
–
See group 4.3.1 Brake fluid pump.

Brake fluid filter, general
page
–
See Brake fluid filter, description page 45.

4 Brakes – 4.5.3 M-valve parking brake 33
4.5.3 M-valve parking brake

Solenoid valve parking brake, description
page
–
The parking brake solenoid valve (Y642) activates the parking brake.
The solenoid valve is fitted on the accumulator charging valve, which
is fitted on the lifting beam in front of the gearbox in the engine com-
partment, see Accumulator charging valve, description page 13.
The solenoid valve opens a connection between the accumulators and
the parking brake calliper at activation. This means that the parking
brake calliper is pressurised and the parking brake is disengaged.
When the voltage feed to the solenoid valve is cut off, the connection
between the accumulators and parking brake calliper is terminated. In-
stead, a connection between the parking brake calliper and tank is
opened and the parking brake applied. This means that the parking
brake is applied if the machine loses electrical power or if the brake
system becomes depressurised.
The solenoid valve is supplied with voltage by Control unit, frame front
(D797-F) on activation.
000437
Solenoid valve parking brake, checking

page
–
D ANGER
The machine may start to roll. Risk of crushing.
Block the wheels so that the machine cannot start to

roll when the parking brake is released.
1 Start the engine and run the engine at idling speed until the warn-
ing lamp for brake pressure goes out and the accumulator charg-
ing valve changes to cooling.
2 Turn off the engine and turn the start key to position I.
3 Release the parking brake with switch parking brake and check
that the parking brake’s brake caliper releases. The brake caliper
should be able to move.
4 Activate the parking brake with the parking brake switch and
check that the parking brake’s brake caliper is applied.

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

Parking brake unit, description
page
–
The parking brake unit keeps the machine stationary when parked.
The parking brake unit is located on the drive axle input shaft between
the propeller shaft and drive axle.
The parking brake acts on the propeller shaft via a disc mounted on
the drive axle input shaft and a brake calliper with dry brake pads
mounted in a bracket on the drive axle.
NOTE
If the hydraulic pressure in the feed circuit drops, a warning is ac-
tivated before the pressure drops so low that the parking brake is
applied. If the parking brake is applied while the machine is in mo-
tion, the brake disc and brake pads must be replaced.
005121
Parking brake unit, checking and adjustment (drive

page
–
axle alternative Kessler)
D ANGER
The machine may start to roll.
Risk of crushing.

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

4 Brakes – 4.5.4.1 Parking brake caliper 35
6 Remove the cover from the brake caliper.
7 Undo the lock nut.

8 Adjust the adjustment 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 lock nut.
NOTE
To avoid turning the adjustment screw as well it must be
held still when tightening the lock nut.
11 Refit the cover to the caliper.
12 Test the operation of the parking brake.
4.5.4.1 Parking brake caliper

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

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

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

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

1 Machine in service position and wheels blocked, see section

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

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

4 Brakes – 4.5.4.3 Parking brake disc 37
6 Pull the attaching bolt out so that the brake pads can be angled
out and removed.
NOTE
The bolt does not need to be removed.
7 Remove the parking brake pads.
8 Clean the brake disc with methylated spirit.
9 Install new parking brake pads.
10 Press the attaching bolt back.
11 Fit the nut and a new split pin.
12 Adjust the parking brake, see Parking brake unit, checking and
adjustment (drive axle alternative Kessler) page 34.
4.5.4.3 Parking brake disc

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

Parking brake NC switch, description
page
–
The parking brake NC switch (S200) detects whether the parking

brake is applied or released. The NC switch is fitted on the accumula-
tor charging valve, which is fitted on the lifting beam in front of the
gearbox in the engine compartment, see Accumulator charging valve,
description page 13.
Break-contact parking brake (S200) senses the pressure in the park-
ing brake circuit. When the pressure is so high that the parking brake
is released, the sensor opens an electric circuit. This is used to indi-
cate that the parking brake is released.
The parking brake NC switch (S200) is supplied voltage by, and sends
a voltage signal to, Control unit, frame front (D797-F). When the pres-
sure increases above the cut-off pressure, the voltage signal to Con-
trol unit, frame front (D797-F) is cut off.
NOTE
Gears cannot be engaged when the parking brake is applied.
000436

page
–

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

cleaning and brake oil
Temperature control, cleaning and brake oil,
page
–
11
D795
D797-F
9
D8 D10
C4
C1
3 4
P T
2
5
1
6 10
8 7
M
006403
˚C ˚C

1 The brake fluid pump pumps fluid from P = 19 ±0.5 MPa Brake fluid pump, description page 7
the brake fluid tank. Brake fluid tank, description page 39
2 The brake oil filter cleans the oil. - Brake fluid filter, description page 45
3 The accumulator charging valve directs Max. 0.1 MPa Accumulator charging valve, description
circuit.
4 The oil cools the wheel brake. - Wheel brake, description page 28
5 The bypass valve in the distribution - Drive axle block, description page 24
block leads oil past the drive axle if the
back pressure through the wheel brake
is too high.
6 The cooler cools the oil. - Oil cooler, description page 41
7 The thermo-bypass valve leads oil past approx. 50 °C Thermal bypass valve, description page 42
the cooler if the temperature is low.
8 The temperature sensor (B762) detects R = 25 kΩ at 20 °C Brake fluid temperature sensor, description
and oil temperature and sends Control page 43
unit, frame front (D797-F) a voltage sig- D8: Diagnostic menu, see section 8 Control
nal proportional to the oil temperature. system , group 8.4.5.2 HYD, menu 2

4 Brakes – 4.8.1 Brake fluid tank 39

9 Control unit, frame front (D797-F) Checked by control sys- Section 11 Common electrics, group
transmits the oil temperature informa- tem, error shown with 11.5.3.2 Control unit, frame front
tion on the CAN bus. error code.
10 When the oil is hot, Control unit, frame U = 24 V with activated Cooling fan, description page 42
front (D797-F) activates the cooling fan fan D10: Diagnostic menu, see section 8 Control
(M674) and increases airflow through Activates at 65 °C system , group 8.4.5.2 HYD, menu 2
the cooler.
Deactivates at 55 °C
11 If temperature is high, the KID control Checked by control sys- Section 11 Common electrics, group
unit (D795) activates the high brake fluid tem, error shown with 11.5.3.12 KID control unit
temperature warning in the display. error code.
4.8.1 Brake fluid tank

Brake fluid tank, description
page
–
The brake fluid tank stores the brake system fluid and is located on the
left side of the machine in front of the fuel tank.
The brake system is separate from other hydraulics and has its own
tank and oil filter. This makes it possible to keep additives out of the
brake system fluid.
Brake fluid is filled directly to the tank. A drain plug is located at the
bottom of the tank. Hatches on top of the tank facilitate internal
cleaning.
The tank is equipped with a filtered breather that allows volume chang-
es in the tank, due to temperature variations and use. See Breather fil-
ter, description page 44.
The tank has a sight glass for checking oil level.
000012

40 4 Brakes – 4.8.2 Tank heater
4.8.2 Tank heater

Tank heater, safety
page
–
C AUTION
High voltage.
The tank heater is connected to high voltage
(110 - 400 V).
Installation and reconnection of the tank heater may

only be performed by personnel authorised for work
with high voltage.
Tank heater, description

page
–
The brake fluid tank can be equipped with a tank heater, which heats
the brake fluid in the tank and sits in a flange on the front short side of
the tank. The tank heater is designed for cold-climate usage.
The tank heater is operated with high voltage. Heater output is adapt-
ed through different connections and adaptation to different operating
voltage - 110, 230 or 400 V AC. Higher voltage generates higher heat-
er output.
The tank heater can be equipped with an adjustable thermostat which
001872
maintains a constant temperature level. The thermostat is mounted di-

rectly on the heating coil and can be adjusted using the control on the
terminal box. The recommended temperature setting is 20 –30 °C.

Brake fluid pump, general
page
–
See group 4.3.1 Brake fluid pump.
4.8.4 Accumulator charging valve

Accumulator charging valve, general
page
–
See 4.3.3 Accumulator charging valve.
4.8.5 Drive axle block

Drive axle block, description
page
–
See Drive axle block, description page 24.
4.8.6 Wheel brake

Wheel brake, general
page
–
See 4.3.9 Wheel brake and drive axle supplier documentation.

4 Brakes – 4.8.7 Oil cooler 41
4.8.7 Oil cooler

page
–
The oil cooler cools the brake system fluid in order to maintain brake
performance. The oil cooler is found inside the side panel on the left
side behind the front wing.
The brake system uses a flow-through cooler with electric cooling fan.
The brake system fluid is cooled when it passes the cooler. Openings
in the frame panel allow air to pass through the cooler.
The cooling fan is screwed onto the cooler. See Cooling fan, descrip-
tion page 42.
000010
Brake system oil cooler, replacement

page
–
NOTE
B Safety.

2 Drain the brake fluid tank; see Brake system fluid, changing page
46.
3 Mark up and disconnect hydraulic hoses from the cooler. Let the
oil in the cooler drain into the collection container.
NOTE
contamination.
4 Disconnect the cabling from the cooling fan.
5 Remove the attaching bolts and lift away the cooler.
6 Transfer the cooling fan to the new cooler.
7 Install the cooler.
8 Connect the cabling to the cooling fan.
9 Connect the hydraulic hoses to the cooler.
1. Cooling fan
NOTE
2. Connector
Check that the O-rings are intact and fitted correctly.
3. Radiator

42 4 Brakes – 4.8.8 Cooling fan
10 Fill the brake fluid tank; see Brake system fluid, changing page
46. The fluid level should be visible in the sight glass.
4.8.8 Cooling fan

Cooling fan, description
page
–
The cooling fan (M674) is a suctioning electronic fan. The fan suctions
air from the outside of the machine through the cooler and increases
airflow through the oil cooler as needed. The cooling fan is mounted
inside the cooler inside the side panel behind the left drive wheel.
The cooling fan (M674) is supplied voltage by Control unit, frame front
(D797-F). The cooling fan is activated when oil temperature is 65 °C
in the brake oil tank and the fan is deactivated when oil temperature is
55 °C.
000009
4.8.9 Thermal bypass valve

Thermal bypass valve, description
page
–
When the oil is cold, the thermo-bypass value guides the oil past the
cooler directly to the tank. The thermo-bypass valve is found inside the
brake fluid tank at the hose connections to and from the cooler.
The thermo-bypass valve is a temperature-regulated bimetal valve
that is open at low temperatures and completely closed at 50 °C.
000023

4 Brakes – 4.8.10 Sensor brake oil temperature 43
Thermo-bypass valve, replacement

page
–
NOTE
B Safety.

B Safety.
46.
4 Remove the thermo-bypass valve located inside the hydraulic oil
tank.
NOTE
Note how the valve is fitted.
5 Fit in reverse order.
4.8.10 Sensor brake oil temperature

Brake fluid temperature sensor, description
page
–
The brake fluid temperature sensor (B762) detects the temperature of

the brake system fluid. The sensor is mounted on the rear short side
of the brake fluid tank and therefore takes the accumulated heat in the
brake system fluid into account.
The brake fluid temperature sensor (B762) is supplied voltage by Con-
trol unit, frame front (D797-F) and sends the control unit a voltage sig-
nal proportional to temperature.
001091
Brake fluid temperature sensor, replacement

page
–
NOTE
B Safety.

46.
3 Disconnect the wiring from the fluid temperature sensor.
4 Remove the fluid temperature sensor.
NOTE
5 Connect the cabling to the sensor.

44 4 Brakes – 4.8.11 Breather filter
6 Fill the brake fluid tank; see Brake system fluid, changing page
46. The fluid level should be visible in the sight glass.
4.8.11 Breather filter

Breather filter, description
page
–
The breather filter cleans the air that passes the tank’s breather upon
volume changes arising due to temperature variations and use. The
breather filter is located in a holder on the top of the brake fluid tank.
The breather filter is a paper insert filter. The filter removes moisture
and dust from the air passing through the tank’s breather.
000017
Breather filter, replacement

page
–
1 Clean the area around the break tank breather filter.

2 Remove the cover from the filter holder.
Remove the centre screw and lift away the cover.
3 Remove the old filter insert.
4 Clean the filter holder.
NOTE
Take care so as not to contaminate the tank.
5 Fit a new filter insert.
1. Brake system fluid filler orifice 6 Refit the cover on the filter holder.
2. Breather filter, brake fluid tank

4 Brakes – 4.8.12 Brake fluid filter 45

Brake fluid filter, description
page
–
The brake fluid filter eliminates contaminants from the fluid in the brake
system. The filter is secured on a mounting in front of the gearbox un-
der the lifting beam.
The brake system fluid filter is a high-pressure filter with removable fil-
ter insert. It is located between the pump and accumulator charging
valve. The fluid is cleaned when it is forced through the (glass-fibre)
material of the filter insert before reaching the accumulator charging
valve.
A bypass valve located between the intake and outlet protects the in-
sert. If resistance through the filter surface becomes too great, the by-
pass valve opens a passage past the insert. The bypass function
opens if the oil is viscous (cold or too low/high viscosity) or if the filter
insert is clogged with dirt.
NOTE
When the filter is clogged, the oil is directed past the filter without
cleaning. Therefore, it is very important to replace the filter at the
prescribed interval.
000018
Brake fluid filter, replacement

page
–
NOTE
B Safety.
I M P OR TA NT
The filter protects the brake system against contami-
nants. It is vital that new contaminants do not enter
the brake system during filter replacement.

2 Depressurise the hydraulic and brake systems; see section
B Safety.
NOTE
Leave the valves open during replacement.

46 4 Brakes – 4.8.13 Pipes and hoses
3 Remove the drain plug on the underside of the filter.

Let the oil run out. Wait a moment since it runs out slowly.
4 Remove the filter holder.
NOTE
The filter holder is heavy. Detach it carefully.
5 Remove the filter insert.
NOTE
Note the location of the O-rings.
6 Clean the filter holder.
7 Fit the O-rings on the filter insert and filter holder. Lubricate the
O-rings with brake fluid.
8 Fit the new filter insert on the filter mounting.
9 Fit the filter holder and drain plug.
10 Close the valves opened for draining the pressure in the hydraulic
system.
11 Start the engine and check the filter holder for leaks.
000018

page
–
4.8.14 Brake system fluid

Brake system fluid, general
page
–
See section F Technical data.
Brake system fluid, changing

page
–
NOTE
B Safety.
2 Depressurise the hydraulic and brake systems; see section
B Safety.
3 Remove the filler cap and drain the brake fluid tank.
4 Remove the drain plug and allow the last of the fluid drain into a
receptacle.
5 Fit the drain plug, using a new gland washer.
6 Fill brake fluid until the fluid level is in the middle of the sight
glass. For volume and grade, see section F Technical data.
7 Fit the filler cap.
1. Brake system fluid filler orifice
2. Breather filter, brake fluid tank

5 Steering 1
5 Steering
Table of Contents 5 Steering

mm mm mm mm mm mm
5 Steering........................................................................................................... 3
5.1.2 Mini-wheel .............................................................................................. 3
5.1.3 Joystick .................................................................................................. 4
5.2 Power assisted system ............................................................................... 6
5.2.1 Hydraulic oil pump ............................................................................... 13
5.2.2 Priority valve ........................................................................................ 14
5.2.3 Steering valve ...................................................................................... 20
5.2.4 Steering cylinder .................................................................................. 23
5.2.5 Steering axle cradle ............................................................................. 26
5.2.6 Link arm ............................................................................................... 27
5.2.7 Wheel spindle ...................................................................................... 27
5.2.8 Wheel hub ............................................................................................ 27
5.2.9 Shuttle valve ........................................................................................ 27
5.2.10 Control valve mini-wheel/joystick control ............................................. 28
5.2.11 Shuttle valve, mini-wheel/lever steering .............................................. 31
5.2.12 Steering angle sensor .......................................................................... 32
5.2.13 Pipes and hoses .................................................................................. 32

2 5 Steering

5 Steering 3
5 Steering
mm mm mm mm mm mm

5.1.2 Mini-wheel
Mini-wheel, description
page
–
3 4
On machines with mini-wheel, the machine is steered with an electric
2 control. A directional valve pressurises the steering cylinder.
The mini-wheel controls are integrated in the left armrest. The controls
1 consist of two rotary potentiometers and three switches to activate the
mini-wheel, select direction of travel and activate the horn.
NOTE
The mini-wheel is deactivated if the standard steering wheel is
used.
Mini-wheel or lever steering can only be activated at speeds
below 3 km/h.
Mini-wheel
5 Rotary potentiometers transmit a 0-5 V signal for one revolution. The
potentiometers have phase displacement to determine the direction of
turning. The rotary potentiometers are supplied voltage by the cab
control unit (D790-1) and send it a voltage signal proportional to the
turn to indicate steering deflection.
The relationship between the deflection of the mini-wheel and that of
the wheels can be set to 31 different settings - from linear to extremely
progressive. It is also possible to set how steering deflection is to be
000583
adapted based on machine speed. This is done via the diagnostic

1. Mini-wheel menus; see section 8 Control system , group 8.5.1 Initiation.
2. Travel direction selector (F / N / R) The signals can be read from the diagnostic menu, see section 8 Con-
3. Switch, mini-wheel activation trol system , group 8.4.11.4 EL-STEERING, menu 1.
4. Acoustic signal
5. Armrest Switch, mini-wheel activation
The mini-wheel switch (position 3) activates steering with the mini-
wheel. The switch is supplied voltage by and sends a voltage signal to
the cab control unit (D790-1).
The signals can be read from the diagnostic menu, see section 8 Con-
trol system , group 8.4.11.4 EL-STEERING, menu 2.
Travel direction selector

The travel direction selector is used to choose direction of travel (for-
ward or reverse) when the mini-wheel is activated. The switch is sup-
plied voltage by and sends a voltage signal to the cab control unit
(D790-1).

4 5 Steering – 5.1.3 Joystick
Acoustic signal
The acoustic signal is used to activate the signal horn when the mini-
wheel is activated. The switch is supplied voltage by and sends a volt-
age signal to the cab control unit (D790-1).
5.1.3 Joystick
Joystick, description
page
–
3 4
On machines with joystick, the machine is steered with an electric con-
2
trol. A directional valve actuates the steering cylinder.
The joystick is integrated in the left armrest. The controls consist of a
1 sliding potentiometer and three switches to activate lever steering, se-
lect direction of travel and activate the horn.
NOTE
Lever steering is deactivated if the standard steering wheel is
used.
Mini-wheel or lever steering can only be activated at speeds be-
low 3 km/h.
Joystick
5 The sliding potentiometer is supplied voltage by the cab control unit
(D790-1) and sends it a voltage signal proportional to movement to in-
dicate steering deflection.
The relationship between the deflection of the joystick and that of the
wheels can be set to 31 different settings - from linear to extremely
000900

adapted based on machine speed. This is done via the diagnostic
1. Joystick
menus; see section 8 Control system , group 8.5.1 Initiation.
2. Travel direction selector (F / N / R)
3. Switch, joystick activation Joystick position (left, centre, right) can be calibrated with the diagnos-
4. Acoustic signal tic menus; see section 8 Control system , group 8.5.2.2 Calibrate
5. Armrest steering.
Switch, joystick activation

The joystick activation switch (position 3) activates steering with the
joystick. The switch is supplied voltage by and sends a voltage signal
to the cab control unit (D790-1).

5 Steering – 5.1.3 Joystick 5
Travel direction selector

The travel direction selector is used to choose direction of travel (for-
ward or reverse) when lever steering is activated. The switch is sup-
plied voltage by and sends a voltage signal to the cab control unit
(D790-1).
Acoustic signal
The acoustic signal is used to activate the horn when the lever steering
is activated. The switch is supplied voltage by and sends a voltage sig-
nal to the cab control unit (D790-1).

6 5 Steering – 5.2 Power assisted system
5.2 Power assisted system

Power assisted system, function description
page
–
(hydraulic oil pump alternative Rexroth)
2
PP P
C1
CF LS
5
P T
LS T L R
3
1 6
007428
1 The hydraulic oil pumps pump oil to the See pressure plate on Section 10 Common hydraulics, group
priority valve. left frame beam. 10.4.2 Axial piston pump with variable dis-
placement
2 The priority valve prioritises pressure sup- Checked by control sys- Priority valve, description (hydraulic oil
ply to the steering valve over the working tem, error shown with pump alternative Rexroth) page 14
hydraulics. The priority valve also trans- error code.
mits a control signal to the hydraulic oil
pump 3 and 4.
3 The shuttle valve selects the strongest Checked by control sys- Section 10 Common hydraulics, group
load signal to the main pump if hydraulic tem, error shown with 10.5.3 Shuttle valve
functions are activated at the same time error code.
as the steering wheel is turned.
4 The steering wheel is turned and acts on - Section 9 Frame, body, cab and accesso-
the steering valve's input shaft. ries, group 9.1 Controls and instruments
5 The steering valve pumps pressurised oil - Steering valve, description page 20
to the steering cylinder and transmits a
load signal to the main pumps.
6 The steering cylinder turns the wheels. - Steering cylinder, description page 23

5 Steering – 5.2 Power assisted system 7
Power assisted system, function description

page
–
(hydraulic oil pump alternative Sauer-Danfoss)
2
PP P
C1
CF LS
5
P T
LS T L R
3
1 6
007428
1 The hydraulic oil pump 2 pumps oil to See pressure plate on left Section 10 Common hydraulics, group
the priority valve. frame beam. 10.4.2 Axial piston pump with variable
displacement
2 The priority valve prioritises pressure Checked by control sys- Priority valve, description (hydraulic oil
supply to the steering valve over the tem, error shown with pump alternative Rexroth) page 14
working hydraulics. The priority valve error code.
also transmits a control signal to the
hydraulic oil pump 2.
3 The shuttle valve selects the strongest Checked by control sys- Section 10 Common hydraulics, group
load signal to the main pump if hydraulic tem, error shown with 10.5.3 Shuttle valve
functions are activated at the same time error code.
as the steering wheel is turned.
5 The steering valve pumps pressurised - Steering valve, description page 20

oil to the steering cylinder and transmits
a load signal to the main pumps.

Joystick control/mini-wheel, function

page
–
description (hydraulic oil pump alternative

Rexroth)
Mini-wheel or lever steering is a steering option that makes it possible

to steer the machine with an electric control.
The relationship between the deflection of the control and that of the
adapted based on machine speed. This is done via the initiation men-
us; see section 8 Control system, group 8.5.1 Initiation.
NOTE
The mini-wheel/lever steering is deactivated if the standard steer-
ing wheel is used.
Mini-wheel or lever steering can only be activated at speeds
below 3 km/h.

Lever steering Voltage signal from switch mini- Mini-wheel, description page 3 or Joystick, description page 4
activated wheel/joystick control. Diagnostic menu, see section 8 Control system , group 8.4.11.4
EL-STEERING, menu 2
Steering wheel No signal from sensor steering Sensor, steering wheel movement, description page 32
stationary wheel movement.
Speed Below 3 km/h (at engagement) -
Safety switch Not activated Section 11 Common electrics, group 11.2.3 Safety switch

1
D12 D1
11
13 2
D790-1
D790-2 D790-3
D797-O
12 3
D3 4 D4
C7 8
PP
P P
CF LS
P LS 5, 9
TP
LS T
T1
T L R A B
10
006404
1 The joystick switch or mini-wheel switch Signal 1, U = 0.5 - 4.5 V Mini-wheel, description page 3 or Joystick,
sends a voltage signal to the cab control Signal 2, U = 0.5 - 4.5 V description page 4
unit (D790-1). (mini-wheel only) D1: Diagnostic menu, see section 8 Control
On machines with Combi attachment system , group 8.4.11.4 EL-STEERING,
the signal is sent to the cab control unit menu 1
option (D790-3).
the desired steering deflection on the tem; error indicated with 11.5.3.1 Cab control unit
On machines with Combi attachment
the cab control unit option (D790-3)
sends steering deflection on the CAN
bus.
3 Control unit, frame option (D797-O) sup- I = 350–550 mA Section 11 Common electrics, group
plies voltage to the solenoid valve for 11.5.3.4 Control unit, frame option
steering right (Y636R) or the solenoid D3: Diagnostic menu, see section 8 Control
valve for steering left (Y636L). system , group 8.4.11.4 EL-STEERING,
menu 4 and 5


4 The solenoid valve, steering right - Control valve for lever steering or mini-
(Y636R) or solenoid valve, steering left wheel, description page 28
(Y636l) pressurises the steering slide in D4: Diagnostic menu, see section 8 Control
the solenoid valve for lever steering or system , group 8.4.11.4 EL-STEERING,
mini-wheel. menu 4 and 5
5 The solenoid valve for lever control or - Control valve for lever steering or mini-
mini-wheel sends a load signal to shuttle wheel, description page 28
valve, steering.
6 The shuttle valve selects the strongest - Shuttle valve for mini-wheel or lever control,
load signal to hydraulic oil pump 3 and 4 description page 31
if hydraulic functions are activated at the
same time as the steering wheel is
turned.
7 Hydraulic oil pumps 3 and 4 pump oil See pressure plate on left Section 10 Common hydraulics, group
from the hydraulic oil tank. frame beam. 10.4.2 Axial piston pump with variable
displacement
8 The priority valve prioritises pressure See pressure plate on left Priority valve page 14
supply to the steering valve over the frame beam.
working hydraulics. The priority valve
also transmits a control signal to the hy-
draulic oil pump 3 and 4.
9 The slide changes position and pressu- - Control valve for lever steering or mini-
rises the steering cylinder. wheel, description page 28
12 Sensor steering axle sends a voltage U = 24 V Sensor, steering wheel movement, descrip-
signal to Control unit, cab (D790-1). tion page 32
D12: Diagnostic menu, see section 8 Con-
trol system , group 8.4.11.4 EL-STEERING,
menu 3
the stop steering on the CAN bus. tem; error indicated with 11.5.3.1 Cab control unit
error code.
Hydraulic diagram, joystick control

Joystick control/mini-wheel, function

page
–
description (hydraulic oil pump alternative

Sauer-Danfoss)
Mini-wheel or lever steering is a steering option that makes it possible

to steer the machine with an electric control.
The relationship between the deflection of the control and that of the
adapted based on machine speed. This is done via the initiation men-
us; see section 8 Control system, group 8.5.1 Initiation.
NOTE
The mini-wheel/lever steering is deactivated if the standard steer-
ing wheel is used.
Mini-wheel or lever steering can only be activated at speeds be-
low 3 km/h.

Lever steering Voltage signal from switch mini- Mini-wheel, description page 3 or Joystick, description page 4
activated wheel/joystick control. Diagnostic menu, see section 8 Control system , group 8.4.11.4
EL-STEERING, menu 2
Steering wheel No signal from sensor steering Sensor, steering wheel movement, description page 32
stationary wheel movement.
Speed Below 3 km/h (at engagement) -
Safety switch Not activated Section 11 Common electrics, group 11.2.3 Safety switch

1
D12 D1
11
13 2
D790-1
D790-2 D790-3
D797-O
12 3
D3 4 D4
C7 8
PP
P P
CF LS
P LS 5, 9
TP
LS T
T1
T L R A B
10
006404
1 The joystick switch or mini-wheel switch Signal 1, U = 0.5 - 4.5 V Mini-wheel, description page 3 or Joystick,
sends a voltage signal to the cab control Signal 2, U = 0.5 - 4.5 V description page 4
unit (D790-1). (mini-wheel only) D1: Diagnostic menu, see section 8 Control
On machines with Combi attachment system , group 8.4.11.4 EL-STEERING,
the signal is sent to the cab control unit menu 1
option (D790-3).
the desired steering deflection on the tem; error indicated with 11.5.3.1 Cab control unit
On machines with Combi attachment
the cab control unit option (D790-3)
sends steering deflection on the CAN
bus.
3 Control unit, frame option (D797-O) sup- I = 350–550 mA Section 11 Common electrics, group
plies voltage to the solenoid valve for 11.5.3.4 Control unit, frame option
steering right (Y636R) or the solenoid D3: Diagnostic menu, see section 8 Control
valve for steering left (Y636L). system , group 8.4.11.4 EL-STEERING,
menu 4 and 5

5 Steering – 5.2.1 Hydraulic oil pump 13

4 The solenoid valve, steering right - Control valve for lever steering or mini-
(Y636R) or solenoid valve, steering left wheel, description page 28
(Y636l) pressurises the steering slide in D4: Diagnostic menu, see section 8 Control
the solenoid valve for lever steering or system , group 8.4.11.4 EL-STEERING,
mini-wheel. menu 4 and 5
5 The solenoid valve for lever control or - Control valve for lever steering or mini-
mini-wheel sends a load signal to shuttle wheel, description page 28
valve, steering.
6 The shuttle valve selects the strongest - Shuttle valve for mini-wheel or lever control,
load signal to hydraulic oil pump 2 if hy- description page 31
draulic functions are activated at the
same time as the steering wheel is
turned.
7 Hydraulic oil pump 2 pumps oil from the See pressure plate on left Section 10 Common hydraulics, group
hydraulic oil tank. frame beam. 10.4.2 Axial piston pump with variable dis-
placement
8 The priority valve prioritises pressure See pressure plate on left Priority valve page 14
supply to the steering valve over the frame beam.
working hydraulics. The priority valve
also transmits a control signal to the hy-
draulic oil pump 2.
9 The slide changes position and pressu- - Control valve for lever steering or mini-
rises the steering cylinder. wheel, description page 28
12 Sensor steering axle sends a voltage U = 24 V Sensor, steering wheel movement, descrip-
signal to Control unit, cab (D790-1). tion page 32
trol system , group 8.4.11.4 EL-STEERING,
menu 3
the stop steering on the CAN bus. tem; error indicated with 11.5.3.1 Cab control unit
error code.
Hydraulic diagram, joystick control
5.2.1 Hydraulic oil pump

Hydraulic oil pump, general (hydraulic oil pump
page
–
Steering is supplied oil by the hydraulic oil pumps 3 and 4, see section
10 Common hydraulics , group 10.4 Pumps.

14 5 Steering – 5.2.2 Priority valve
Hydraulic oil pump, general (hydraulic oil pump

page
–
Steering is supplied oil by the hydraulic oil pump 2, see section
10 Common hydraulics , group 10.4 Pumps.
5.2.2 Priority valve

Priority valve, description (hydraulic oil pump
page
–
The priority valve divides the oil flow from the main pump 3 and 4 so
that there is always oil to the steering valve. The residual flow goes to
working hydraulics.
The priority valve is load sensing and pilot pressure compensating.
Load sensing means that the valve adapts the control signal to the
steering valve’s consumption. Pilot pressure compensating means
that the priority valve compensates for the pressure drop between the
priority valve and steering valve via a separate line.
The priority valve has a built-in pressure limiter on the load signal. The
pressure limiter maximises the load signal’s pressure.
001016
Steering pressure, checking (hydraulic oil pump

page
–
NOTE
B Safety.
1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, 50 °C.
˚C 3 Depressurising removed.
˚C
000475
Operating menu, hydraulic oil temperature

5 Steering – 5.2.2 Priority valve 15
4 Connect the pressure gauge to the measuring outlet for hydraulic

oil pump 3 or 4.
5 Start the engine and increase engine speed to approx. 1200 rpm.
Measuring outlet, hydraulic oil pumps

1. Hydraulic oil pump 1
6 Turn the steering wheel fully and read pump pressure during
steering wheel movement. Compare this to the steering pressure
on the hydraulics plate. The max. pressure measured on the
pump should be 1.5 MPa more than the steering pressure on the
hydraulics plate.
MPa 7 Stop the engine and turn the starter key to position I.
8 Depressurising removed.
MPa
power.
MPa
MPa MPa MPa measuring outlet.
MPa
MPa
MPa MPa
001033
920643.0024

Priority valve, description (hydraulic oil pump

page
–
The priority valve divides the oil flow from the main pump 2 so that
there is always oil to the steering valve. The residual flow goes to
working hydraulics.
The priority valve is load sensing and pilot pressure compensating.
Load sensing means that the valve adapts the control signal to the
steering valve’s consumption. Pilot pressure compensating means
that the priority valve compensates for the pressure drop between the
priority valve and steering valve via a separate line.
The priority valve has a built-in pressure limiter on the load signal. The
011345 pressure limiter maximises the load signal’s pressure.

Steering pressure, checking (hydraulic oil pump

page
–
NOTE
B Safety.
es operating temperature, 50 °C.
˚C 3 Depressurising removed.
˚C
000475
4 Connect the pressure gauge to the measuring outlet for hydraulic
oil pump 2.
5 Start the engine and increase engine speed to approx. 1200 rpm.
Measuring outlet, hydraulic oil pumps

6 Turn the steering wheel fully and read pump pressure during
steering wheel movement. Compare this to the steering pressure
on the hydraulics plate. The max. pressure measured on the
pump should be 1.5 MPa more than the steering pressure on the
MPa hydraulics plate.
MPa 7 Stop the engine and turn the starter key to position I.
power.
MPa
measuring outlet.
MPa
MPa MPa MPa MPa MPa MPa MPa
A49195.0400

Priority valve, replacement

page
–
NOTE
B Safety.
B Safety.
power.
4 Mark up and detach the hydraulic hoses from the priority valve.
NOTE
5 Remove the priority valve attaching bolts.
6 Release the priority valve from the collection block.
7 Remove the priority valve.
8 Transfer the connection adapters to the new priority valve.
NOTE
Transfer one connection at a time so that the marking is not
mixed up.
9 Connect the new priority valve to the collection block.
C AUTION
Do not tighten the hydraulic connection between pri-
ority valve and collection block before all other con-
nections and attaching bolts are fitted.
Stresses in the priority valve may result in incorrect

function.
10 Fit the priority valve attaching bolts.

11 Connect the hydraulic hoses to the priority valve.
12 Check that the collection block is not pressing against the priority
valve.
13 Tighten the hydraulic connection between priority valve and col-
lection block.

NOTE
15 Close the relief valve for top lift.
C AUTION

010475
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
16 Start the engine and check that the hydraulic connections at the
priority valve are sealed.
17 Check the oil level in the hydraulic oil tank with the lift cylinders
fully down and the extension cylinder fully in. The oil level should
be in the centre of the level glass. Top up if necessary, for grade
see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
The hydraulic oil level is checked with the boom com-

pletely lowered and retracted.
18 Check steering pressure, see Steering pressure, checking (hy-

draulic oil pump alternative Rexroth) page 14.

20 5 Steering – 5.2.3 Steering valve
5.2.3 Steering valve

Steering valve, description
page
–
The steering valve is a "progressive, closed centre, non-reaction

valve" with load signal connection to the priority valve.
The load signal generates load-dependent control of oil flow from the
priority valve to the steering valve. Closed centre means that the steer-
ing valve is closed in its neutral position. This is necessary so that sig-
nal pressure can be connected to the steering valve.
The steering valve consists of a gear pump and a distribution valve.
When the steering wheel is turned, oil flows from the main pump over
the gear pump to the distribution valve, which guides oil to the steering
cylinder. The gear pump ensures that the oil flow fed to the cylinder is
proportional to the steering wheel angle.
There are double shock and anti-cavitation valves in the steering
valve. The shock valves protect the hydraulics against pressure spikes
which can arise from impacts on the steering wheels. The anti-cavita-
tion valves (non-return valves) protect against vacuum on the piston’s
rear side, which can lead to cavitation.
001082

5 Steering – 5.2.3 Steering valve 21
Steering valve, replacement

page
–
NOTE
B Safety.
1 Remove the cover plates over the engine compartment.
2 Slide the cab forward so that the control valve is accessible from
below.
B Safety.
power.
1. Water valve
2. Steering valve
6 Detach the steering valve from the brake pedal.
Remove the steering valve attaching bolts and lower the steering
valve.
7 Mark up and detach the hydraulic hoses from the steering valve.
NOTE
8 Remove the steering valve.
9 Transfer the connection adapters to the new steering valve.
NOTE
Transfer one at a time so that the marking is not mixed up.
10 Connect the hydraulic hoses to the steering valve in accordance
with the marking.
NOTE
11 Connect the new steering valve to the brake pedal.
Place the steering valve and check that the steering wheel shaft’s
splines enter straight in the steering valve’s slot. Install the at-
taching bolts.

22 5 Steering – 5.2.3 Steering valve
12 On machines with manual sliding cab:

Lock the cab in its rearmost position with both locking catches.
000270
B C
A. Location, lock handle
B. Lock pin
NOTE
C AUTION

010475

5 Steering – 5.2.4 Steering cylinder 23

16 Check that the connections on the steering valve are sealed.
17 Steer very carefully a few times right - left, to bleed the steering
valve and steering cylinder.
C AUTION

5.2.4 Steering cylinder

Steering cylinder, description
page
–
The steering cylinder acts on the wheels via the link arms. The steer-
1 2 3 4 5 6 7 8 ing cylinder is a double-acting hydraulic cylinder.
001446
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle
5. Suspension
6. Steering cylinder
7. Rear mounting
8. Counterweight

24 5 Steering – 5.2.4 Steering cylinder
Steering cylinder, replacement

page
–
NOTE
B Safety.
1 Park the machine with the wheels fully turned so that the steering
cylinder can be lifted out to one side.
B Safety.
4 Disconnect the link arms from the steering cylinder.
5 Mark up and disconnect the hydraulic hoses from the steering
cylinder.
NOTE
1. Link arm mounting

2. Hydraulic connection
6 Remove the steering cylinder’s attaching bolts.
7 Change the steering cylinder. Lift aside the steering cylinder.
NOTE
The steering cylinder is heavy, use lifting equipment.
8 Support the new steering cylinder so that the holes in the attach-
ing bolts are lined up directly opposite the holes in the steering
axle.
9 Fit and lubricate the steering cylinder attaching bolts. Tighten
them crosswise in steps until 680 Nm is achieved.
10 Transfer parts to the new steering cylinder.
Attaching bolts steering cylinder.
NOTE

5 Steering – 5.2.4 Steering cylinder 25
11 Fit the link arms to the steering cylinder.

12 Connect the hydraulic hoses to the steering cylinder.
NOTE
1. Link arm mounting

2. Hydraulic connection
NOTE
C AUTION
010475

26 5 Steering – 5.2.5 Steering axle cradle
C AUTION

Hydraulic cylinders, repairs

page
–
See section 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.
5.2.5 Steering axle cradle

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

5 Steering – 5.2.6 Link arm 27
5.2.6 Link arm

Link arm, description
page
–
The link arm transfers the lateral movement of the steering cylinder to
1 2 3 4 5 6 7 8 turning the wheel spindles.
The setting of the steering wheels cannot be adjusted. If the link arms
are deformed in a way that changes the setting of the steering wheels,
they must be replaced.
The link arms must be turned to the right direction, otherwise they can
be damaged by the rims with large wheel angles.
001446
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle
5. Suspension
7. Rear mounting
8. Counterweight
5.2.7 Wheel spindle

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

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

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

28 5 Steering – 5.2.10 Control valve mini-wheel/joystick control
5.2.10 Control valve mini-wheel/joystick

control
Control valve for lever steering or mini-wheel,
page
–
description
1
On machines with joystick control or mini-wheel, steering cylinder dis-
placement is regulated by the control valve for joystick control or mini-
6 2
wheel. The control valve is located on the inside of the right frame
member in front of the engine. The control valve is regulated by Con-
5 3 trol unit, frame option (D797-O).
The control valve is an electro-hydraulically controlled, proportional
4 and pressure-compensated directional valve. Electrically controlled
pressure reducing valves convert electrical current to servo pressure.
The servo pressure controls the spring-centred valve slides, which
control pressure and flow for the function in question. The valve slides
have flow limits so that several functions can be activated
simultaneously.
Valve slide, steering

The valve slide controls the direction and steering angle by controlling
002205
the hydraulic pressure to the steering cylinder.

The valve slide is controlled by servo valve right and servo valve left.
1. Load signal (LS)
2. Pressure supply (P)
Servo valve right
3. Tank return (T)
4. Connection, steering cylinder (B) Servo valve right controls servo pressure to valve slide, steering, so
5. Tank return (TP) that it controls oil pressure for steering right.
6. Connection, steering cylinder (A) Servo valve right regulates electrically with the solenoid valve steering
right (Y636R), which is activated by Control unit, frame option
(D797-O).
Servo valve left

Servo valve left controls servo pressure to valve slide, steering, so that
it controls oil pressure for steering left.
Servo valve left regulates electrically with the solenoid valve steering
left (Y636L), which is activated by Control unit, frame option (D797-O).

5 Steering – 5.2.10 Control valve mini-wheel/joystick control 29
Control valve for joystick control or mini-wheel,

page
–
replacement
NOTE
B Safety.
B Safety.
3 Mark up and detach the hydraulic hoses from the control valve.
1
NOTE
6 2 Plug all connections immediately to protect the hydraulic
5 3 4 Mark up and detach the wiring from the control valve.
5 Remove the control valve.
4
Remove the attaching bolts and lift away the valve. Place the
valve on a clean and protected surface.
6 Transfer parts to the new control valve.
NOTE
Check that the O-rings on the hydraulic connections are in-
tact and in place.
NOTE
002205
Transfer one adapter component at a time so that the mark-

1. Load signal (LS)
ing is not mixed up.
3. Tank return (T) 7 Mark up the servo valves on the new control valve.
4. Connection, steering cylinder (B) 8 Fit the valve.
5. Tank return (TP)
9 Connect the wiring to the control valve in accordance with the
6. Connection, steering cylinder (A)
marking.
10 Connect the hydraulic hoses to the control valve in accordance
with the marking.
NOTE

30 5 Steering – 5.2.10 Control valve mini-wheel/joystick control
NOTE
C AUTION

010475

14 Check the function.
C AUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the steering carefully and drive a couple of

times with lowest possible speed to avoid cavitation.
C AUTION


5 Steering – 5.2.11 Shuttle valve, mini-wheel/lever steering 31
5.2.11 Shuttle valve, mini-wheel/lever

steering
Shuttle valve for mini-wheel or lever control,
page
–
description
Machines with lever steering or mini-wheel have an extra shuttle valve

for the control signal cables of the hydraulic oil pumps. The shuttle
1 valves are fitted on the bracket for oil filling and dipsticks between en-
gine and transmission.
2 The shuttle valve forwards the control signal from the control valve to
the main pumps.
3
4
002203
Shuttle valves on attachment plate between engine

and transmission
1. Shuttle valve, frame option
2. Shuttle valve lifting / steering
3. Shuttle valve joystick control/mini-wheel
4. Shuttle valve lifting / attachment

32 5 Steering – 5.2.12 Steering angle sensor
5.2.12 Steering angle sensor

Sensor, steering wheel movement, description
page
–
1
2
The steering angle sensor (B770) detects if the steering wheel is
turned and sends a signal to the KIT control unit (D790-2). This is used
to disengage joystick control or the mini-wheel. The sensor is located
by the steering axle inside the panels. The sensor is tripped by an in-
dicator ring on the steering axle with four lobes. The location of the
sensor and lobes’ spacing means that small steering wheel move-
ments can be detected.
002628
1. Indicator ring
2. Sensor steering wheel movement (B770)
Position sensor, checking and adjustment

page
–
See section 7 Load handling.

page
–

6 Suspension 1
6 Suspension
Table of Contents 6 Suspension

mm mm mm mm mm mm
6 Suspension..................................................................................................... 3
6.2 Suspension ................................................................................................. 3
6.2.1 Steering axle cradle ............................................................................... 5
6.2.2 Wheel spindle ........................................................................................ 7
6.2.3 Wheel hub ............................................................................................ 11
6.3 Tyres and rims .......................................................................................... 16
6.3.1 Tyres .................................................................................................... 18
6.3.2 Rims ..................................................................................................... 19
6.3.3 Nut, washer and clamp ........................................................................ 20

2 6 Suspension

6 Suspension 3
6 Suspension
mm mm mm mm mm mm
6.2 Suspension
Bushing steering axle mounting, changing
page
–
D ANGER
Steering axle and machine are very heavy.
It is not permissible to go under a machine which has

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

power.
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 Connect lifting equipment to the rear of the machine and take up
the slack so that the steering axle’s mounts are relieved.
NOTE
Do not lift so much that the wheels are off the ground.
6 Remove the shafts holding the steering axle.
7 Lift the machine up so that the frame is lifted away from the axle.
8 Support the machine under the frame.
9 Move the steering axle so that the mountings can be accessed.
NOTE
If needed, disconnect the cabling for the sensors on the
steering axle.
The illustration shows rear attachment.

4 6 Suspension – 6.2 Suspension
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 mounting.

13 Assemble the parts of the bushing and press in the new bushing.
Lubricate the bushing with grease in order to simplify installation.
C AUTION
The bearing halves must be mounted horizontally.
14 Fit the washers that hold the bushing in place. Use locking fluid
and tighten the bolts to a torque of 45 Nm.
Parts of bushing steering axle 15 Move the steering axle into place under the frame.
1. Inner race
16 Grease and install the pins by the steering axle’s mounts.
2. Bearing halves
17 Remove the lifting equipment from the machine.
18 Fit the counterweights.
NOTE
Make sure that all counterweights are refitted and that they
are fitted in the exact same location as before. The stability
of the machine is affected if the counterweights are
changed.

6 Suspension – 6.2.1 Steering axle cradle 5
6.2.1 Steering axle cradle

Steering axle cradle, description
page
–
The steering axle is pendulum suspended with a double-acting steer-

1 2 3 4 5 6 7 8 ing cylinder. The construction comprises a minimum of moving parts
to minimise service points and simplify maintenance.
The frame suspension comprises maintenance-free parts. The rear
suspension is designed with a leading knee which is used to indicate
too low load on the steering axle, a so-called mechanical overload sys-
tem, see section 8 Control system , group 8.2.1 Overload System.
001446
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle
5. Front mounting
7. Rear mounting
8. Counterweight
Steering axle cradle, replacement

page
–
D ANGER
Steering axle and machine are very heavy.
It is not permissible to go under a machine which has

been lifted by a jack or similar. For machine weights,
please refer to section F Technical data.
1 Clean the steering axle and its surrounding area.

B Safety.
power.

6 6 Suspension – 6.2.1 Steering axle cradle
5 Remove the counterweights on the rear of the machine.
NOTE
Mark the locations of the counterweights so that they can be
refitted at the same spot. This is important for the machine’s
stability.
6 Connect the lifting equipment to the rear section of the machine.
7 Tension the lifting equipment, do not lift so high that the wheels
start to hang.
8 Support the machine’s rear section.
9 Detach the wiring from the overload sensor (applies only to ma-
chines with mechanical overload system).
10 Detach the hydraulic hoses from the steering cylinder.
NOTE
contamination.
11 Remove the shafts holding the steering axle.
12 Lift the machine up so that the frame is lifted away from the axle.
13 Lift out the steering axle.
C AUTION
The steering axle may start to roll.
Crushing injury!
Make sure that the steering axle does not start

uncontrolled movement.
14 Adjust the support so that the machine is secured in the new po-
sition.
15 Lift the steering axle into place underneath the frame.
16 Remove the support under the frame.
17 Lower the rear of the machine.
18 Fit the shafts at the steering axle mountings.
19 Connect the hydraulic hoses to the steering cylinder.
NOTE
Check that the O-rings are intact and that they are fitted cor-
rectly.
20 Attach the wiring to the overload sensor (applies only to ma-
chines with mechanical overload system).

6 Suspension – 6.2.2 Wheel spindle 7
21 Remove the lifting equipment from the machine.

22 Fit the counterweights.
NOTE
Make sure that all counterweights are refitted and that they
are fitted in the exact same location as before. The stability
of the machine is affected if the counterweights are
changed.
6.2.2 Wheel spindle

Wheel spindle, description
page
–
The wheel spindle is the link between steering axle and wheel hubs
1 2 3 4 5 6
which means that the wheels can be turned.
5
010483
1. Wheel spindle
2. Spindle bolt
3. Seal
4. Slide bearing washer
5. Cover
6. Spindle bolt bearing
7. Thrust bearing
8. Lock screw
Spindle bolt bearing, replacement

page
–
1 Clean the wheel spindle and its surrounding area.

2 Lift the machine under the steering axle at the wheel in question.
Support the steering axle in a suitable way.
3 Remove the steering wheel in question.

8 6 Suspension – 6.2.2 Wheel spindle
4 Detach the link arm from the wheel spindle.

2
Remove the lock screw and then remove the axle. Move the link
arm aside.
1 5 Position a lifting strap inside the hub to secure the spindle.
6 Remove the covers at the spindle bolt’s upper and lower bearing.
7 Remove the grease between the cover and spindle bolt.
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 the like con-
nected to the threaded hole in the centre of the spindle bolt.
11 Remove the wheel spindle.
Place the wheel spindle on a soft surface.
12 Remove the thrust bearings from the steering axle.

1
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 in the same place.
14 Clean the surfaces inside the steering axle.
15 Press in the new bearing bushings. Make sure that the space
ends up at the same spot 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 bearing

6 Suspension – 6.2.2 Wheel spindle 9
16 Fit new thrust washers on the steering axle. Only fit three bolts in
the manner illustrated. The fourth bolt cannot be fitted until the
wheel spindle is in place. Only tighten the bolts slightly (5-10 Nm)
so that the thrust bearings are secured in position.
Thoroughly coat the bearing bushings with grease. For grade,
NOTE
Be sure to position the nuts as illustrated.
17 Fit new O-rings on the wheel spindle.
011152
Pull the O-ring toward the hub.
18 Lift the wheel spindle into place on the steering axle.
19 Coat the wear surface of the lower wear washer with lubricating
grease and align the bearing between the wheel spindle and the
lower thrust washer. Use a rubber mallet to get the bearing to the
right position. Check that the bearing is centred in the wheel spin-
dle by looking in the spindle from below.
20 Coat the wear surface of the upper wear washer with lubricating
grease and align the bearing between the wheel spindle and the
upper thrust washer. Use a rubber mallet to get the bearing to the
right position. Check that the bearing is centred in the wheel spin-
dle by looking in the spindle from above.
011163
21 Fit the spindle bolt.

Coat the spindle bolt with lubricating grease 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 spin-
dle bolt into place.

10 6 Suspension – 6.2.2 Wheel spindle
22 Fit the lock screws and tighten with the lock nuts. Tighten to
250 Nm (oiled screw).
23 Coat the space between the wheel spindle and steering axle with
lubricating grease.
24 Position the O-rings.
25 Fit the remaining bolts to the thrust bearings’ wear washer as il-
1
lustrated. Tighten to 25 Nm (oiled screw).
004517
1. Wear washer, thrust bearing

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

6 Suspension – 6.2.3 Wheel hub 11
6.2.3 Wheel hub

Wheel hub, description
page
–
The wheel hub holds the wheel in place and allows the wheel to rotate.
1 2 3 4 5 6
001443
1. Hub nut with locking washer

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

page
–
1 Lift the machine under the steering axle by the wheel in question.
Support securely under the steering axle.
2 Remove the steering wheel in question.
3 Clean the hub cover and its surrounding area.

4 Remove the hub cover.
5 Wipe away grease from hub cover and hub nuts. Handle it as en-
vironmentally hazardous waste.

12 6 Suspension – 6.2.3 Wheel hub
6 Secure the hub with a lifting strap.

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

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

14 6 Suspension – 6.2.3 Wheel hub
19 Fit the hub on the wheel spindle.
20 Install the outer bearing, protecting washer, and bearing nut.

Pack in 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 Torque the bearing nut as follows.

A. Lubricate the thread and the side of the nut facing the
bearing with oil (SAE 80W/140).
B. Tighten the nut to 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 Grease the lock washer and fit it.
24 Fit the lock nut and tighten to at least 250 Nm (oiled screw) or
then more to engage the locking washer in the closest groove.
Lock the bearing nut and lock nut with the locking washer.

25 Fit the bearing casing and fill it with grease.

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

16 6 Suspension – 6.3 Tyres and rims
6.3 Tyres and rims

Tyres and rims, safety
page
–
D ANGER
Always block the wheels on the side of the axle that is
not going to be worked on before positioning the jack.
Always secure the jack to prevent it from sliding out
of position.
Deflate the tyre before removal. Otherwise the conical
ring and locking clips can loosen and shoot out when
the pressure is changed. With double wheel fitting
both tyres must be deflated!
Do not release air through the valve if the tyre or rim

is damaged. Drill a hole in the tread to release the air.
Damaged tyres may explode.
Never stand directly in front of the wheel when deflat-

ing or inflating. The conical ring and locking clips can
loosen and shoot out when the pressure is changed.
Never install damaged tyres or rims.
It's prohibited to repair rims with welding.
It's prohibited to operate the machine if one of the

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

6 Suspension – 6.3 Tyres and rims 17
C AUTION
When removing wheels, the wheel nuts should be left
in place after loosening. If the wheel nuts are removed
immediately, the wheel may release from the hub.
When removing drive wheels, make sure that the
wheels are secured in position when the spacer rings
are removed. If the wheels move they may displace
the spacer rings, with crushing injuries as a result.
When installing 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 ap-
proved instructions when changing tyres.
Never use a steel hammer to install or remove rim

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

ficient tyre pressure impairs stability and reduces the
machine’s capacity.
Remove penetrating objects, such as crushed glass,
pieces of wood and metal filings.
Check if tyre wear is abnormal. This could indicate a

mechanical fault. Rectify faults immediately and
change damaged tyres.

18 6 Suspension – 6.3.1 Tyres
6.3.1 Tyres
Tyres, description
page
–
The tyres are the point of contact between the machine and the
ground. These absorb unevenness and provide suspension.
The drive axle is subject to major forces during operation. If each tyre’s
rolling circumference differs, the stresses on the drive axle increase.
For this reason it is important that the tyres on the drive axle have
equal wear and correct air pressure.
Spare and replacement tyres must be from a manufacturer approved
by Cargotec.
002027
Front wheels
002026
Rear wheels
Tyre replacement
page
–
D ANGER
Changing tyres is complicated and dangerous work.
FATAL DANGER!
Leave tyre work to authorised personnel/ tyre

company.
The wheel rims must be checked when tyres are changed. See Main-
tenance manual DRF 400–450 section 6 Suspension.

6 Suspension – 6.3.2 Rims 19
6.3.2 Rims
Rim, description
page
–
The rim is split to make it possible to fit a tyre, the rim consists of the
1 2 3 4 5 6 following parts.
• Rims
• Rim bead seat
• Rim flange
• Lock ring
• Lock lugs
• Hub plate
7
001444
1. Lock ring
2. Rim flange
3. Tapered rim bead seat
4. O-ring
5. Rims
6. Rim flange
7. Wheel nut
8. Wheel clamp

20 6 Suspension – 6.3.3 Nut, washer and clamp
6.3.3 Nut, washer and clamp

Nut, washer and clamp, description
page
–
The rim is attached to the wheel hub with nuts and clamps.
1 2 3 4 5 6
The number of nuts and clamps varies depending on the type of drive
axle and steering axle used.
7
001444
1. Lock ring
2. Rim flange
3. Tapered rim bead seat
4. O-ring
5. Rims
6. Rim flange
7. Wheel nut
8. Wheel clamp

6 Suspension – 6.3.3 Nut, washer and clamp 21
Wheel bolt, replacing

page
–

2 Raise the machine with a jack positioned under the steering axle.
3 Remove the steering wheel, see Maintenance Manual DRF
400-450 section 6 Suspension.
4 Knock out the bolt with a sledge hammer.

5 Replace the bolt.

22 6 Suspension – 6.3.3 Nut, washer and clamp

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

mm mm mm mm mm mm
7 Load handling................................................................................................. 5
7.1.1 Control lever .......................................................................................... 7
7.1.2 Switch, lock twistlocks ........................................................................... 9
7.1.3 Switch, automatic spreading ................................................................ 10
7.1.5 Switch, stop at 30' or 35' ...................................................................... 10
7.2 Lifting/lowering ......................................................................................... 11
7.2.2 Servo filter ............................................................................................ 16
7.2.3 Pressure reducer ................................................................................. 16
7.2.4 Accumulator servo circuit ..................................................................... 18
7.2.5 Control valve lift, lower and extension ................................................. 20
7.2.6 Shuttle valve ........................................................................................ 22
7.2.7 Valve block lift cylinder ........................................................................ 23
7.2.8 Lift cylinder ........................................................................................... 27
7.2.9 Sensor hydraulic pressure lift cylinder ................................................. 32
7.2.10 Lift boom .............................................................................................. 35
7.2.11 Sensor, boom angle ............................................................................. 35
7.2.12 Pipes and hoses .................................................................................. 35
7.2.16 Sensor, attachment damping ............................................................... 36
7.3 Extension .................................................................................................. 37
7.3.2 Servo filter ............................................................................................ 44
7.3.3 Pressure reducer ................................................................................. 44
7.3.4 Accumulator servo circuit ..................................................................... 45
7.3.5 Control valve lift, lower, extension ....................................................... 45
7.3.6 Shuttle valve ........................................................................................ 46
7.3.7 Valve block, extension cylinder ............................................................ 47
7.3.8 Extension cylinder ................................................................................ 47
7.3.9 Valve block, pump relief ....................................................................... 51
7.3.10 Lift boom .............................................................................................. 53
7.3.11 Sensor, boom length ............................................................................ 55
7.3.12 Pipes and hoses .................................................................................. 55
7.4 Side shift ................................................................................................... 56
7.4.2 Valve block, top lift hydraulics .............................................................. 58
7.4.3 Control valve attachment ..................................................................... 59
7.4.4 Shuttle valve ........................................................................................ 63
7.4.5 Side shift cylinder ................................................................................. 64
7.4.6 Side shift frame .................................................................................... 65
7.4.7 Main beam, attachment ....................................................................... 69
7.4.8 Relief valve, attachment ...................................................................... 69
7.4.9 Pipes and hoses .................................................................................. 70
7.5 Spreading ................................................................................................. 71

2 7 Load handling
7.5.1 Hydraulic oil pump ................................................................................ 78

7.5.3 Control valve attachment ...................................................................... 78
7.5.4 Shuttle valve ......................................................................................... 78
7.5.5 Valve block, spreading motor ............................................................... 79
7.5.6 Spreading motor ................................................................................... 79
7.5.7 Spreader chains ................................................................................... 83
7.5.8 Spreader beam ..................................................................................... 91
7.5.9 Main beam, attachment ........................................................................ 93
7.5.10 Position sensor, spreading ................................................................... 93
7.5.11 Relief valve, attachment ....................................................................... 93
7.5.12 Pipes and hoses ................................................................................... 93
7.5.13 Buzzer, automatic spreading 20'-40' .................................................... 94
7.6 Rotation ..................................................................................................... 95
7.6.1 Hydraulic oil pump ................................................................................ 99
7.6.3 Control valve attachment .................................................................... 100
7.6.4 Shuttle valve ....................................................................................... 100
7.6.5 Valve block, rotation motor ................................................................. 101
7.6.6 Rotation motor unit ............................................................................. 102
7.6.7 Rotation yoke ..................................................................................... 105
7.6.8 Ring gear ............................................................................................ 108
7.6.9 Side shift frame .................................................................................. 109
7.6.10 Sensor, rotation stop .......................................................................... 110
7.6.11 Relief valve, attachment ..................................................................... 110
7.6.12 Pipes and hoses ................................................................................. 110
7.7 Tilt ........................................................................................................... 111
7.7.1 Hydraulic oil pump .............................................................................. 116
7.7.2 Valve block, top lift hydraulics ............................................................ 116
7.7.3 Damping block, tilt .............................................................................. 117
7.7.4 Lock valve, tilt ..................................................................................... 119
7.7.6 Shuttle valve ....................................................................................... 120
7.7.7 Tilt cylinder ......................................................................................... 121
7.7.8 Lift boom ............................................................................................. 121
7.7.9 Rotation yoke ..................................................................................... 121
7.7.10 Relief valve, attachment ..................................................................... 121
7.7.11 Pipes and hoses ................................................................................. 121
7.8 Levelling .................................................................................................. 122
7.8.1 Hydraulic oil pump .............................................................................. 126
7.8.2 Valve block, top lift hydraulics ............................................................ 126
7.8.4 Shuttle valve ....................................................................................... 128
7.8.5 Overcentre valve, levelling ................................................................. 128
7.8.6 Valve block, levelling cylinders ........................................................... 128
7.8.7 Levelling cylinders .............................................................................. 129
7.8.8 Side shift frame .................................................................................. 129

7 Load handling 3
7.8.9 Relief valve, attachment .................................................................... 129

7.8.10 Pipes and hoses ................................................................................ 129
7.9 Load carrier ............................................................................................ 130
7.9.1 Twistlocks .......................................................................................... 130
7.9.2 Lifting jacks ........................................................................................ 144
7.10 Other functions ....................................................................................... 172
7.10.1 Support jacks ..................................................................................... 172
7.10.2 Weight indicator ................................................................................. 181
7.10.3 Container counter .............................................................................. 187
7.10.4 Synchronised lift ................................................................................ 192

4 7 Load handling

7 Load handling 5
7 Load handling
mm mm mm mm mm mm
Position sensor, checking and

page
–
adjustment
1
2
4
3
3
5 6 7 8
9 12, 13 11
11
10
14
15
16
008212
1. Sensor, boom length 5. Sensor, twistlocks 13. Sensor, clamping position

9. Sensor, support jacks up
2. Sensor, rotation stop 6. Spreading sensor 10. Sensor, support jacks down 14. Sensor, knee
3. Sensor, contact 7. Sensor, end position 11. Sensor, lifting jacks

15. Sensor, lowered cab
damping
4. Sensor, steering wheel 8. Sensor, steering axle 12. Sensor, contact
16. Sensor, overheight-jacks up
movement

6 7 Load handling

2 Check that the sensor in question is free of damage and dirt.
C-C
4±1 mm
3 Check that the distance between the position sensor and
indicator is 4±1 mm. Adjust if necessary.
C-C
4±1 mm
I M P OR TA NT
It is very important that the bolt head on the steering
008209
4±1 mm axle sensor is in right front of the centre of the sensor
Adjusting position sensor - indicator and that the bolt head is turned so that the edge is
parallel with the top of the sensor.

7 Load handling – 7.1 Controls and instruments 7

7.1.1 Control lever
Control lever, description
page
–
The control lever (S815) is used to control the boom and attachment.
The lever sends a voltage signals to the cab control unit (D790-1).
1 2 The control lever has three or four potentiometer-controlled functions
3
and six on/off functions.
4
Lifting/lowering
5 Lifting/lowering is controlled by moving the control lever forward (lower
7 boom) or rearward (lift boom). See Lifting/lowering, function descrip-
6 tion page 11.
8 Control system , group 8.4.8.1 BOOM, menu 1.
Extension
Extension is controlled by moving the control lever right (boom out) or
000442
left (boom in). See Extension, function description (hydraulic oil pump
alternative Rexroth) page 37.
1. Tilt lock (S815-T3.1) The signal can be checked from the diagnostic menu, see section 8
2. Levelling lock (S815-T3.2) Control system , group 8.4.8.1 BOOM, menu 1.
3. Rotation (S815-P3)
4. Side shift right (S815-T1.2) Sideshift or spreading
5. Side shift left (S815-T1.1) When switch (position 4) is pressed down sideshift right is activated,
6. Opening of twistlocks (S815-T2) upon full contact and when switch (position 5) is pressed down sideshift left is activated.
See Side shift, function description page 56.
7. Tilt (S815-P4)
If the pistol trigger (position 8) is pressed in at the same time as side
8. Pistol trigger (S815-T4): Activates weighing ,
shift right (position 4), spreading out is activated. If the pistol trigger
changes function of side shift to spreading out
(position 8) is pressed in at the same time as side shift left (position 5),
(S815-T1.2) and spreading in (S815-T1.1) as well as
spreading in is activated. See Spreading, function description page
lift to synchronised lift 71.
Control system , group 8.4.9.2 ATTACH, menu 2.
Rotation
When the potentiometer (position 3) is pressed down on the left side
rotation clockwise is activated, and when right side is pressed in rota-
tion anticlockwise is activated. See Rotation, function description page
95.

8 7 Load handling – 7.1.1 Control lever
Opening of twistlocks
When the switch (position 6) is activated, the twistlocks are opened if
the conditions for such are fulfilled. See Twistlocks, function descrip-
tion page 130.
As an option the machine can be equipped with sensors on the

attachment that activate damping when the attachment is approaching
a container.
Tilt
When the top edge of the potentiometer (position 7) is pressed down,

tilt out is activated. When the bottom edge is pressed down, tilt in is
activated. See Tilt control, function description page 114.
Tilt lock
When the switch (position 1) is pressed down, the tilt lock is activated.
The light in the switch remains lit while the lock is active. See Tilt lock-
ing, function description page 112.
The signal can be checked from the diagnostic menu; see section 8
Levelling
When the rotation potentiometer (position 3) is pressed down on the

left side at the same time as the pistol trigger (position 8) is pressed in
then levelling right is activated. When the right side is pressed down at
the same time as the pistol trigger is pressed in, levelling left is activat-
ed. See Hydraulic levelling, function description page 122.
Levelling lock
When the switch (position 2) is pressed down, the levelling lock is ac-
tivated. The indicator light in the switch remains lit while the lock is ac-
tive. See Levelling lock, function description page 125.

7 Load handling – 7.1.2 Switch, lock twistlocks 9
Pistol trigger
The pistol trigger (position 8) activates weighing if the machine is

equipped with a weight indicator. See Weight indicator, description
page 181.
The pistol trigger also changes the function of other buttons of the con-
trol lever.
If side shift is activated at the same time as the pistol trigger is pressed
in, spreading is activated. See Spreading, function description page
71.
If lift is activated at the same time as the pistol trigger is pressed

in, synchronised lift is activated if the machine is equipped with this op-
tion. See Synchronised lift, function description page 192.
7.1.2 Switch, lock twistlocks

Switch, lock twistlocks, description
page
–
The switch for lock twistlocks (S1001) controls locking of twistlocks.

The switch has three positions: two fixed and one rocker with the fol-
lowing functions.
1. Automatic locking of the twistlocks at full contact and released
parking brake.
2. Twistlocks open (off).
3. Manual locking of the twistlocks at full alignment and released
parking brake (rocker switch).
000443
Twistlocks are opened with the switch on the control lever, see Control
lever, description page 7.
The switch is supplied voltage by and sends a voltage signal to the KIT
control unit (D790-1).

10 7 Load handling – 7.1.3 Switch, automatic spreading
7.1.3 Switch, automatic spreading

Switch automatic spreading, description
page
–
Switch, automatic spreading (S1012) activates automatic spreading.

When the switch is depressed, spreading automatically goes to the
next position (20, 30 or 40 feet) if spreading is activated with the con-
trol lever.
The switch is supplied with voltage from and sends a voltage signal to
the cab control unit (D790-1) when the switch is activated.
000444
WARN IN G
Risk of crushing and product damage!
Automatic spreading is stopped by activating spread-

ing in the opposite direction or deactivating the func-
tion with the switch.
7.1.5 Switch, stop at 30' or 35'

Switch, stop at 30’ or 35’, description
page
–
Switch, stop at 30’ or 35’ (S1004) activates 30 and 35 foot stop. When
the switch is depressed the function for spreading is changed from
20’–40’ to stop at 30’.
35
30- The switch is supplied voltage by and sends a voltage signal to the KIT
000447

7 Load handling – 7.2 Lifting/lowering 11
7.2 Lifting/lowering
Lifting/lowering, function description
page
–

Safety switch Disengaged Section 11 Common electrics, group 11.5.1.4
Emergency stop switch voltage
Twistlocks Locked or unlocked, not intermediate position Twistlocks, description page 137
Overload system Boom up: passive Section 8 Control system , group 8.2.1 Overload
Boom down: passive or bypass activated system
Contact Boom down: no alignment Twistlocks, function description page 130
Bypassed or boom height lower than height Section 8 Control system, group 8.2.4 Height
Height limitation
limitation limitation
D1
1
2, 4 5 24 D23
D790-1 D794 D791-1
D797-F D797-R
3 13, 18 D22
D18
D3
D17
6 6 D13 14 19
11 C10 22 23
12
PSS PSL
10 PP C-M Pa 16, 21
A1 VA
C-
P B1 T
C+
LS D
8 Pa
7 C+M
17
C9 15, 20
9
010492

12 7 Load handling – 7.2 Lifting/lowering

1 Control lever (S815-P1) sends the cab Lower: US815/P1 = 0.5–2.0 V Control lever, description page 7
control unit (D790-1) a voltage signal D1: Diagnostic menu, see section 8
Zero position: US815/P1 =
proportional to lever movement. Control system group 8.4.8.1 BOOM,
2.0-3.0 V
menu 1
Lift: US815/P1 = 3.0–4.5 V
0.5 V is the fastest lowering

speed and 4.5 V is the fastest
lift speed. Lower voltages than
0.5 V and higher voltages than
4.5 V are used to detect mal-
functions in cabling and con-
trols.
2 Control unit, cab (D790-1) transmits the Checked by control system, er- Section 11 Common electrics, group
request for Boom up or Boom down with ror shown with error code. 11.5.3.1 Cab control unit
the speed information on the CAN bus.
3 Control unit, frame front (D797-F) acti- I = 380–650 mA Section 11 Common electrics, group
vates Servo valve, lift (Y6005) or Servo 11.5.3.2 Control unit, frame front
valve, lower (Y6004). D3: Diagnostic menu, see section 8
Control system group 8.4.8.4 BOOM,
menu 4 and 8.4.8.5 BOOM, menu 5
4 The cab control unit (D790-1) transmits Checked by control system, er- Section 11 Common electrics, group
are request for increased engine speed ror shown with error code. 11.5.3.1 Cab control unit
on the CAN bus.
5 The engine control unit (D794) increases Checked by control system, er- Section 11 Common electrics, group
engine speed. ror shown with error code. 11.5.3.10 Engine control unit
6 Servo valve, lift (Y6005) or Servo valve, - Control valve lift, lower and extension
lower (Y6004) pressurises the control page 20
valve’s lift slide with servo pressure. D3: Diagnostic menu, see section 8
Control system group 8.4.8.4 BOOM,
7 The control valve’s lift slide changes posi- - Control valve lift, lower and extension
tion and pressurises valve block, lift cylin- page 20
der and sends a load signal to the
hydraulic oil pumps.
8 The shuttle valve forwards the strongest - Section 10 Common hydraulics,

load signal if several functions are activat- group 10.5.3 Shuttle valve
ed simultaneously.
9 The hydraulic oil pumps pump oil from the See pressure plate on left Section 10 Common hydraulics,
hydraulic oil tank. frame beam. group 10.4.2 Axial piston pump with
variable displacement
10 The pressure reducer reduces the oil See pressure plate on left Pressure reducer, description page
pressure from the hydraulic pumps to ser- frame beam. 16
vo pressure for the control valve.

7 Load handling – 7.2 Lifting/lowering 13

11 The accumulator stores servo pressure. See pressure plate on left Accumulator servo circuit, description
The non-return valve in the pressure re- frame beam. page 18
ducer makes it possible to store the pres-
sure when the engine is shut off.
12 The servo filter cleans the servo oil before - Servo filter, description page 16
the control valve.
13 With boom down Control unit, frame front U = 24 V Section 11 Common electrics, group
(D797-F) activates Servo valve, blocking 11.5.3.2 Control unit, frame front
right (Y6001) and Servo valves, blocking D13: Diagnostic menu, see section 8
left (Y6002). Control system, group 8.4.8.2
BOOM, menu 2
14 With boom down Servo valve, blocking - Lift cylinder valve block, description
right (Y6001) and Servo valve, blocking page 23
left (Y6002) act on the blocking valves in D13: Diagnostic menu, see section 8
the valve blocks for left and right lift cylin- Control system, group 8.4.8.2
der respectively. BOOM, menu 2
15 With boom up the blocking valves in the - Lift cylinder valve block, description
valve blocks are opened for left and right page 23
lift cylinder respectively by the hydraulic
pressure from the control valve.
With boom down the blocking valve opens
so that the pressure from the lift cylinder
can be released.
16 The lift cylinders’ piston side is pressu- - Lift cylinder, description page 27
rised and the boom is lifted.
17 Regeneration UB768-L1/1 = 5 V Lift cylinder hydraulic pressure sen-

The lift cylinder hydraulic pressure sensor, description page 32
UB768-L1/2 = 0 V
sor, piston side left (B768-L1) sends Con- D17: Diagnostic menu, see section 8
UB768-L1/5 = 0.5-4.5 V
trol unit, frame front (D797-F) a voltage Control system, group 8.4.10.3 OP,
signal proportional to oil pressure. Regeneration is activated menu 3
when the pressure in the lift
NOTE cylinders is 8.5 MPa. Regener-
ation is stopped if the pressure
Regeneration is not possible in the
reaches 18.5 MPa.
proximity of end position or in the
event of overload.
18 Control unit, frame front (D797-F) acti- U = 24 V Section 11 Common electrics, group
vates solenoid valve, regeneration right 11.5.3.2 Control unit, frame front
(Y6051) and solenoid valve, regeneration D18: Diagnostic menu, see section 8
left (Y6052) if the pressure is sufficiently Control system, group 8.4.8.3
low for regeneration. BOOM, menu 3
19 The regeneration servo valve pressurised - Lift cylinder valve block, description
the regeneration valve. page 23

14 7 Load handling – 7.2 Lifting/lowering

20 The regeneration valve changes position - Lift cylinder valve block, description
and directs oil from the rod side of the lift page 23
cylinder to the piston side.
21 Lift speed increases. - -
22 Damping Checked by control system, er- Section 8 Control system, group

When the beam is approx. 4° from an end ror shown with error code. 8.2.1.5 Sensor, boom angle
position then damping is activated. Section 11 Common electrics, group
Sensor, boom angle (B771) sends a volt- 11.5.3.3 Control unit, frame rear
age signal proportional to the boom angle D22: Diagnostic menu, see section 8
to Control unit, frame rear (D797-R) re- Control system, group 8.4.8.8
questing damping on the CAN bus. BOOM, menu 8
23 U = 0-10 V Sensor, attachment damping, de-

Container damping
scription page 36
Sensor, attachment damping (B796)
sends a voltage signal proportional to the
Control system, group 8.4.9.22 AT-
container distance to Control unit, attach-
TACH, menu 22
ment (D791-1).
24 Checked by control system, er- Section 11 Common electrics, group

Container damping
ror shown with error code. 11.5.3.5 Control unit, attachment
When the voltage signal from Sensor, at-
tachment damping (B796) is equivalent to
Control system, group 8.4.9.22 AT-
the set limit for damping then Control unit,
TACH, menu 22
attachment (D791-1) requests damping
on the CAN bus.

7 Load handling – 7.2.1 Hydraulic oil pump 15
Lowering speed, checking

page
–
D ANGER
The lowering speed must correspond. If speed lower-
ing is too high there is a risk of rollover.
The machine must absolutely not be operated before

lowering speed is verified.
1 Operate the machine and hydraulics until the hydraulic oil reach-
es the operating temperature of 50 °C.
2 Lift a container weighing 35-45 tonnes.
3 Move the machine away to a level and a safe place.
NOTE
It is important that the ground is level and without gradient.
4 Retract the boom fully and lift to maximum.
5 Note the time for how long it takes to lower from the top position
until the container is about 20 cm from the ground.
Lowering should take 18-21 seconds.
6 If the time does not correspond then contact Cargotec for further
instructions.

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

with variable displacement.

16 7 Load handling – 7.2.2 Servo filter
7.2.2 Servo filter

Servo filter, description
page
–
The servo filter protects the control valve’s servo circuits against con-
taminants. The servo filter is located in the front edge of the lifting
beam on the right of the engine compartment, between the pressure
reducer and the control valve for lift, lower and extension.
The servo filter is a low-pressure filter with detachable filter insert. The
oil is cleaned when it passes through the filter insert’s filter material.
The filter insert is pressed against the upper section of the filter hous-
ing by a spring. Rubber gaskets seal between the insert and filter
housing. If the back pressure through the filter is too great the insert is
pressed down so that the oil passes by the insert. This occurs if the oil
is viscous (cold or incorrect viscosity) or if the filter insert is clogged.
000534
7.2.3 Pressure reducer

Pressure reducer, description
page
–
The pressure reducer reduces the pressure from hydraulic oil pumps
to servo pressure for the control valve. The pressure reducer is located
1 to the right on the lifting beam in the engine compartment fitted togeth-
7 er with the accumulator for servo pressure.
2 Servo pressure is stored in an accumulator. A built-in non-return valve

6 prevents pressure leakage from the accumulator when the machine is
not in use.
5
3
000432
1. Servo pressure accumulator

2. Servo pressure test outlet
3. Pressure feed from servo filter
4. Return to tank
5. Servo pressure to control valve
6. Servo pressure adjusting screw.
7. Pressure reducer

7 Load handling – 7.2.3 Pressure reducer 17
Servo pressure, checking and adjustment

page
–
NOTE
Read the instructions for oil before working; see section B Safety.
1 Operate and warm up the machine so that the hydraulic oil is at

operating temperature, at least 50 °C. As an alternative, operate
until the cooling fan is activated.
˚C 2 Machine in service position, see section B Safety.
˚C
000475
on the pressure reducing valve.
4 Start the engine and check the servo pressure. Compare with the
pressure plate.
MPa Turn the steering wheel or activate a load handling function to ac-
tivate the hydraulic oil pumps. The servo pressure is higher than
the standby pressure of the hydraulic oil pumps.
MPa
MPa
MPa MPa MPa

MPa
MPa
MPa MPa
001029
920643.0024
The appearance of the pressure plate may vary, but

the symbols are the same.

18 7 Load handling – 7.2.4 Accumulator servo circuit
5 If necessary, adjust the pressure with the adjusting screw. Loos-

en 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.
Counter-clockwise: increase pressure.
measuring outlet.
7.2.4 Accumulator servo circuit

Accumulator servo circuit, description
page
–
The accumulator stores pressurised oil and ensures that there is servo
pressure for activating control valve functions. The accumulator is lo-
cated to the right on the lifting beam in the engine compartment.
The accumulator is a diaphragm type and is divided into two spaces
by a diaphragm. One side of the diaphragm is pressurised with nitro-
gen gas. The other side is pressurised by hydraulic oil which compacts
the nitrogen gas.
Furthest up on the accumulator is a test outlet for checking gas pres-
sure and filling gas.
001095
Accumulator servo circuit, replacement

page
–
NOTE
B Safety.
B Safety.

7 Load handling – 7.2.4 Accumulator servo circuit 19
3 Detach the accumulator from its mounting.

4 Replace the accumulator.
NOTE
C AUTION

010475
C AUTION


20 7 Load handling – 7.2.5 Control valve lift, lower and extension
7.2.5 Control valve lift, lower and extension

Control valve lift, lower and extension, description
page
–
(model year -2008)

The control valve controls the speed and direction of lift and extension.
9 The control valve is located on a bracket in the space between the lift-
ing beam and front axle.
8 The valve has two sections - one for the lift function and one for boom
extension. The sections have many similarities, but are described sep-
7 1
arately under the respective function. For extension, see Control valve
lift, lower, extension page 45. Electric servo valves control the flow
6 2 from the valve.
5 The control valve is a proportional valve that is controlled by servo
3 valves. This means that both volume and direction of the flow from the
valve can be adjusted and that the valve can also send a control signal
4 to the variable pumps.
Electrically controlled pressure reducing valves (servo valves) convert
electrical current into a low hydraulic pressure that is proportional to
the current, known as the servo pressure. The servo pressure acts on
the spring-centred control slide in the control valve for the function in
question and thereby controls the main flow.
The speed of the function is controlled by means of the flow being reg-
ulated in proportion to the lever movement.
000529
1. Servo valve, boom out (Y6006) Lift slide

2. Servo valve, boom in (Y6007) The lift slide controls direction and flow of oil to the lift cylinder.
3. Servo valve, lower (Y6004)
4. Servo valve, lift (Y6005) Servo valve, lift
5. Connection, rod side, right lift cylinder (B2) The lift servo valve controls servo pressure to the lift slide so that it
6. Connection, piston side, right lift cylinder (A1) controls oil pressure for lifting. The valve is controlled electrically with
7. Connection, feed from hydraulic oil pumps (P) the lift solenoid valve (Y6005), which is activated by Control unit, frame
8. Connection, rod side, extension cylinder (B1) front (D797-F).
9. Connection, piston side, extension cylinder (A1)
The signals can be checked from the diagnostic menu, see section
Servo valve, lower

The lower servo valve controls servo pressure to the lift slide so that it
controls oil pressure for lowering. The valve is controlled electrically
with the lower solenoid valve (Y6004), which is activated by Control
unit, frame front (D797-F).

7 Load handling – 7.2.5 Control valve lift, lower and extension 21

page
–
(model year 2009-)

The control valve controls the speed and direction of lift and extension.
The control valve is located on a bracket in the space between the lift-
1 ing beam and front axle.
The valve has two sections - one for the lift function and one for boom
9 2 extension. The sections have many similarities, but are described sep-
arately under the respective function. For extension, see Control valve
8 3 lift, lower, extension page 45. 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 can also send a control signal to
5
the variable pumps.
Electrically controlled pressure reducing valves (servo valves) convert
electrical current into a low hydraulic pressure that is proportional to
the current, known as the servo pressure. The servo pressure acts on
the spring-centred control slide in the control valve for the function in
010490
question and thereby controls the main flow.
1. Connection, rod side, extension cylinder (B1) The speed of the function is controlled by means of the flow being reg-
2. Servo valve, boom out (Y6006) ulated in proportion to the lever movement.
3. Servo valve, lift (Y6005)
Lift slide
4. Connection, rod side, right lift cylinder (B2)
5. Connection, piston side, right lift cylinder (A2) The lift slide controls direction and flow of oil to the lift cylinder.
6. Servo valve, lower (Y6004)
7. Servo valve, boom in (Y6007) Servo valve, lift
8. Connection, feed from hydraulic oil pumps (P) The lift servo valve controls servo pressure to the lift slide so that it
9. Connection, piston side, extension cylinder (A1) controls oil pressure for lifting. The valve is controlled electrically with
the lift solenoid valve (Y6005), which is activated by Control unit, frame
front (D797-F).
Servo valve, lower

The lower servo valve controls servo pressure to the lift slide so that it
controls oil pressure for lowering. The valve is controlled electrically
with the lower solenoid valve (Y6004), which is activated by Control

22 7 Load handling – 7.2.6 Shuttle valve
Control valve lift, lower and extension, replacement

page
–
D ANGER
After replacing control valve lift, lower and extension or parts of the
valve, lowering speed must be checked. See Lowering speed, check-
ing page 15.
7.2.6 Shuttle valve

page
–

7 Load handling – 7.2.7 Valve block lift cylinder 23
7.2.7 Valve block lift cylinder

Lift cylinder valve block, description
page
–
The lift cylinder valve block directs oil to the lift cylinder and is mounted
1
directly on the lower part of the lift cylinder. The valve block comprises
2 the blocking valve, regeneration valve, non-return valve and shock
valve.
3
Blocking valve
4 The blocking valve prevents unwanted lowering and angling of the lift
cylinders. The blocking valve holds the load by ensuring that the con-
5
nection to the lift cylinder’s piston side is closed. (The pressure passes
6 through a restriction as blocking pressure and holds the valve slide
closed.)
9
7 Servo valve blocking actuates the blocking valve. The servo valve is
controlled electrically with Solenoid valve, blocking left (Y6002) and
8
Solenoid valve, blocking right (Y6001), which are activated by Control
Control system , group 8.4.8.2 BOOM, menu 2.
Regeneration valve
The regeneration valve directs oil from the rod side of the cylinder back
to the piston side. This allows the oil to be re-used during lifting. For
000473
more information on regeneration see Lifting/lowering, function de-

scription page 11. The regeneration valve is regulated by the regener-
1. Connection, rod side, lift cylinder (C-) ation servo valve.
2. Solenoid valve regeneration (Y6051 or Y6052)
The regeneration servo valve actuates the regeneration valve. The
3. Pressure feed connection (VA)
servo valve is regulated electrically with solenoid valve, regeneration
4. Connection tank (T)
right (Y6051) or solenoid valve, regeneration left (Y6052), which are
5. Pressure sensor, piston side (C+M)
activated by Control unit, frame front (D797-F).
6. Draining servo valves (D)
7. Shock valve The signal can be checked from the diagnostic menu, see section 8
8. Solenoid valve blocking (Y6001 or Y6002) Control system , group 8.4.8.3 BOOM, menu 3.
9. Pressure sensor, rod side (C-M)
Shock valve
The shock valve protects the hydraulic system against pressure surg-
es which can occur when operating with a load. The shock valve
opens a connection between the lift cylinder piston side and tank if the
pressure becomes too high.
Non-return valve
The non-return valve prevents oil from going the wrong way during re-
generation.

24 7 Load handling – 7.2.7 Valve block lift cylinder
Lift cylinder valve block, replacing

page
–
NOTE
B Safety.
B Safety.
power.
4 Mark up and detach the wiring from the valve block.
5 Remove the wiring’s clamping at the valve block.
6 Mark up and detach the hydraulic hoses from the valve block.
NOTE
Plug all connections immediately to protect the hydraulic

7 Load handling – 7.2.7 Valve block lift cylinder 25
7 Remove the valve block from the lift cylinder.

Remove the attaching bolts and lift away the valve block.
8 Transfer the connection adapters, sensors and servo valves to
the new valve block.
NOTE
NOTE
Transfer one part at a time so that the marking is not mixed
up.
9 Fit the new valve on the lift cylinder.
NOTE
10 Connect the hydraulic hoses to the valve block in accordance

with the marking.
NOTE

26 7 Load handling – 7.2.7 Valve block lift cylinder
11 Connect the cable harness to the valve block in accordance with

the marking.
12 Clamp the cable harness as before.
NOTE
C AUTION

010475

7 Load handling – 7.2.8 Lift cylinder 27
16 Activate the lift carefully.
C AUTION
product damage.
Activate the functions carefully and operate at the

lowest possible speed a couple of times to avoid
cavitation.
17 Check for leaks.

C AUTION

19 Check the lowering speed, see Lowering speed, checking page

15.
7.2.8 Lift cylinder

Lift cylinder, description
page
–
The lift cylinders lift and lower (angle) the lift boom. The lift cylinders
are located between boom and frame in the front edge of the machine,
one on the right and one on the left-hand side.
Each lift cylinder houses a valve block that controls pressurization and
regeneration of the lift cylinder.
The lift cylinder is equipped with guide bearings both in the cylinder
end and the piston rod mounting. The piston rod mounting is threaded
in the piston rod and locked with a lock nut.
The lift cylinders are connected in parallel and are supplied from the
lift, lower and extension control valve, see Control valve lift, lower and
extension page 20.
001096

28 7 Load handling – 7.2.8 Lift cylinder
Lift cylinder, replacement

page
–
D ANGER
Fatal danger, risk of crushing!
Be certain to compensate for the lift cylinder’s sup-

port of the boom by lifting the boom’s leading edge
with the lifting equipment.
A lift cylinder weighs approx. 2 tonnes. Use wooden

blocks as protection between cab and lift cylinder
when the lift cylinder is lowered or lifted.
The boom may move when the shafts are removed.

Make sure that the shafts are unloaded. Stand to the
side of the boom mounting so that the mounting pro-
tects in the event of movement.
1 Move the cab into the front position.

3 Depressurise the hydraulic and brake systems, section B Safety.
power.
5 Connect the lifting equipment at the front edge of the boom.
6 Lift the boom at the front edge so that the bearings on the lift cyl-
inders are unloaded.

7 Mark up and detach the hydraulic hoses from the lift cylinder.
8 Attach lifting equipment to the lift cylinder.
9 Remove the upper shaft for the lift cylinder.

10 Unload the lower bearing of the lift cylinder.
11 Remove the lower shaft for the lift cylinder.
12 Lift away the lift cylinder.
13 Fit new bearing races in the lift cylinder.
14 Lubricate the lift cylinder’s bearing races and the holes for the
shafts in the frame and the boom with plenty of aluminium paste.
NOTE
The bearings are only lubricated during replacement.
15 Lift the new lift cylinder into place.
16 Fit the shafts for the lift cylinder.

30 7 Load handling – 7.2.8 Lift cylinder
17 Connect the hydraulic hoses to the lift cylinder.

NOTE
C AUTION

010475

21 Carefully activate the lift function.
C AUTION
product damage.
lowest possible speed a couple of times to avoid cav-
itation.
22 Check for leaks.

C AUTION

24 Check the lowering speed, see Lowering speed, checking page

15.

page
–

32 7 Load handling – 7.2.9 Sensor hydraulic pressure lift cylinder
7.2.9 Sensor hydraulic pressure lift

cylinder
Lift cylinder hydraulic pressure sensor, description
page
–
The lift cylinder hydraulic pressure sensor measures the pressure in

the lift cylinders and is located on the lift cylinder valve block.
Pressure is measured to determine if regeneration can be activated. A
sensor measures the pressure on the piston side of the left lift cylinder.
If the machine is equipped with the fixed scale option then an extra
pressure sensor is used, on the piston side for the right lift cylinder.
2 1
If the machine is equipped with the electrical dynamic scale option
then two pressure sensors are used, one for the rod side and one for
the piston side on right and left-hand lift cylinders respectively (a total
of four pressure sensors).
The sensors are supplied with power by, and send a voltage signal
proportional to the hydraulic oil pressure, to Control unit, frame front
(D797-F).
001097
8 Control system , group 8.4.10.3 OP, menu 3.
1. Sensor, hydraulic pressure lift cylinder, piston side,

left (B768-L1)
Sensor, hydraulic pressure lift cylinder, piston
side, right (B768-R1)
2. Sensor, hydraulic pressure lift cylinder, rod
side, left (B768-L2)
Sensor, hydraulic pressure lift cylinder, rod side,
right (B768-R2)
Lift cylinder hydraulic pressure sensor, replace

page
–
NOTE
B Safety.
B Safety.
3 Detach the cable harness from the lift cylinder hydraulic pressure
sensor.
4 Remove the lift cylinder hydraulic pressure sensor.
NOTE

7 Load handling – 7.2.9 Sensor hydraulic pressure lift cylinder 33
5 Fit the new sensor.
NOTE
6 Connect the cable harness to the hydraulic pressure sensor.
7 Clamp the cable harness as before.
NOTE
C AUTION

010475

34 7 Load handling – 7.2.9 Sensor hydraulic pressure lift cylinder
11 Activate the lift carefully.
C AUTION
product damage.

itation.
12 Check that the hydraulic connections of the valve block do not

leak and the lifting/lowering works correctly.
C AUTION

14 Check the function of the sensor from the diagnostic menu. See
DIAG OP 3(x) section 8 Control system, group 8.4.10.3 OP, menu 3.
PRESENT INPUT SIGNAL
LIFT CYL LE RI Raise the boom and check that the sensor is sending values. The
C- X.XXV X.XXV value should be approximately the same as from the sensor on
C+ X.XXV X.XXV the second lift cylinder (RI/LE).
C-
C+
008213

7 Load handling – 7.2.10 Lift boom 35
7.2.10 Lift boom

Lift boom, description
page
–
The lift boom lifts the load. The rear section of the boom is secured into
the frame with two bearing-mounted shafts. In the front edge is the lift
attachment and in the centre on each side of the boom are lift cylinders
which are secured with bearing-mounted shafts. The lift cylinders an-
gle the boom and raise the front section of the boom in this way. The
lift boom is available in several versions depending on reach and load
capacity.
The boom consists of outer boom and inner boom manufactured in
high-strength steel with a minimum number of welds to provide maxi-
mum strength.
The inner boom runs in the outer boom and can be extended longitu-
dinally with the extension cylinder. There are slide plates between in-
ner boom and outer boom which reduce the friction between them.
The slide plates are located in the front edge of the outer boom and
the rear edge of the inner boom.
Running along the left-hand side is a cable chain for hydraulic hoses
and cables between outer and inner boom.
1 2
001239
9 8 7 8 6 5 4 3
1. Outer boom 4. Mounting, attachment 7. Lift cylinder

2. Inner boom 5. Tilt cylinder left side 8. Mounting, lift cylinder
3. Tilt cylinder right side 6. Extension cylinder 9. Rear boom mounting
7.2.11 Sensor, boom angle

Sensor, boom angle, general
page
–
See section 8 Control system, group 8.2.1.5 Sensor, boom angle.

page
–

36 7 Load handling – 7.2.16 Sensor, attachment damping
7.2.16 Sensor, attachment damping

Sensor, attachment damping, description
page
–
Sensor, attachment damping (B769) is an ultrasonic sensor that de-

tects whether there is anything under the attachment. The sensor is fit-
ted in the lower edge in the centre of the attachment’s side shift frame.
The sensors are supplied with power by, and send a voltage signal
proportional to the distance to the object under the attachment to Con-
trol unit, attachment (D791-1).
010491

7 Load handling – 7.3 Extension 37
7.3 Extension
Extension, function description (hydraulic oil
page
–
pump alternative Rexroth)

Safety switch Disengaged Section 11 Common electrics, group 11.5.1.4 Emergency stop
switch voltage
Overload system Boom out: passive Section 8 Control system , group 8.2.1 Overload system
Bypassed or the attachment Section 8 Control system, group 8.2.3 Load centre limitation
is within the limit for the load
Load centre limitation centre limitation.
Bypassed or boom height Section 8 Control system, group 8.2.4 Height limitation
lower than height limitation
Height limitation
1
D1
2, 4 5
D790-1 D794
Pa 18
D797-F D797-R
3,19 14, 20 D18 D24
D20
6 6 D6 D14 15 21 m
12
C11 13
7 PS PL 24
11 PP A1 VA
16, 22
A1 VA
C- 17, 23
P B1 VB C+
LS D
8
D3
9
C10
10
006406

38 7 Load handling – 7.3 Extension

1 Control lever (S815-P2) sends the cab Boom in: US815/P2 = Control lever, description page 7
control unit (D790-1) a voltage signal 0.5-2.0 V D1: Diagnostic menu, see section 8
proportional to lever movement. Control system group 8.4.8.1 BOOM,
2.0–3.0 V menu 1
Boom out: US815/P2 =

3.0-4.5 V
0.5 V is the fastest retraction
extension speed. Lower volt-
ages than 0.5 V and higher
voltages than 4.5 V are used
to detect malfunctions in wir-
ing and controls.
2 Control unit, cab (D790-1) transmits the Checked by control system, Section 11 Common electrics, group
request for boom out or boom in with the error shown with error code. 11.5.3.1 Cab control unit
speed information on the CAN bus.
3 Control unit, frame front (D797-F) acti- I = 380-650 mA Control valve lift, lower and extension
vates Servo valve, boom out (Y6006) or page 20
Servo valve, boom in (Y6007). D3: Diagnostic menu, see section 8
During retraction of the boom Control Control system group 8.4.8.6 BOOM,
unit, frame rear (D797-R) activates So- menu 6 and 8.4.8.7 BOOM, menu 7 and
lenoid valve pump relief (Y6062). 8.4.8.2 BOOM, menu 2
are request for increased engine speed error shown with error code. 11.5.3.1 Cab control unit
on the CAN bus.
5 The engine control unit (D794) increas- Checked by control system, Section 11 Common electrics, group
es engine speed. error shown with error code. 11.5.3.10 Engine control unit
6 Servo valve, boom out (Y6006) or Servo - Control valve lift, lower and extension
valve, boom in (Y6007) pressurises the page 20
control valve’s extension slide with ser- D6: Diagnostic menu, see section 8
vo pressure. Control system group 8.4.8.6 BOOM,
7 The control valve’s extension slide - Control valve lift, lower and extension
changes position and pressurises valve page 20
block, extension cylinder and sends a
load signal to the hydraulic oil pumps.
8 When the boom is retracted the valve - Valve block, pump relief, description (hy-
block, pump relief load signal, drains to draulic oil pump alternative Rexroth)
two of the hydraulic oil pumps to the tank page 51
so that only two pumps generate pres-
sure.
9 The shuttle valve forwards the strongest - Section 10 Common hydraulics, group
load signal if several functions are acti- 10.5.3 Shuttle valve
vated simultaneously.


10 The hydraulic oil pumps pump oil from See pressure plate on left Section 10 Common hydraulics, group
the hydraulic oil tank. frame beam. 10.4.2 Axial piston pump with variable
displacement
11 The pressure reducer reduces pressure See pressure plate on left Pressure reducer, description page 16
from the hydraulic oil pumps to servo frame beam.
pressure.
12 Servo pressure is stored in the accumu- See pressure plate on left Accumulator servo circuit, description
lator. The non-return valve in the pres- frame beam. page 18
sure reducer makes it possible to store
the pressure when the engine is shut off.
13 The servo filter filters the oil before the - Servo filter, description page 16
control valve.
14 For boom in Control unit, frame rear U = 24 V Valve block extension cylinder, descrip-
(D797-R) activates Servo valve, block- tion page 47
ing extension (Y6050). D14: Diagnostic menu, see section 8
Control system, group 8.4.8.2 BOOM,
menu 2
15 For boom in Servo valve, blocking ex- - Valve block extension cylinder, descrip-
tension (Y6050) actuates the blocking tion page 47
slide in valve block, extension cylinder.
16 For boom out the blocking slide is - Valve block extension cylinder, descrip-
opened in valve block, extension cylin- tion page 47
der by the hydraulic pressure from the
control valve.
For boom in the blocking valve opens
and releases pressure from the exten-
sion cylinder.
17 Extension cylinder extends or retracts - Extension cylinder, description page 47

the boom.
18 Regeneration UB768-L1/1 = 5 V Lift cylinder hydraulic pressure sensor,

The lift cylinder hydraulic pressure sen- description page 32
UB768-L1/2 = 0 V
sor, piston side left (B768-L1) sends D18: Diagnostic menu, see section 8
UB768-L1/3 = 0.5–4.5 V
Control unit, frame front (D797-F) a volt- Control system, group 8.4.10.3 OP,
age signal proportional to the cylinder menu 3
pressure in the lift cylinders.
19 Control unit, frame front (D797-F) sends Checked by control system, Section 11 Common electrics, group
information about the pressure in the lift error shown with error code. 11.5.3.2 Control unit, frame front
cylinders.
20 Control unit, frame rear (D797-R) acti- U = 24 V Valve block extension cylinder, descrip-
vates Servo valve, regeneration tion page 47
(Y6046), if the pressure is low enough D20: Diagnostic menu, see section 8
for regeneration. Control system, group 8.4.8.3 BOOM,
menu 3


21 Servo valve, regeneration (Y6046) pres- - Valve block extension cylinder, descrip-
surises the regeneration valve. tion page 47
22 The regeneration valve changes posi- - Valve block extension cylinder, descrip-
tion and directs oil from the rod side of tion page 47
the lift cylinder to the piston side.
23 Extension speed increases. - Valve block extension cylinder, descrip-

tion page 47
24 Damping - Section 8 Control system, group 8.2.1.6

When the extension is about 0.4 m from Sensor, boom length
the end position damping is activated. Mechanical overload system:
Mechanical overload system: D24: Diagnostic menu, see section 8
Sensor, boom length (B769-3 or B769- Control system, group 8.4.10.1 OP,
4) sends a voltage signal to Control unit, menu 1,
frame rear (D797-R) which sends damp-
ing on the CAN bus.
Mechanical overload system with ana-
logue position sensors or Electronic
Mechanical overload system with ana- overload system:
logue position sensors or Electronic D24: Diagnostic menu, see section 8
overload system: Control system, group 8.4.10.4 OP,
Sensor, boom length (B777) sends a menu 4 and 8.4.10.6 OP, menu 6
voltage signal proportional to the boom
extension to Control unit, frame rear
(D797-R) that sends damping on the
CAN bus.

Extension, function description (hydraulic oil

page
–
pump alternative Sauer-Danfoss)

switch voltage
Overload system Boom out: passive Section 8 Control system , group 8.2.1 Overload system
Bypassed or the attachment Section 8 Control system, group 8.2.3 Load centre limitation
is within the limit for the load
Load centre limitation centre limitation.
Height limitation
1
D1
2, 4 5
D790-1 D794
Pa 18
D797-F D797-R
3,19 14, 20 D18 D24
D20
6 6 D6 D14 15 21 m
12
C11 13
7 PS PL 24
11 PP A1 VA
16, 22
A1 VA
C- 17, 23
P B1 VB C+
LS D
8
D3
9
C10
10
006406


1 Control lever (S815-P2) sends the Boom in: US815/P2 = 0.5-2.0 V Control lever, description page 7
cab control unit (D790-1) a voltage D1: Diagnostic menu, see section 8 Control
signal proportional to lever system group 8.4.8.1 BOOM, menu 1
2.0-3.0 V
movement.
Boom out: US815/P2 =
3.0-4.5 V
0.5 V is the fastest retraction
extension speed. Lower volt-
ages than 0.5 V and higher
voltages than 4.5 V are used
to detect malfunctions in wir-
ing and controls.
2 Control unit, cab (D790-1) transmits Checked by control system, Section 11 Common electrics, group
the request for boom out or boom in error shown with error code. 11.5.3.1 Cab control unit
with the speed information on the
CAN bus.
3 Control unit, frame front (D797-F) ac- I = 380-650 mA Control valve lift, lower and extension page
tivates Servo valve, boom out 20
(Y6006) or Servo valve, boom in D3: Diagnostic menu, see section 8 Control
(Y6007). system, group 8.4.8.6 BOOM, menu 6,
During retraction of the boom Control 8.4.8.7 BOOM, menu 7 and 8.4.8.2
unit, frame rear (D797-R) activates BOOM, menu 2
Solenoid valve pump relief (Y6062).
4 The cab control unit (D790-1) trans- Checked by control system, Section 11 Common electrics, group
mits are request for increased engine error shown with error code. 11.5.3.1 Cab control unit
speed on the CAN bus.
5 The engine control unit (D794) in- Checked by control system, Section 11 Common electrics, group
creases engine speed. error shown with error code. 11.5.3.10 Engine control unit
6 Servo valve, boom out (Y6006) or - Control valve lift, lower and extension page
Servo valve, boom in (Y6007) pressu- 20
rises the control valve’s extension D6: Diagnostic menu, see section 8 Control
slide with servo pressure. system, group 8.4.8.6 BOOM, menu 6 and
8.4.8.7 BOOM, menu 7
7 The control valve’s extension slide - Control valve lift, lower and extension page
changes position and pressurises 20
valve block, extension cylinder and
sends a load signal to the hydraulic oil
pumps.
8 When the boom is retracted the valve - Valve block, pump relief, description (hy-
block, pump relief load signal, drains draulic oil pump alternative Sauer-Danfoss]
to one of the hydraulic oil pumps to page 52
the tank so that only one pump gener-
ates pressure.


9 The shuttle valve forwards the strong- - Section 10 Common hydraulics, group
est load signal if several functions are 10.5.3 Shuttle valve
activated simultaneously.
10 The hydraulic oil pumps pump oil See pressure plate on left Section 10 Common hydraulics, group
from the hydraulic oil tank. frame beam. 10.4.2 Axial piston pump with variable dis-
placement
11 The pressure reducer reduces pres- See pressure plate on left Pressure reducer, description page 16
sure from the hydraulic oil pumps to frame beam.
servo pressure.
12 Servo pressure is stored in the accu- See pressure plate on left Accumulator servo circuit, description page
mulator. The non-return valve in the frame beam. 18
pressure reducer makes it possible to
store the pressure when the engine is
shut off.
13 The servo filter filters the oil before - Servo filter, description page 16
the control valve.
14 For boom in Control unit, frame rear U = 24 V Valve block extension cylinder, description
(D797-R) activates Servo valve, page 47
blocking extension (Y6050). D14: Diagnostic menu, see section 8 Con-
trol system, group 8.4.8.2 BOOM, menu 2
15 For boom in Servo valve, blocking ex- - Valve block extension cylinder, description
tension (Y6050) actuates the block- page 47
ing slide in valve block, extension
cylinder.
16 For boom out the blocking slide is - Valve block extension cylinder, description
opened in valve block, extension cyl- page 47
inder by the hydraulic pressure from
the control valve.
For boom in the blocking valve opens
and releases pressure from the ex-
tension cylinder.
17 Extension cylinder extends or retracts - Extension cylinder, description page 47

the boom.
18 Regeneration UB768-L1/1 = 5 V Lift cylinder hydraulic pressure sensor, de-

The lift cylinder hydraulic pressure scription page 32
UB768-L1/2 = 0 V
sensor, piston side left (B768-L1) D18: Diagnostic menu, see section 8 Con-
UB768-L1/3 = 0.5–4.5 V
sends Control unit, frame front (D797- trol system, group 8.4.10.3 OP, menu 3
F) a voltage signal proportional to the
cylinder pressure in the lift cylinders.
19 Control unit, frame front (D797-F) Checked by control system, Section 11 Common electrics, group
sends information about the pressure error shown with error code. 11.5.3.2 Control unit, frame front
in the lift cylinders.

44 7 Load handling – 7.3.1 Hydraulic oil pump

20 Control unit, frame rear (D797-R) ac- U = 24 V Valve block extension cylinder, description
tivates Servo valve, regeneration page 47
(Y6046), if the pressure is low enough D20: Diagnostic menu, see section 8 Con-
for regeneration. trol system, group 8.4.8.3 BOOM, menu 3
21 Servo valve, regeneration (Y6046) - Valve block extension cylinder, description

pressurises the regeneration valve. page 47
22 The regeneration valve changes po- - Valve block extension cylinder, description
sition and directs oil from the rod side page 47
of the lift cylinder to the piston side.
23 Extension speed increases. - Extension cylinder, description page 47
24 Damping - Section 8 Control system, group 8.2.1.6

When the extension is about 0.4 m Sensor, boom length
from the end position damping is acti- Mechanical overload system:
vated. D24: Diagnostic menu, see Workshop
Mechanical overload system: Manual section 8 Control system, group
Sensor, boom length (B769-3 or 8.4.10.1 OP, menu 1
B769-4) sends a voltage signal to
Control unit, frame rear (D797-R)
which sends damping on the CAN Mechanical overload system with analogue
bus. position sensors or Electronic overload
system:
Mechanical overload system with an- trol system, group 8.4.10.4 OP, menu 4
alogue position sensors or Electronic and 8.4.10.6 OP, menu 6
overload system:
Sensor, boom length (B777) sends a
voltage signal proportional to the
boom extension to Control unit, frame
rear (D797-R) that sends damping on
the CAN bus.

page
–

7.3.2 Servo filter

Servo filter, description
page
–
See Servo filter, description page 16.
7.3.3 Pressure reducer

Pressure reducer, description
page
–
See Pressure reducer, description page 16.

7 Load handling – 7.3.4 Accumulator servo circuit 45
7.3.4 Accumulator servo circuit

Accumulator servo circuit, description
page
–
See Accumulator servo circuit, description page 18.
7.3.5 Control valve lift, lower, extension

page
–
(model year -2008)

The control valve has two sections: one for the lift function and one for
9 boom extension. The sections have many similarities but are de-
scribed separately for each function.
8 For general information on the control valve, refer to Control valve lift,
lower and extension page 20.
7 1
Extension slide
6 2
The extension slide controls direction (in or out) and oil flow to valve
5 block extension cylinder.
3
Servo valve, boom out
4 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, frame front
(D797-F).
000529
Servo valve, boom in

1. Servo valve, boom out (Y6006) Servo valve boom in, controls servo pressure to the extension slide so
2. Servo valve, boom in (Y6007) that it controls oil pressure for boom retraction.
3. Servo valve, lower (Y6004) Servo valve boom in is controlled electrically with Solenoid valve boom
4. Servo valve, lift (Y6005) in (Y6007) which is activated by Control unit, frame front (D797-F).
5. Connection, rod side, right lift cylinder (B2)
6. Connection, piston side, right lift cylinder (A1) The signal can be checked from the diagnostic menu, see section
7. Connection, feed from hydraulic oil pumps (P) 8 Control system , group 8.4.8.6 BOOM, menu 6.
8. Connection, rod side, extension cylinder (B1)
Shock valve, extension
Two shock valves protect the hydraulic system against surges which
can occur when operating on uneven ground or when stopping.
The shock valve opens a connection between the extension cylinder
piston side and tank if the pressure becomes too high.


page
–
(model year 2009-)

The control valve has two sections: one for the lift function and one for
boom extension. The sections have many similarities but are de-
1 scribed separately for each function.
For general information on the control valve, refer to Control valve lift,
9 2 lower and extension page 20.
8 3 Extension slide
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, frame front
(D797-F).
010490
1. Connection, rod side, extension cylinder (B1) 8 Control system , group 8.4.8.7 BOOM, menu 7.
2. Servo valve, boom out (Y6006)
Servo valve, boom in
3. Servo valve, lift (Y6005)
4. Connection, rod side, right lift cylinder (B2) Servo valve boom in, controls servo pressure to the extension slide so
5. Connection, piston side, right lift cylinder (A2) that it controls oil pressure for boom retraction.
6. Servo valve, lower (Y6004) Servo valve boom in is controlled electrically with Solenoid valve boom
7. Servo valve, boom in (Y6007) in (Y6007) which is activated by Control unit, frame front (D797-F).
8. Connection, feed from hydraulic oil pumps (P)
Shock valve, extension

Two shock valves protect the hydraulic system against surges which
can occur when operating on uneven ground or when stopping.
The shock valve opens a connection between the extension cylinder
piston side and tank if the pressure becomes too high.
7.3.6 Shuttle valve

page
–

7 Load handling – 7.3.7 Valve block, extension cylinder 47
7.3.7 Valve block, extension cylinder

Valve block extension cylinder, description
page
–
Valve block extension cylinder directs pressure to the extension cylin-

1
der. The valve block is located at the rear edge of the extension cylin-
7 der in the lift boom and contains a blocking valve, regeneration valve,
2 and non-return valve.
6
3 Blocking valve
5 The blocking valve prevents unwanted lowering. The valve holds the
4 load by keeping the connection to the extension cylinder’s piston side
closed. The pressure passes through a restriction providing a blocking
pressure and holds the valve slide closed.
Solenoid valve blocking (Y6050) actuates the blocking valve. Solenoid
valve, blocking extension (Y6050) which is activated by Control unit,
frame rear (D797-R).
Regeneration valve
000474
The regeneration valve directs oil from the rod side back to the piston
side. This allows the oil to be re-used during extension. For more in-
1. Connection, rod side, (C-) formation on regeneration see Extension, function description (hy-
2. Draining (D) draulic oil pump alternative Rexroth) page 37 or Extension, function
3. Solenoid valve regeneration (Y6046) description (hydraulic oil pump alternative Sauer-Danfoss) page 41.
4. Connection control valve (VB) The regeneration valve is regulated by the regeneration servo valve.
5. Connection control valve (VA)
Solenoid valve, extension (Y6046) pressurises the regeneration valve.
6. Connection control valve (VA)
7. Solenoid valve blocking (Y6050) Solenoid valve, extension (Y6046) is activated by Control unit, frame
rear (D797-R).
7.3.8 Extension cylinder

Extension cylinder, description
page
–
The extension cylinder forces out and pulls in the inner boom. The ex-
tension cylinder is located in the lift boom. The rear section is secured
in the outer boom, the front section is secured in the inner boom. On
the extension cylinder is a valve block which controls pressurising of
the cylinder and regeneration for boom out.
The extension cylinder piston rod end is designed as a lug with a
flange which is secured on the piston rod with hexagonal bolts.

48 7 Load handling – 7.3.8 Extension cylinder
Extension cylinder, replacement

page
–
NOTE
Safety.
Removal
2 Operate the boom out until the inspection holes in the side of the
inner boom become accessible.
B Safety.
4 Remove the lock rings and press out the shaft for the front cylin-
der mounting in the inner boom.
5 Machine with analogue sensor boom length.

Remove the sensor for boom length from the boom, see section
8 Control systems, group 8.2.1.6 Sensor boom length.
6 Mark up and detach the hydraulic hoses from the extension
cylinder.
NOTE
Plug all hydraulic connections immediately.
7 Mark up and detach the wiring from the valve block on the exten-
sion cylinder.
8 Remove the valve block from the extension cylinder.
NOTE
9 Remove the lock rings and press out the outer shafts for the rear
cylinder mountings in the outer boom.
10 Connect lifting equipment to the rear extension cylinder
mounting.
11 Tighten the extension cylinder carefully. When the cylinder has
come out slightly connect a second lifting device that is moved
forward on the lift cylinder during the entire disassembly in order
to stabilise the lifting.
12 Place the cylinder on wooden blocks.
Outer shafts extension cylinder
13 Transfer parts to the new extension cylinder.

7 Load handling – 7.3.8 Extension cylinder 49
Installation
14 Clean and lubricate all bearing surfaces with lubricating grease.
15 Measure how far the old extension cylinder is extended and ex-
tend the new cylinder to the same length.
NOTE
If this is not carried out then the front cylinder mounting will
not reach far enough forward.
16 Lift the extension cylinder into place.
C AUTION
Use the dual lifting devices to achieve balance during
the lifting. The front should be positioned behind the
support at the front edge of the cylinder so that it can
be slid into the boom.
17 Fit the shaft at the front cylinder mounting in the inner boom.
NOTE
Lubricate the shaft with lubricating grease before
installation.
18 Fit the lock rings on the shaft.
19 Fit the shafts at the rear cylinder mountings.
NOTE
Lubricate the shaft with lubricating grease before
installation.
20 Fit the lock rings on the shafts.
21 Fit the valve block on the extension cylinder.
NOTE
22 Connect the hydraulic hoses and the wiring to the extension
cylinder.
23 Machine with analogue sensor boom length.

Fit the sensor for boom length, see section 8 Control system,
group 8.2.1.6 Sensor boom length.

50 7 Load handling – 7.3.8 Extension cylinder
NOTE
C AUTION

010475

C AUTION
28 Calibrate the sensor for boom length, see section 8 Control sys-
tem, group 8.5.2.1 Calibrate SCALE steps 9 - 12.

page
–

7 Load handling – 7.3.9 Valve block, pump relief 51
7.3.9 Valve block, pump relief

Valve block, pump relief, description (hydraulic oil
page
–

For boom in, only a small oil flow is required. Solenoid valve pump re-
1 2 3 4
lief (Y6062) drains the control signal for hydraulic oil pump 2, to the
tank. This results in only one pump unit building up pressure, which re-
duces the use of engine power and thus fuel consumption. If other
5 functions are activated at the same time, the pressure signal will pass
through the shuttle valve, see section 10 Common hydraulics, group
6 10.5.3 Shuttle valve. The load signal goes to the pumps that are need-
10
ed. The valve block is located standing on the bracket for the oil filling
point between the engine and transmission.
7
9 Solenoid valve, pump relief (Y6062) is supplied with voltage by Control
8 unit, frame rear (D797-R) on activation.
003623
1. Solenoid valve, engagement of hydraulic pressure

(Y6003)
2. Pressure signal to hydraulic oil pump 2
3. Valve block, top lift hydraulics
4. Tank drain
5. Pressure signal in, from shuttle valve
6. Valve block, pump relief
8. Solenoid valve, pump relief (Y6062)
9. Tank drain
10. Pressure signal in, from shuttle valve 1

52 7 Load handling – 7.3.9 Valve block, pump relief
Valve block, pump relief, description (hydraulic oil

page
–
pump alternative Sauer-Danfoss]

For boom in, only a small oil flow is required. Solenoid valve pump re-
1 2 3 4
lief (Y6062) drains the control signal for hydraulic oil pump 2, to the
tank. This results in only one pump unit building up pressure, which re-
duces the use of engine power and thus fuel consumption. If other
5 functions are activated at the same time, the pressure signal will pass
through the shuttle valve, see the Workshop Manual, section 10 Com-
6 mon hydraulics, group 10.5.3 Shuttle valve. The load signal goes to
10
the pumps that are needed. The valve block is located standing on the
bracket for the oil filling point between the engine and transmission.
7
9 Solenoid valve, pump relief (Y6062) is supplied with voltage by Control
8 unit, frame rear (D797-R) on activation.
003623

(Y6003)
4. Tank drain
9. Tank drain

7 Load handling – 7.3.10 Lift boom 53
7.3.10 Lift boom

Lift boom, general
page
–
See Lift boom, description page 35.
Slide plates, lift boom, replacement

page
–
NOTE
When adjusting the side-mounted slide plates, it is important to
check the clearance for the whole travel of the boom and that the
inner boom is centred in the outer boom.
Front slide plates
1 Move the boom to the lowest position with the inner boom extend-
ed approx. 50 cm.
2 Remove the cover plate for the side-mounted slide plates and re-
move the spacer plates and slid plate.
4 Check the clearance between the boom and slide plate, the clear-
ance should be 1 mm, adjust with spacer plates as required.
NOTE
1. Side-mounted slide plates Inner boom must be centred in the outer boom.
2. Lower slide plates 5 Remove the lock screws and the slide plates’ brackets, and pull
out the upper slide plates and the spacer plates.
6 Unload the lower slide plates, lift the inner boom at the front edge
and use wooden shims.
WARN IN G
Secure the inner boom relative to the outer boom with
wooden blocks.
7 Remove the lock screws, slide plates’ brackets and pull out the
lower slide plates.
8 Transfer the nuts for the lock screws for the lower slide plates to
the new slide plates.
9 Fit the new lower slide plates, lock screws and brackets.
10 Remove the wooden blocks and ease down the inner boom so
that it rests on the lower slide plates.
11 Transfer the nuts for the lock screws for the upper slide plates to
12 Fit the new slide plates, spacer plates, lock screws and brackets.

54 7 Load handling – 7.3.10 Lift boom
13 Check the clearance between the boom and stop at the front
edge/top edge of the boom, the clearance must be max. 2 mm,
adjust the slide plates with spacer plates if necessary.
Check attachment levelling
14 Park the machine on level ground.
15 Lower the boom fully and centre the attachment.
16 Measure the distance between the extension beam and the
ground on the right and left-hand sides of the attachment.
The difference between the dimensions for right (A) and left (B)
sides must not be more than 50 mm at 20' position, or 100 mm
for 40' position.
Check both the dimensions with the boom fully retracted and fully
A B extended.
008217
17 If necessary, adjust the lower slide plates so that the attachment

Measuring points, levelling, attachment is straight.
Rear slide plates
18 Start the engine and operate the boom inwards completely (fully
retracted).
19 Remove the cover plate for the side-mounted slide plates and re-
move the spacer plates and slid plate.
21 Check the clearance between the boom and slide plate, the clear-
ance should be 1 mm, adjust with spacer plates as required.
22 Unload the lower slide plates, use wooden shims.
1. Upper slide plates WARN IN G

2. Side-mounted slide plates
3. Lower slide plates
wooden blocks.
23 Remove the cover plates, spacer plates and the lower slide
plates.
24 Fit new slide plates, spacer plates and cover plate.
25 Unload the upper slide plates, use wooden shims.
WARN IN G

wooden blocks.

7 Load handling – 7.3.11 Sensor, boom length 55
26 Remove the lock screws, the slide plates’ brackets and pull out
the upper slide plates and the spacer plates.
27 Transfer the nuts for the lock screws for the upper slide plates to
28 Fit the new slide plates, spacer plates, lock screws and brackets.
29 Check the clearance between the outer and inner boom, the
clearance should be max. 2 mm, adjust the slide plates with
spacer plates as required.
Lubrication
004874
Sliding surfaces, boom
30 Operate the inner boom outwards completely and lubricate the
sliding surfaces inside the outer boom and on the inner boom with
white lubricating paste.
31 Operate the boom in and out about 10 times and stop with the
boom fully out.
32 Wipe away excess lubricating paste at the slide plates and on
sliding surfaces.
7.3.11 Sensor, boom length

Sensor, boom length, general
page
–
See section 8 Control system, group 8.2.1.3 Sensor, boom length.

page
–

56 7 Load handling – 7.4 Side shift
7.4 Side shift

Side shift, function description
page
–
Condition Reference Reference

value
Safety switch Disengaged Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage
1
D1
2
D790-1
D797-R D791-1
3 7 D7
D3 8
C6
P1 A
10
9
4
T1 B
5
C6
6
006407
1 The control lever (S815-T1.1) sends a Left: US815-T1.1 = 24 V Control lever, description page 7
voltage signal to the cab control unit D1: Diagnostic menu, see section 8 Control
Right: US815-T1.2 = 24 V
(D790-1). system, group 8.4.9.2 ATTACH, menu 2
mits side shift left or right on the CAN tem, error shown with er- Cab control unit
bus. ror code.
3 Control unit, frame rear (D797-R) acti- U = 24 V Section 11 Common electrics, group 11.5.3.3
vates the solenoid valve, engagement Control unit, frame rear
of hydraulics for top lift (Y6003). D3: Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6
4 Solenoid valve, engagement of hy- - Valve block, top lift hydraulics, description
draulics for top lift (Y6003) opens and page 58
pressurises valve block lift cylinder and D3: Diagnostic menu, see section 8 Control
sends a load signal to hydraulic oil system, group 8.4.5.6 HYD, menu 6
pump 2.


5 The shuttle valve forwards the strong- - Section 10 Common hydraulics, group 10.5.3
est load signal to the hydraulic oil Shuttle valve
pumps if several functions are activat-
ed simultaneously.
6 Hydraulic oil pump 2 pumps oil from See pressure plate on left Section 10 Common hydraulics, group 10.4.2
the hydraulic oil tank. frame beam. Axial piston pump with variable displacement
7 Control unit, attachment (D791-1) acti- U = 24 V Section 11 Common electrics, group 11.5.3.5
vates the servo valve for side shift left Control unit, attachment
(Y6020) or servo valve for side shift D7: Diagnostic menu, see section 8 Control
right (Y6021). system, group 8.4.9.8 ATTACH, menu 8
8 The servo valve for side shift left - Attachment control valve, description page
(Y6020) or servo valve for side shift 59
right (Y6021) pressurises the side shift D7: Diagnostic menu, see section 8 Control
slide in the attachment control valve. system, group 8.4.9.8 ATTACH, menu 8
9 The control valve’s side shift slide - Attachment control valve, description page
changes position and pressurizes the 59
side shift cylinders.
10 The side shift cylinders push the main - Side shift cylinder, description page 64
beam in sideways in relation to the
side shift frame.
Hydraulic diagram, top lift

Hydraulic diagram, top lift, tilt lock and controllable tilt
Hydraulic diagram, combi yoke
Hydraulic diagram, top lift, tilt lock and controllable tilt and hydraulic
levelling

page
–


58 7 Load handling – 7.4.2 Valve block, top lift hydraulics
7.4.2 Valve block, top lift hydraulics

Valve block, top lift hydraulics, description
page
–
The valve block for top lift hydraulics is an electrically controlled valve.
1 2 3 4
It leads an unloaded constant pressure as the load signal to the hy-
draulic oil pumps when attachment functions are activated. The valve
block is positioned horizontally on the bracket for the oil filling point be-
5 tween the engine and transmission.
When the solenoid valve is activated, pressure is routed from the top
10 6 hydraulics’ supply through a shuttle valve to the hydraulic oil pumps for
steering. A restriction before the valve block ensures that pressure for
7 control of the hydraulic oil pumps does not become too high. When the
9 solenoid valve is not activated, the load signal is drained to the tank
8 and the inlet from the top hydraulics’ supply is closed.
The valve is controlled electrically with Solenoid valve, engagement
hydraulic pressure (Y6003) which is activated by Control unit, frame
rear (D797-R).
003623
Control system , group 8.4.5.6 HYD, menu 6.
(Y6003)
4. Tank drain
9. Tank drain

7 Load handling – 7.4.3 Control valve attachment 59
7.4.3 Control valve attachment

Attachment control valve, description
page
–
1 2 3 4 5 6 7 8 9 10
11
28
27 12
26
13
25
24
001098
23 22 21 20 19 18 17 16 15 14
16. Connection to side shift cylinder

1. Solenoid valve, tilt out (Y6010)
17. Connection to side shift cylinder
2. Solenoid valve, tilt in (Y6011)
18. Connection to rotation motor
3. Solenoid valve rotation clockwise (Y6008)
19. Connection to rotation motor
4. Solenoid valve rotation anticlockwise (Y6009)
20. Connection to tilt cylinder
5. Solenoid valve, side shift right (Y6021)
6. Solenoid valve, side shift left (Y6020) 21. Connection to tilt cylinder
7. Solenoid valve, spreading out (Y6018)
22. Connection to levelling cylinder
8. Solenoid valve, spreading in (Y6019)
23. Connection to levelling cylinder
9. "Lock twistlocks" solenoid valve (Y6040)
24. Test outlet, feed pressure to control valve
10. "Open twistlocks" solenoid valve (Y6039)
25. Feed from hydraulic oil pump 2
11. Drain to tank
26. Return to tank (through tank filter)
12. Connection to lock cylinder
13. Connection to lock cylinder 27. Solenoid valve, levelling right (Y6035)
14. Connection to spreader motor 28. Solenoid valve, levelling left (Y6036)
15. Connection to spreader motor
Side shift is controlled by a separate section of the attachment control

valve.
The attachment control valve controls hydraulic functions on the at-
tachment. The control valve is located at the centre rear of the attach-
ment. Electric servo valves control the flow from the valve.

60 7 Load handling – 7.4.3 Control valve attachment

and pressure-compensated directional valve. Electrically controlled
servo valves convert current to servo pressure. The servo pressure
controls the spring-centred valve slides, which control pressure and
flow for the function in question. The valve slides have a flow limit so
that several functions can be used simultaneously. This enables them
to control main flow.
The control valve has built-in supply of pilot pressure. This means that
the valve has built-in pressure reduction which converts feed pressure
to servo pressure for the various functions. Supply of pilot pressure is
common for all functions. This reduces pressure variations due to long
hoses and reduces the number of hoses to the valve.
The control valve has the following sections:
• Side shift
• Spreading
• Rotation
• Twistlocks
• Controllable tilt
• Hydraulic levelling
Side shift slide

The valve slide controls side shift direction and speed.
The valve slide is controlled by a servo valve for side shift right and a
servo valve for side shift left.
Servo valve, side shift left

The servo valve for side shift left directs pressure to the side shift slide
so that the side shift slide opens and pressurises the side shift
cylinders.
The servo valve for side shift left is controlled electrically by the sole-
noid valve for side shift left (Y6020), which is activated by the attach-
ment control unit (D791-1). The servo valve directs servo pressure to
the side shift slide in proportion to the control current to the solenoid
valve.
Servo valve, side shift right

The servo valve for side shift right directs pressure to the side shift
slide so that the side shift slide opens and pressurises the side shift
cylinders.
The servo valve for side shift is controlled electrically by the solenoid
valve for side shift right (Y6021), which is activated by the attachment
control unit (D791-1). The servo valve directs servo pressure to the
side shift slide in proportion to the control current to the solenoid valve.

Attachment control valve, replacement

page
–
NOTE
B Safety.
B Safety.
NOTE
4 Mark up and detach the wiring from the control valve.
6 Transfer the connection adapters to the new control valve.
NOTE
NOTE
Transfer one adapter at a time so that the marking is not
mixed up.
7 Mark up the servo valves on the new control valve.
8 Fit the valve.
Lift the valve into place and fit the attaching bolts.
marking.
with the marking.
NOTE

NOTE
C AUTION

010475

14 Check that the valve's hydraulic connections are sealed.
15 Check that the attachment is working.
C AUTION
product damage.

itation.
C AUTION


7 Load handling – 7.4.4 Shuttle valve 63
Attachment control valve, checking hydraulic

page
–
pressure
NOTE
Read the instructions for oil before working; see section B Safety.
1 Operate and warm up the machine so that the hydraulic oil is at

operating temperature, at least 50 °C. As an alternative, operate
until the cooling fan is activated.
˚C 2 Machine in service position, see section B Safety.
˚C
Operating menu, hydraulic oil temperature 000475
3 Connect a pressure gauge to measuring outlet PL on the attach-

ment control valve.
4 Start the engine and run it at idling speed. Check the pressures
in the attachment’s different functions by letting each function go
to its end-position and then reading off the pressure gauge.
Function Pressure
Side shift 16.0 MPa
Spreading 12.0 MPa
Rotation 15.0 MPa

008226
15.0 MPa
Tilt control
Measuring outlet, control valve, attachment 15.5 MPa
Levelling
Twistlocks Same as feed pressure.
10.0 MPa
Overheight jacks, lowering
10.0 MPa
Lifting jacks, knee in/out
13.0 MPa
Lifting jacks, jack up/down
13.0 MPa
Lifting jacks, clamping
measuring outlet.
7.4.4 Shuttle valve

page
–

64 7 Load handling – 7.4.5 Side shift cylinder
7.4.5 Side shift cylinder

Side shift cylinder, description
page
–
The side shift cylinders are two cross connected hydraulic cylinders
1 which extend the attachment’s main beam laterally in relation to the
sideshift frame. The side shift cylinders are located along the front and
10 rear of the attachment and are used to centre the load’s centre of
gravity.
9
8 2
3
4 001500
7 6 5
1. Side shift frame

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

page
–

7 Load handling – 7.4.6 Side shift frame 65
7.4.6 Side shift frame

Side shift frame, description
page
–
The attachment is secured in the boom with the rotation yoke. The side
1 2 3 4 5 6 shift frame is located under the rotation yoke. The attachment’s main
beam is located in the side shift frame. The main beam can be extend-
ed laterally in relation to the side shift frame with two hydraulic cylin-
ders. Inside the main beam are two spreader beams which can be
extended in and out with a hydraulic motor.
The position of the attachment can be adjusted laterally by moving the
main beam in relation to the side shift frame. The main beam runs on
slide pates in the sides and in the bottom. The side shift cylinders se-
cure the lateral position.
The side shift frame is available in two versions:
• Standard top lift. The side shift frame allows the main beam to be
000526
levelled 5°. Side shift 800 mm.
1. Main beam • Pile-slope top lift

2. Ring gear
The side shift frame is located in the rotation yoke with four hy-
3. Rotation motor unit
draulic cylinders which mean that the levelling can be controlled
4. Rotation yoke
for adaptation to angled containers. Side shift 800 mm.Side shift
5. Control valve attachment
frame, description page 129
6. Side shift frame

66 7 Load handling – 7.4.6 Side shift frame
Slide plates, side shift frame, replacement

page
–
1 Undo the cover plate’s attaching bolt and remove the cover plate.
2 Remove the spacer plates and slide plate.
3 Repeat steps 1 - 3 on the other slide plates.
4 Measure the distance between the edge of the cover plate and
the attachment’s main beam slide surface on all slide plates.
5 Centre the boom so that the distance between the attachment’s
main beam and edge is the same on all slide plates.
6 Fit the new slide plate.

7 Check the slide plate’s clearance by measuring the distance be-
tween the slide plate and the edge of the cover plate. The clear-
ance between the attachment’s main beam and slide plates must
be 1 mm.
8 Fit the spacer plates until the distance is correct.

9 Fit the cover plate.

10 Repeat steps 7 - 10 on the other slide plates.
Lubrication
004875
Sliding surfaces, attachment
11 Lubricate the sliding surfaces of the attachment with white lubri-
cating paste.
12 Operate full side shift from right to left approx. 10 times.
sliding surfaces.

68 7 Load handling – 7.4.6 Side shift frame
Lower slide plates, side shift frame, replacement

page
–
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 released.
D ANGER
Place spacers between the crossmember and the at-

tachment’s main boom for both crossmembers.
3 Remove the attaching bolts and remove the slide plates.

4 Install new slide plates.
5 Remove the spacer.
7 Lift the attachment and remove the stands.
Lubrication
The illustration shows a crossmember
004875
Slide plates, attachment

cating paste.
9 Operate full side shift from right to left approx. 10 times.
sliding surfaces.

7 Load handling – 7.4.7 Main beam, attachment 69
7.4.7 Main beam, attachment

Attachment main beam, description
page
–
The main beam attachment is located in the side shift frame. The main
1 2 3 4 5 6 beam contains equipment for spreading (spreader beams, hydraulic
motor, chains, slide plates and sensors). On the attachment’s main
beam are also the control valves for the attachment’s hydraulic
functions.
000526
1. Main beam
2. Ring gear
4. Rotation yoke
6. Side shift frame
7.4.8 Relief valve, attachment

Attachment relief valve, description
page
–
The attachment relief valve opens the connection between the attach-
ment’s pressure supply and the tank. This is used to drain the pressure
in the attachment hoses prior to work on the hydraulic system. The re-
lief valve is located at the rear of the lifting beam in front of the
transmission.
002269

70 7 Load handling – 7.4.9 Pipes and hoses

page
–

7 Load handling – 7.5 Spreading 71
7.5 Spreading
Spreading, function description
page
–

Safety switch Disengaged Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage
Twistlocks Unlocked or by- Twistlocks, description page 137

pass activated Section 8 Control system, group 8.2.2 Bypassing
Overload system Passive Section 8 Control system , group 8.2.1 Overload system
1 D1
+
2
D790-1
D797-R D791-1
3 7, 13 D12
D3 D7
8, 14
C6
12
P1 A
4
11, 16
T1 B
9, 15 10
5
C6
6
006408

1 The control lever (S815-T1.x and Spreading: US815-T4 = 24 V Control lever, description page 7
S815-T4) sends a voltage signal to the D1: Diagnostic menu, see section 8 Control
Out: US815-T1.2 = 24 V
cab control unit (D790-1). system, group 8.4.9.2 ATTACH, menu 2
In: US815-T1.1 = 24 V
2 The cab control unit (D790-1) trans- Checked by control sys- Section 11 Common electrics, group
mits a signal on the CAN bus. tem, error shown with error 11.5.3.1 Cab control unit
code.

72 7 Load handling – 7.5 Spreading

3 Control unit, frame rear (D797-R) acti- U = 24 V Section 11 Common electrics, group
vates the solenoid valve, engagement 11.5.3.3 Control unit, frame rear
4 Solenoid valve, engagement of hy- - Valve block, top lift hydraulics, description
draulics for top lift (Y6003) opens and page 58
sends a load signal to the hydraulic oil D3: Diagnostic menu, see section 8 Control
pumps. system, group 8.4.5.6 HYD, menu 6
5 The shuttle valve forwards the strong- - Section 10 Common hydraulics, group
est load signal to the hydraulic oil 10.5.3 Shuttle valve
pumps if several functions are activat-
ed simultaneously.
6 Hydraulic oil pump 2 pumps oil from See pressure plate on left Section 10 Common hydraulics, group
the hydraulic oil tank. frame beam. 10.4.2 Axial piston pump with variable dis-
placement
7 The attachment control unit (D791-1) I = 350–600 mA Section 11 Common electrics, group
activates the servo valve for spreading 11.5.3.5 Control unit, attachment
out (Y6018) or spreading in (Y6019). D7: Diagnostic menu, see section 8 Control
system, group 8.4.9.13 ATTACH, menu 13
and 8.4.9.14 ATTACH, menu 14
8 The servo valve for spreading out - Attachment control valve, description page
(Y6018) or spreading in (Y6019) pres- 59
surizes the spreader slide in the at- D7: Diagnostic menu, see section 8 Control
tachment’s control valve. system, group 8.4.9.13 ATTACH, menu 13
9 The control valve’s spreader slide - Attachment control valve, description page
changes position and directs pressure 59
to the spreader motor.
10 The motor valve block directs the pres- - Spreader motor valve block, description
sure to the motor and prevents the mo- page 79
tor from pumping (rotating faster than
supplied pressure).
11 The motor drives the chains that ex- - Spreader motor, description page 79
tend or retract the spreader beams.
12 The sensor for end position 20’-40’ Sensor directly opposite in- Position sensor spreading, description
(B769) sends a voltage signal to the at- dicator plate: U > 24 V page 93
tachment control unit (D791-1). D12: Diagnostic menu, see section 8 Con-
trol system, group 8.4.9.5 ATTACH, menu 5
13 The attachment control unit (D791-1) - Section 11 Common electrics, group

reduces control current to the servo 11.5.3.5 Control unit, attachment
valve for spreading out (Y6018) or D7: Diagnostic menu, see section 8 Control
spreading in (Y6019). system, group 8.4.9.13 ATTACH, menu 13


14 The servo valve for spreading out - Attachment control valve, description page
(Y6018) or spreading in (Y6019) re- 78
duces pressure to the spreader slide in D7: Diagnostic menu, see section 8 Control
the attachment’s control valve. system, group 8.4.9.13 ATTACH, menu 13
15 The control valve’s spreader slide - Attachment control valve, description page
changes position and reduces pres- 78
sure to the spreader motor.
16 The speed of the spreader motor is re- - Spreader motor, description page 79
duced.

levelling

Spreading 30’ stop, function description

page
–

Safety switch Disengaged Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage
Twistlocks Unlocked or bypass Twistlocks, description page 137

activated Section 8 Control system, group 8.2.2 Bypassing
2
1
35
D2
30-
D1 3
D790-1
D791-1 D5 D7
6, 8
D8
5 7
006409

1 The switch for stop at 30’-35’ (S1004) Switch in ON position: Switch, stop at 30’ or 35’, description page
sends a voltage signal to the cab con- Conn 1: U = 0 V 10
trol unit (D790-1). D1: Diagnostic menu, see section 8 Control
Conn 5: U = 24 V
Switch in OFF position:
Conn 1: U = 24 V
Conn 5: U = 24 V
2 The control lever (S815-T1.2 and Spreading: US815-T4 = 24 V Control lever, description page 7
S815-T4) sends a voltage signal to the D2: Diagnostic menu, see section 8 Control
Out: US815-T1.2 = 24 V
cab control unit (D790-1). system, group 8.4.9.2 ATTACH, menu 2
In: US815-T1.1 = 24 V
spreading 30’ on the CAN bus. tem, error shown with error 11.5.3.1 Cab control unit
code.
4 Spreading is activated in the same way - Spreading, function description page 71

as steps 3–11 of normal spreading.


5 When spreading approaches the 30’ Sensor directly opposite in- Position sensor spreading, description
position, the end position 30’ sensor dicator plate: U = 24 V page 93
(B777-3) sends a voltage signal to the D5: Diagnostic menu, see section 8 Control
attachment control unit (D791-1). system, group 8.4.9.5 ATTACH, menu 5
6 The attachment control unit (D791-1) - Spreading, function description page 71

dampens the speed the same way as
in steps 13–16 of normal spreading.
7 When spreading is in the 30’ position, Sensor directly opposite in- Position sensor spreading, description
the 20’-40’ end position sensor (Y769) dicator plate: U = 24 V page 93
sends a voltage signal. D7: Diagnostic menu, see section 8 Control
8 Spreading is interrupted by the attach- U=0V Attachment control valve, description page
ment control unit (D791-1) cutting of 78
current to the servo valve for spreading D8: Diagnostic menu, see section 8 Control
out (Y6018) or spreading in (Y6019). system, group 8.4.9.13 ATTACH, menu 13

levelling

Automatic spreading 20-40 foot, function

page
–
description

Safety switch Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch volt-
age
Twistlocks Unlocked or bypass Twistlocks, function description page 130

activated
Overload system Passive Section 8 Control system, group 8.2.1.1 Mechanical overload system
Doors Closed Section 9 Frame, body, cab and accessories, group 9.10.2 Doors
Parking brake Released Section 4 Brakes, group 4.5 Parking brake system
2 D2
1
+
3 9
D1 D790-1 D795
D791-1
4, 5, 8, 11 D10 D7
D5
D4 10 7
6
006884

1. The control lever (S815-T1.2 and Spreading: US815/T4 = 24 V Control lever, description page 7
S815-T4) sends a voltage signal D1: Diagnostic menu, see section 8 Control
Out: US815/T1.2 = 24 V
to the cab control unit (D790-1). system, group 8.4.9.2 ATTACH, menu 2
In: US815/T1.1 = 24V
2. The switch for automatic spread- Switch in ON position: Switch automatic spreading, description page
ing 20’-40’ (S199-2) sends a volt- US199-2/2 = 0 V 10
age signal to the cab control unit D2: Diagnostic menu, see section 8 Control sys-
(D790-1). US199-2/5 = 24 V
tem, group 8.4.9.4 ATTACH, menu 4
US199-2/2 = 24 V
US199-2/5 = 24 V
3. The cab control unit (D790-1) Checked by control sys- Section 11 Common electrics, group 11.5.3.1
transmits "automatic spreading tem, error shown with error Cab control unit
out" or "automatic spreading in" on code.
the CAN bus.


4. The attachment control unit - Spreading, function description page 71
(D791-1) activates spreading the D4: Diagnostic menu, see section 8 Control
same way as in steps 2-11 of nor- system, group 8.4.9.13 ATTACH, menu 13 and
mal spreading. 8.4.9.14 ATTACH, menu 14
5. The attachment control unit Buzzer active: U = 24 V Buzzer for automatic spreading 20’-40’, descrip-
(D791-1) activates the automatic tion page 94
spreading buzzer (H9003). D5: Diagnostic menu, see section 8 Control sys-
6. The automatic spreading buzzer Buzzer active: U = 24 V Buzzer for automatic spreading 20’-40’, descrip-
(H9003) generates an acoustic tion page 94
warning signal. D5: Diagnostic menu, see section 8 Control sys-
7. When spreading approaches the Sensor directly opposite in- Position sensor spreading, description page 93
30' position, the end position 30’ dicator plate: U = 24 V D7: Diagnostic menu, see section 8 Control sys-
sensor (B777-3) sends a voltage tem, group 8.4.9.5 ATTACH, menu 5
signal to the attachment control
unit (D791-1).
8. The attachment control unit - Spreading, function description page 71

(D791-1) dampens the spreading
in the same way as in position 13-
16 of normal spreading.
9 When automatic spreading is ac- - Section 11 Common electrics, group 11.5.3.12

tive, the KID control unit (D795) KID control unit
activates the Automatic spreading
event menu.
10. When spreading is at the 20' posi- Sensor directly opposite in- Position sensor spreading, description page 93
tion, 30' position or 40' position, dicator plate: U = 24 V D10: Diagnostic menu, see section 8 Control
the 20’-40’ end position sensor system, group 8.4.9.5 ATTACH, menu 5
(B769) sends a voltage signal to
the attachment control unit
(D791-1).
11. The attachment control unit I = 0 mA Attachment control valve, description page 78
(D791-1) cuts off control current to D4: Diagnostic menu, see section 8 Control sys-
the servo valve for spreading out tem, group 8.4.9.13 ATTACH, menu 13 and
(Y6018) or spreading in (Y6019). 8.4.9.14 ATTACH, menu 14

levelling


page
–


page
–
See Valve block, top lift hydraulics, description page 58.

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

trol valve. For a more detailed description of the valve and component
locations, see Attachment control valve, description page 59.
Spreader slide
The valve slide controls the direction and speed of spreading. The
valve slide is controlled by a servo valve for spreading out and a servo
valve for spreading in.
Servo valve, spreading out

The servo valve for spreading out directs pressure to the spreader
slide so that it opens and pressurizes the spreader motor.
The servo valve is controlled electrically by the solenoid valve for
spreader out (Y6018), which is activated by the attachment control unit
(D791-1). The servo valve directs servo pressure to the spreading
slide in proportion to the control current to the solenoid valve.
Servo valve, spreading in

The servo valve for spreading in directs pressure to the spreader slide
so that it opens and pressurizes the spreader motor.
The servo valve is controlled electrically by the solenoid valve for
spreader in (Y6019), which is activated by the attachment control unit
(D791-1). The servo valve directs servo pressure to the spreading

page
–
See Attachment control valve, replacement page 61.
7.5.4 Shuttle valve

page
–

7 Load handling – 7.5.5 Valve block, spreading motor 79
7.5.5 Valve block, spreading motor

Spreader motor valve block, description
page
–
The spreader motor valve block regulates the oil’s direction to the
spreader motor. The valve block sits on the spreader motor all the way
out out to the left on the front side of the attachment’s main beam.
The valve block maintains a balance between supply and spreading
speed. Balance means that the valve block prevents the motor from
pumping oil, i.e. rotates faster than the supply of oil allows. The
spreading valve block contains overcentre valves that block the outlet
if pressure on the outlet side is higher than pressure on the inlet side.
I II
001004
Hydraulic diagram, spreader motor valve block
7.5.6 Spreading motor

Spreader motor, description
page
–
Via two chains, the spreader motor moves the spreader beams in and
1 out in the attachment’s main beam. The spreader motor sits all the way
out out to the left on the front side of the attachment’s main beam.
10
The hydraulic motor is integrated with a planetary gear that reduces
speed and makes the motor more powerful. A valve block with two
9
overcentre valves is located on the hydraulic connections and pre-
vents the motor from rotating faster than the supplied hydraulic
8 2 pressure.
3
4
001500
7 6 5
1. Side shift frame

4. Sensor alignment
5. Twistlock
6. Twistlock sensor
8. Spreading boom
9. Spreading motor

80 7 Load handling – 7.5.6 Spreading motor
Spreader motor, replacement

page
–
NOTE
B Safety.
2 Remove the cover on the left side of the attachment’s main beam.
3 Start the engine and run spreading out until the chain tensioners
are visible in the inspection holes.
B Safety.
power.
7 Measure and note the chain tensioners’ length to attain the cor-
rect chain tension when refitting.
8 Slacken the chain tensioner on the engine side and remove the
chain from the tensioner.
9 Remove the protective plate from over the spreader motor.

7 Load handling – 7.5.6 Spreading motor 81
10 Mark up and detach the hydraulic hoses from the valve block of
the spreader motor.
11 Remove the spreader motor assembly.
12 Transfer the valve block to the new motor assembly.
NOTE
13 Clean the contact surfaces between the planetary gear and the
attachment’s main beam.
14 Fit the motor unit. Tighten the bolts crosswise in steps until
117 Nm is achieved.
15 Attach the hydraulic hoses to the valve block.

82 7 Load handling – 7.5.6 Spreading motor
16 Connect the spreader chain to the chain tensioner. Check that

the chain runs straight in the hydraulic motor sprocket.
17 Tension the chain tensioner to the same degree as before.
19 Check that the hydraulic connections are sealed tightly.
20 Check that spreading is working.
21 Fit the protective plate over the motor.
22 Grease the spreader chain with lubricating grease.
23 Fit the cover plates on the attachment’s main beam.
NOTE
C AUTION

010475
C AUTION


7 Load handling – 7.5.7 Spreader chains 83
7.5.7 Spreader chains

Spreader chains, description
page
–
The spreader chains move the extension beams in and out of the at-
tachment’s main beam. The force from the spreading motor is trans-
ferred to extension beams via two chains. The chains run inside the
attachment between the extension beams.
The chains are fastened crosswise with one end at the bottom of one
M extension beam and the other end along the side of the other exten-
sion beam.
Openings in the sides of the extension beams and the attachment’s
main beam make it possible to access the chains for maintenance
purposes.
000472
Principle diagram, spreader chains
Spreader chains, checking

page
–
1 Before adjustment, the clearance between the slide plates and

extension beams must be checked so that the chain mountings
are not damaged. See Maintenance manual, section 7 Load han-
dling, group 7.5.8 Spreader beam.
20-foot position
2 Start the engine, run spreading in to the 20-foot position and
switch off the engine.
3 Check that both spreader beams are against the 20-foot stop and
that the distance between the spreader beam and spreader mo-
tor mounting is at least 3 mm.
4 Check the C-C measurement between the twistlocks.
C-C 20 feet: 5853±3 mm.
If the 20-foot setting is correct proceed to step 8.

84 7 Load handling – 7.5.7 Spreader chains
5 If necessary, adjust the distance by moving washers between the

right and left 20-foot stop. Do not change the number of washers.
NOTE
Note the distance the stop was adjusted.
Run spreading out a little to make it possible to move the
washers.
C AUTION
20-foot stop
Incorrect chain tension.
Risk of damage to the attachment.
If the 20-foot stop is adjusted, the spreader chains

must be adjusted by the same amount.
6 Remove the cover plate on the attachment’s main beam.
7 If the 20-foot stop is adjusted, the spreader chains must be

adjusted by the same amount, see step 14.
NOTE
Check the vertical position of the chain tensioner so that the
chain runs straight to the sprocket.
005105

40-foot position
8 Start the engine, run spreading out to the 40-foot position and
switch off the engine.
9 Check the C-C measurement between the twistlocks.
C-C 40 feet: 11985±3 mm.
If the 40-foot setting is correct proceed to step 11.
10 Adjust the 40-foot stop if necessary.
Chain tension
11 Start the engine and run spreading out to the 40-foot position.
12 Wait 2 minutes and then check the tension of the chains.
005106
40-foot stop
13 Use suspension scales and measure how far the chain moves
100 N
815 mm when pulled outward with a force of 100 N at 815 mm from the
main beam’s internal reinforcement collar as illustrated.
Standard attachment: X = 8-13 mm.
Overheight attachment: X = 5-6 mm.
815mm
100 N
0N
010486
100 N
X
14 Adjust chain tension if necessary.

Start the engine and operate spreading outwards until the chain
tensioners are visible in the inspection holes (approx. 250 mm).
Adjust the chains, hold the chain tensioner in place with a
spanner so that the chain does not rotate during adjustment.
NOTE
Adjust max. 2 mm on the chain tightener at a time.
15 Repeat steps 11–14 until the chains have the correct tension.

16
If the machine is equipped with a 30 or 35-foot stop, start the en-
gine, run spreading out to the 30 or 35-foot position, switch off the
engine and check the C-C measurement between the twistlocks.
C-C 30 feet: 8918±3 mm
C-C 35 feet: 10488±3 mm
I M P OR TA NT
Check the distance at stop from both 20’ and 40’.
17 Grease the spreader chain with lubricating grease.

Spreader chain, replacement

page
–
1 Park the machine with the attachment as far down as possible.

2 Remove the cover plate on the attachment’s main beam.
3 Start the engine and run spreading out until the chain tensioners
are visible in the inspection holes.
005105

5 Slacken the chain tensioner of the chain in question 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 sprocket of the chain in question.
NOTE
Note the location of the spacer ring.
If the sprocket on the engine side must be removed, fist remove
the spreader motor. See Spreader motor, replacement page 80.
7 Pull the chain out through the sprocket hole so that the chain runs
along the spreader beam.
8 Temporarily fasten the chain along the cable rack to prevent the
chain from being pinched.

9 Pull out the spreader beam.

Use a machine or the like to pull the spreader beam out of the at-
tachment’s main beam. Stop when the spreader beam is close to
the 40-foot stop.
NOTE
Support the spreader beam to minimise breaks. If neces-
sary, 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.

16 Fasten the chain along the cable rack so that it runs straight along
the spreader beam.
17 Grease the chain with lubricating grease.
18 Slide in the spreader beam so that the extension stop can be

fitted.
19 Fit the extension stop.
20 Connect the cable rack to the attachment’s main beam.
21 Fit the hydraulic hoses’ clamping on the attachment’s main
beam.
22 Slide in the spreader beam until it is extended the same amount
as the other one. This facilitates fitting of the chains.
23 Detach the chain from the cable rack and insert it through the
sprocket hole.
24 Fit the sprocket. The spacer ring should sit on the underside of
the sprocket.
If the rotation motor has been removed, refit it. See Spreader mo-
tor, replacement page 80.
NOTE
Check that the chain runs straight in the sprockets.

25 Connect the chain to the chain tensioner.
NOTE
Use a new split pin.
005105
26 Lubricate the sprocket bearings with grease.

27 Tension the spreader chain to the same degree as before.
Tighten the lock nut.
28 If the slide plates have been removed, refit them.
30 Check that spreading is working properly.
31 Stop the engine
32 Check chain tension. See Spreader chains, checking page 83.

7 Load handling – 7.5.8 Spreader beam 91
7.5.8 Spreader beam

Spreader beam, description
page
–
The spreader beams are the part of the attachment that grip the con-
1 tainer. Two spreader beams run along the main beam. The spreader
beams are slid in and out via the spreader motor and spreader chains.
10
The spreader beam houses twistlocks. See Twistlocks, description
page 137.
9
8 2
3
4
001500
7 6 5
1. Side shift frame

4. Sensor alignment
5. Twistlock
6. Twistlock sensor
8. Spreading boom
9. Spreading motor
Slide plates, extension beam, replacement

page
–

2 Take the strain off the glide 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 attachment’s main beam.
The photo depicts the inner slide plates of the


92 7 Load handling – 7.5.8 Spreader beam
3 Remove the attaching bolts for the glide plate’s bracket.

4 Remove the guide plate’s guide pin.
5 Pull out the glide plate with spacer plate and bracket.
The photo depicts the inner slide plates of the

6 Position the new slide plate.
Check the clearance between the extension beam and the slide
plate. Clearance should be max. 1 mm with all slide plates fitted.
Use a spacer plate to adjust the clearance.
7 Fit the slide plate bracket and guide screw.
Lubrication
004875

cating paste.
9 Run spreading completely in and out approximately 10 times and
check the spreading function.
sliding surfaces.
11 Try to lift a container and check the extension beams’ clearance
in the attachment’s main beam.

7 Load handling – 7.5.9 Main beam, attachment 93
7.5.9 Main beam, attachment

page
–
See Attachment main beam, description page 69.
7.5.10 Position sensor, spreading

Position sensor spreading, description
page
–
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 located under the
protective plate on the top left side of the attachment’s main beam.
The end position sensor (B769) indicates the end position of 20 and
40-foot containers. The sensor detects the spreader beam end posi-
tions via two indicator plates on the top of the spreader beams. The
sensor is used to activate damping.
With the 30-foot stop option, there is an extra sensor - position sensor
(B779) - and two indicator plates. The sensor is used to activate the
30-foot stop.
The sensors are supplied power by and send a 24 V signal to the at-
tachment control unit (D791-1) when the indicator plates pass the sen-
sor. Indicator plates on the spreader units are mounted so that the
sensors generate a signal when the spreader unit passes the sensor.
The indicator plates and the position of the sensors are designed so
that the distance between the spreaders becomes 20’ (30’) and 40’.
8 Control system , group 8.4.9.5 ATTACH, menu 5.
003165
1. Indicator plate 20’

2. Sensor, damping 20’ and 40’, Stop 30’
3. Sensor, damping 30’
4. Indicator plate, 30’ or 35’
5. Indicator plate 40’

page
–
See Position sensor, checking and adjustment page 5.

page
–
See Attachment relief valve, description page 69.

page
–

94 7 Load handling – 7.5.13 Buzzer, automatic spreading 20'-40'
7.5.13 Buzzer, automatic spreading 20'-40'

Buzzer for automatic spreading 20’-40’, description
page
–
The buzzer for automatic spreading 20'-40' (H9003) is fitted on the

boom nose on machines with automatic spreading 20'-40'. The buzzer
is activated during automatic spreader movement.

7 Load handling – 7.6 Rotation 95
7.6 Rotation
Rotation, function description
page
–

value
D1
1
2
D790-1
D797-R D791-1
3 7
D8
D4
8
C6
P1 A
11, 12
4 T1 B
9 10
C6 5
006410

96 7 Load handling – 7.6 Rotation

1 Control lever (S815-P3) sends the Anticlockwise: US815/P3 = Section 9 Frame, body, cab and accessories,
cab control unit (D790-1) a voltage 0.5–2.0 V group 9.1 Controls and instruments
signal proportional to lever D1: Diagnostic menu, see section 8 Control
movement. system, group 8.4.9.1 ATTACH, menu 1
2.0–3.0 V
Clockwise: US815/P3 =
3.0-4.5 V
0.5 V and 4.5 V represent
the maximum rotation
speed. Lower voltages
than 0.5 V and higher
voltages than 4.5 V are
used to detect malfunc-
tions in wiring and
controls.
2 Control unit, cab (D790-1) transmits Checked by control sys- Section 11 Common electrics, group 11.5.3.1
clockwise rotation or anticlockwise tem, error shown with er- Cab control unit
rotation on the CAN bus. ror code.
3 Control unit, frame rear (D797-R) U = 24 V Section 11 Common electrics, group 11.5.3.3
activates the solenoid valve, en- Control unit, frame rear
gagement of hydraulics for top lift D4: Diagnostic menu, see section 8 Control
(Y6003). system, group 8.4.5.6 HYD, menu 6
4 Solenoid valve, engagement of hy- - Valve block, top lift hydraulics, description page
draulics for top lift (Y6003) opens 58
and pressurises valve block lift cyl- D4: Diagnostic menu, see section 8 Control sys-
inder and sends a load signal to the tem, group 8.4.5.6 HYD, menu 6
hydraulic oil pumps.
5 The shuttle valve forwards the - Section 10 Common hydraulics, group 10.5.3
strongest load signal to hydraulic oil Shuttle valve
pump 2 if several functions are acti-
vated simultaneously.
6 Hydraulic oil pump 2 pumps oil from See pressure plate on left Section 10 Common hydraulics, group 10.4.2
the hydraulic oil tank. frame beam. Axial piston pump with variable displacement
7 Control unit, attachment (D791-1) I = 435–650 mA Section 11 Common electrics, group 11.5.3.5
activates servo valve, rotation Control unit, attachment
clockwise or servo valve, rotation D8: Diagnostic menu, see section 8 Control sys-
anticlockwise. tem, group 8.4.9.11 ATTACH, menu 11 and
8.4.9.12 ATTACH, menu 12
8 Servo valve, rotation clockwise - Attachment control valve, description page 100
(Y6008) or servo valve, rotation an- D8: Diagnostic menu, see section 8 Control sys-
ticlockwise (Y6009) pressurise the tem, group 8.4.9.11 ATTACH, menu 11 and
rotation slide in the attachment con- 8.4.9.12 ATTACH, menu 12
trol valve.

7 Load handling – 7.6 Rotation 97

9 The rotation slide in the attachment - Attachment control valve, description page 100
control valve changes position and
controls the pressure to the hydrau-
lic motor valve block.
10 The hydraulic motor valve block - Valve block rotation motor, description page 101
controls the pressure to both
motors.
11 The hydraulic motors’ disc brakes - Rotation motor unit, description page 102
are disengaged.
12 The hydraulic motors rotate the - Rotation motor unit, description page 102
attachment.

levelling

98 7 Load handling – 7.6 Rotation
Rotation stop, function description

page
–
Rotation stop is used to avoid rotating the attachment into the boom in
the raised position.

value
1 D1
2
3 7
D2 D790-1 D795
D791-1 D5
6
D6
006411
5

1 The rotation stop switch Switch in ON position: Section 9 Frame, body, cab and accesso-
(S1014) sends a voltage sig- US1014/1 = 0 V ries, group 9.1 Controls and instruments
nal to the cab control unit D1: Diagnostic menu, see section 8 Control
(D790-1). US1014/5 U = 24 V
US1014/1 = 24 V
US1014/5 U = 24 V
2 Control lever (S815-P3) sends Anticlockwise: US815/P3 = 0.5–2.0 V Section 9 Frame, body, cab and accesso-
the cab control unit (D790-1) a ries, group 9.1 Controls and instruments
Zero position: US815/P3 = 2.0–3.0 V
voltage signal proportional to D2: Diagnostic menu, see section 8 Control
lever movement. Clockwise: US815/P3 = 3.0–4.5 V
0.5 V is the minimum rotation speed
and 4.5 V is the maximum rotation
speed. Lower voltages than 0.5 V
and higher voltages than 4.5 V are
used to detect malfunctions in ca-
bling and controls.


3 Control unit, cab (D790-1) Checked by control system, error Section 11 Common electrics, group
transmits clockwise rotation to shown with error code. 11.5.3.1 Cab control unit
stop or anticlockwise rotation
to stop on the CAN bus.
4 Rotation is activated in the - Rotation, function description page 95

same way as steps 3–12 of
normal rotation.
5 Sensor rotation stop (B7225) Sensor directly opposite indicator Sensor rotation stop, description page 110
sends a voltage signal to the plate: U = 24 V D5: Diagnostic menu, see section 8 Control
attachment control unit system, group 8.4.9.21 ATTACH, menu 21
(D791-1).
6 The rotation is stopped by the - Attachment control valve, description page

attachment control unit (D791- 100
1) cutting off the current to the D6: Diagnostic menu, see section 8 Control
servo valve, rotation clockwise system, group 8.4.9.11 ATTACH, menu 11
(Y6008) or servo valve, rota- and 8.4.9.12 ATTACH, menu 12
tion anticlockwise (Y6009).
7 When rotation stop has been - Section 11 Common electrics, group

achieved the KID control unit 11.5.3.12 KID control unit
(D795) activates the event
menu for rotation stop.

levelling

page
–


page
–


page
–
Rotation is regulated by a separate section in the attachment’s control

valve. For a general description of the valve and component locations,
see Attachment control valve, description page 59.
Rotation slide
The valve slide controls the direction and speed of rotation. The valve
slide is controlled by servo valve, rotation clockwise and servo valve,
rotation anticlockwise.
Servo valve, rotation clockwise

Servo valve, rotation clockwise controls pressure to the rotation slide
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 the attach-
ment control unit (D791-1). The servo valve directs servo pressure to
the rotation slide in proportion to the control current to the solenoid
valve.
Servo valve, spreading anticlockwise

Servo valve, rotation anticlockwise controls pressure to the rotation
slide so that the rotation slide opens and pressurises the rotation
motors.
Servo valve, rotation anticlockwise is controlled electrically by sole-
noid valve, rotation anticlockwise (Y6009), which is activated by the at-
tachment control unit (D791-1). The servo valve directs servo
pressure to the rotation slide in proportion to the control current to the
solenoid valve.

page
–
7.6.4 Shuttle valve

page
–

7 Load handling – 7.6.5 Valve block, rotation motor 101
7.6.5 Valve block, rotation motor

Valve block rotation motor, description
page
–
Valve block, rotation motor controls pressure to the rotation motors.

The valve block is located on one of the rotation motors.
The valve block provides a controlled rotation by preventing the load
from pulling away and provides faster rotation than the hydraulic mo-
tor. The valve block contains a shuttle valve and overcentre valves.
1
1
2
2
3 3
4 4
6 5
7
000530
1. Hydraulic motor rotation

2. Disc brake
3. Planetary gear
4. Gear wheel
5. Rotation yoke
6. Ring gear
7. Side shift frame

102 7 Load handling – 7.6.6 Rotation motor unit
7.6.6 Rotation motor unit

Rotation motor unit, description
page
–
The rotation motors rotate the attachment in relation to the boom. The
motors are located along the front pf the attachment’s rotation yoke.
The motors work against the ring gear between the rotation yoke and
the side shift frame. The rotation motor unit consists of hydraulic mo-
tor, disc brake and planetary gear which are built together into one
unit.
The hydraulic motor is located on the disc brake housing. Between the
motor and the discs is a gear wheel.
The disc brake prevents accidental rotation. The disc brake is applied
1 with springs and is disengaged when the hydraulic pressure is built up
1
to rotate the yoke.
2
2 The planetary gear reinforces the output in the motor and disc brake.
3 The planetary gear changes the motor speed down so that motor pow-
3
er is greater.
4 4
6 5
7
000530

2. Disc brake
3. Planetary gear
4. Gear wheel
5. Rotation yoke
6. Ring gear
7. Side shift frame

7 Load handling – 7.6.6 Rotation motor unit 103
Rotation motor unit, replacement

page
–
NOTE
B Safety.
B Safety.
3 Mark up and detach the hydraulic hoses from the motor.
NOTE
4 Remove the hydraulic motor’s attaching bolts.
5 Lift away the rotation motor unit. Position the motor unit so that
the pinion and planetary gear are not damaged.
6 Clean the contact surfaces on the motor unit and rotation yoke.
7 Lift the new motor unit into place.
8 Fit the motor unit. Tighten the bolts crosswise in steps until
117 Nm is achieved.

104 7 Load handling – 7.6.6 Rotation motor unit
9 Connect the hydraulic hoses to the motor and brake in accord-

NOTE
NOTE
C AUTION

010475

13 Check that the hydraulic connections are sealed tightly.
14 Check that the rotation is working.

7 Load handling – 7.6.7 Rotation yoke 105
C AUTION

7.6.7 Rotation yoke

Rotation yoke, description
page
–
The rotation yoke is a part of the attachment which connects the at-
1 2 3 4 5 6 tachment to the boom. The rotation yoke is secured on the inner boom
with two shafts which run in bearing equipped attaching lugs. In the
bottom of the rotation yoke is the ring gear with lead-through bolts.
Using the rotation motors which act on the ring gear the remaining
parts of the attachment can be rotated in relation to the lift boom.
The rotation yoke’s mounting in the lift boom facilitates longitudinal
motion (so-called tilt). The oscillating motion is dampened by two hy-
draulic cylinders which are secured between the upper yoke and the
upper edge on the inner boom.
000526
1. Main beam
2. Ring gear
4. Rotation yoke
6. Side shift frame

106 7 Load handling – 7.6.7 Rotation yoke
Rotation yoke, replacement

page
–
1 Clean the attachment and boom nose.

2 Release the attachment from the boom.
3 Remove the rotation motors from the rotation yoke.
4 Fit the lifting equipment on the rotation yoke.
5 Remove the pipes for ring gear lubrication.
The illustration shows removed rotation yoke and ring

gear.
6 Remove the rotation yoke 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 shafts
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 lu-
brication lines can be fitted.
13 Grease the rotation yoke’s mounting shafts with lubricating
grease and fit them in the rotation yoke.

7 Load handling – 7.6.7 Rotation yoke 107
14 Tighten the rotation yoke’s attaching bolts to a torque of 331 Nm.
15 Fit the pipes for the ring gear lubrication lines.

16 Lubricate the ring gear with lubricating grease.
Rotate the yoke during lubrication it so that the grease is distrib-
uted evenly.
17 Rotate the yoke so that it is straight.
18 Fit the rotation motors. See Rotation yoke, description page 105.
NOTE
If necessary, rotate the rotation yoke so that the rotation mo-
tor’s gear wheel aligns against the ring gear.
19 Connect the attachment to the boom.
20 Start the motor and check that the rotation is working.
21 Clean the attachment.
completely down and the extension cylinder completely in. The
oil level should be in the top of the level glass. Top up as needed.
C AUTION
Overfilling of oil.
Leakage and environmental damage.


108 7 Load handling – 7.6.8 Ring gear
7.6.8 Ring gear

Ring gear, description
page
–
The ring gear is the joint between the rotation yoke and the side shift
frame. The ring gear consists of gear wheel, bearings and mounting
parts. The unit is bolted into the rotation yoke and side shift frame.
1
1
2
2
3 3
4 4
6 5
7
000530

2. Disc brake
3. Planetary gear
4. Gear wheel
5. Rotation yoke
6. Ring gear
7. Side shift frame

Ring gear, replacement

page
–
1 Remove the rotation yoke, see Rotation yoke, replacement page

106.
2 Remove the lubricating pipes from the ring gear.
NOTE
Note down the locations of the lubricating pipes to facilitate
fitting.
The illustration shows removed rotation yoke and ring 3 Remove the attaching bolts between the ring gear and the side
gear. shift frame.
4 Lift away the ring gear.
5 Clean the contact surfaces on the side shift frame and ring gear.
6 Lift the new ring gear into place.
NOTE
Rotate it so that the connections for the lubricating pipes are
in the same positions as before.
7 Lubricate the inner attaching bolts with lubricating grease and fit
them. Tighten the bolts crosswise in turns to a torque of 331 Nm.
8 Fit the rotation yoke, see Rotation yoke, replacement page 106.
9 Fit the lubricating pipes to the ring gear.
10 Lubricate the ring gear with lubricating grease.
11 Start the motor and check the function of the rotation.
The illustration shows removed rotation yoke and ring

gear.
completely down and the extension cylinder completely in. The
oil level should be in the top of the level glass. Top up as needed.
C AUTION
Overfilling of oil.
Leakage and environmental damage.


page
–
See Side shift frame, description page 65.

110 7 Load handling – 7.6.10 Sensor, rotation stop
7.6.10 Sensor, rotation stop

Sensor rotation stop, description
page
–
Sensor rotation stop (B7225) indicates when rotation is 25° from the
centre position and is used to activate rotation stop. The sensor is lo-
cated on a bracket on the left side of the rotation yoke and detects 25°
towards the rotation yoke’s mechanical stop.
The sensors are supplied with voltage and send 24 V signal to the at-
tachment control unit (D791-1) when the raised parts pass the sensor.

page
–

page
–

page
–

7 Load handling – 7.7 Tilt 111
7.7 Tilt
Tilt damping, function description
page
–
2
C1-
A C2+
C
B C1+
C2- 3
1
000461
1 Hydraulic oil pump 2 pumps oil. See pressure plate on Section 10 Common hydraulics, group
left frame beam. 10.4.2 Axial piston pump with variable dis-
placement
2 The tilt damping block distributes oil to the - Damping block tilt, description page 117
tilt cylinders.
3 The tilt cylinders suppress the attachment’s - Tilt cylinder, description page 121
movements.

112 7 Load handling – 7.7 Tilt
Tilt locking, function description

page
–
1 D1
2 11
D790-1 D795
D797-R D791-1
3 7
D3 8 D7
C1-
A C2+
10
4
B C1+
C2-
5 9
C6
6
006412
1 The control lever (S815-T3.1) sends a US815-T3.1 = 24 V Section 9 Frame, body, cab and accessories,
voltage signal to the cab control unit group 9.1 Controls and instruments
(D790-1). D1: Diagnostic menu, see section 8 Control
2 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group 11.5.3.1
tilt locking on the CAN bus. tem, error shown with Cab control unit
error code.
3 Control unit, frame rear (D797-R) acti- U = 24 V Valve block, top lift hydraulics, description
vates the solenoid valve, engagement of page 58
hydraulics for top lift (Y6003). D3: Diagnostic menu, see section 8 Control
4 Solenoid valve, engagement of hydrau- - Valve block, top lift hydraulics, description
lics for top lift (Y6003) opens and pres- page 58
surises valve block lift cylinder and D3: Diagnostic menu, see section 8 Control
sends a load signal to the hydraulic oil system, group 8.4.5.6 HYD, menu 6
pumps.
5 The shuttle valve forwards the strongest - Section 10 Common hydraulics, group 10.5.3
load signal to the hydraulic oil pumps if Shuttle valve
several functions are activated simulta-
neously.


6 Hydraulic oil pump 2 pumps oil from the See pressure plate on Section 10 Common hydraulics, group 10.4.2
hydraulic oil tank. left frame beam. Axial piston pump with variable displacement
7 The attachment control unit (D791-1) ac- Float position: U = 24 V Section 11 Common electrics, group 11.5.3.5
tivates the servo valve, tilt lock (Y6012). Lock position: U = 0 V Control unit, attachment
8 Servo valve, tilt lock (Y6012) pressuris- - Lock valve tilt, description page 119
es the lock valve in the attachment con- D7: Diagnostic menu, see section 8 Control
trol valve. system, group 8.4.9.15 ATTACH, menu 15
9 The lock valve changes position and - Lock valve tilt, description page 119
blocks the connections to the tilt cylin-
ders.
10 The tilt cylinders lock the attachment’s - Tilt cylinder, description page 121
inclination.
11 When tilt locking is activated, the KID - Section 11 Common electrics, group
control unit (D795) shows the tilt locking 11.5.3.12 KID control unit
event menu.
When tilt locking is activated, the ma-
chine’s speed is limited to max. 5 km/h.

levelling

114 7 Load handling – 7.7 Tilt
Tilt control, function description

page
–

value
D1
1
2
D790-1
D797-F D791-2 D791-1

3 7 10
D7
D3
8 11 D10
C6
C1-
P1 A A C2+
13
4
T1 B B C1+
C2-
C6 9 12
5
6
013027
1 Control lever (S815-P4) sends the Tilt out: US815/P4 = 0.5–2.0 V Section 9 Frame, body, cab and accessories,
cab control unit (D790-1) a voltage group 9.1 Controls and instruments
signal proportional to lever move- D1: Diagnostic menu, see section 8 Control
2.0-3.0 V
ment. system, group 8.4.9.1 ATTACH, menu 1
Tilt in: US815/P4 = 3.0–4.5 V
2 The cab control unit (D790-1) Checked by control system, Section 11 Common electrics, group 11.5.3.1
transmits tilt in or tilt out on the error shown with error code. Cab control unit
CAN bus.
3 Control unit, frame rear (D797-R) U = 24 V Section 11 Common electrics, group 11.5.3.3
activates the solenoid valve, en- Control unit, frame rear
gagement of hydraulics for top lift D3: Diagnostic menu, see section 8 Control
(Y6003). system, group 8.4.5.6 HYD, menu 6


4 Solenoid valve, engagement of - Valve block, top lift hydraulics, description
hydraulics for top lift (Y6003) page 58
opens and pressurises valve block D3: Diagnostic menu, see section 8 Control
lift cylinder and sends a load sig- system, group 8.4.5.6 HYD, menu 6
nal to the hydraulic oil pumps.
5 The shuttle valve forwards the - Section 10 Common hydraulics, group 10.5.3
strongest load signal to the hy- Shuttle valve
draulic oil pumps if several func-
tions are activated simultaneously.
6 Hydraulic oil pump 2 pumps oil See pressure plate on left Section 10 Common hydraulics, group 10.4.2
from the hydraulic oil tank. frame beam. Axial piston pump with variable displacement
7 The attachment control unit option I = 400–650 mA Section 11 Common electrics, group 11.5.3.6
(D791-2) activates servo valve, tilt Control unit, attachment option or section 11
out (6010) or servo valve, tilt in Common electrics, group 11.5.3.8 Control
(Y6011). unit, attachment right jack pair
Machine with lifting jacks
The attachment control unit right and 8.4.9.17 ATTACH, menu 17
jack pair (D791-4) activates servo
valve, tilt out (6010) or servo
valve, tilt in (Y6011).
8 The servo valve for tilt out (Y6010) - Attachment control valve, description page
or tilt in (Y6011) pressurises the tilt 120
slide in the attachment’s control D7: Diagnostic menu, see section 8 Control
valve. system, group 8.4.9.16 ATTACH, menu 16
9 The control valve’s tilt slide chang- - Attachment control valve, description page
es position and pressurises the 120
damping block.
10 The attachment control unit Float position: U = 24 V Section 11 Common electrics, group 11.5.3.5
(D791-1) activates the servo Lock position: U = 0 V Control unit, attachment
valve, tilt lock (Y6012). D10: Diagnostic menu, see section 8 Control
11 Servo valve, tilt lock (Y6012) pres- - Lock valve tilt, description page 119
surises the lock valve in the at- D10: Diagnostic menu, see section 8 Control
tachment control valve. system, group 8.4.9.15 ATTACH, menu 15
12 The lock valve changes position - Damping block tilt, description page 117
and directs oil crosswise to the tilt
cylinders.
13 The tilt cylinders change the at- - Tilt cylinder, description page 121
tachment’s inclination.


levelling
Tilt damping, adjustment

page
–
NOTE
B Safety.
NOTE
Tilt damping may need to be adjusted after running-in due to me-
chanical tolerances.
1 Engine at idling speed.
2 Raise the boom without a load and check that the attachment is
suspended horizontally throughout the lifting movement.
3 Adjust tilt damping as required by adjusting the screws on the
damping block. Adjust both screws by the same amount.
1 Clockwise: increase damping.
Anticlockwise: decrease damping.
4 Lift a loaded container, test drive, and brake, check that the con-
tainer does not swing uncontrollably. If necessary, adjust the
damping in accordance with Step 3.
5 Start the machine and check that the function is working
satisfactorily.
005350
1. Adjusting screws

page
–


page
–

7 Load handling – 7.7.3 Damping block, tilt 117
7.7.3 Damping block, tilt

Damping block tilt, description
page
–
The damping block contains restrictions which create resistance to the

1
tilt cylinder’s movements, which in turn dampen the attachment’s os-
cillations. The damping block is located in the centre of the boom nose.
The damping block is supplied with oil via the return from the attach-
ment’s control valve. The feed means that the cylinders are always
filled with oil. Precisely adjusted restrictions mean that the feed does
2 2
not affect the tilting. The constant feed means that the tilt cylinders do
not need bleeding after work on tilting.
The damping block contains two shock valves which protect the valve
000535
against surges.
1. Damping block
2. Tilt cylinder
Damping block tilt, replacement

page
–
NOTE
B Safety.
B Safety.
3 Mark up and detach the hydraulic hoses from the valve block.
NOTE
4 Remove the valve block from the boom.

118 7 Load handling – 7.7.3 Damping block, tilt
5 Transfer the connection adapters to the new valve. Transfer one

adapter at a time so that the marking is not mixed up.
NOTE
6 Fit a new valve block to the boom nose.
The illustration shows the damping block with control-

lable tilt.
7 Connect the hydraulic hoses to the damping block in accordance
with the marking.
NOTE
NOTE
C AUTION

010475

7 Load handling – 7.7.4 Lock valve, tilt 119
10 Start the machine and check seal integrity and function.

Check both tilt and attachment functions.
C AUTION

7.7.4 Lock valve, tilt

Lock valve tilt, description
page
–
On machines with tilt lock, there are two solenoid valves on the damp-
ing block’s return lines. When the solenoid valves are activated the
connection between the cylinders is blocked and locks the tilt position.
The lock valves are located on the damping block.
Solenoid valve tilt (Y6012) is supplied with voltage by Control unit, at-
tachment option (D791-2) when tilt lock is not activated.


page
–
Controllable tilt is regulated by a separate section in the attachment’s

control valve. For a general description of the valve and component lo-
cations, see Attachment control valve, description page 59.
Tilt slide
The valve slide controls the direction and speed of attachment tilting.
The valve slide is controlled by servo valve, tilt in and servo valve, tilt
out.
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.
The servo valve tilt out is controlled electrically by the solenoid valve
for tilt out (Y6010), which is activated by Control unit, attachment op-
tion (D791-2). The servo valve directs servo pressure to the tilt slide in
proportion to the control current to the solenoid valve.
Servo valve, tilt in

Servo valve tilt in controls pressure to the tilt slide so that the tilt slide
opens and pressurises the tilt cylinders.
The servo valve tilt in is controlled electrically by the solenoid valve for
tilt in (Y6011), which is activated by Control unit, attachment option
(D791-2). The servo valve directs servo pressure to the tilt slide in pro-
portion to the control current to the solenoid valve.
The signal can be checked from the diagnostic menu; see section

page
–
7.7.6 Shuttle valve

page
–

7 Load handling – 7.7.7 Tilt cylinder 121
7.7.7 Tilt cylinder

Tilt cylinder, description
page
–
The tilt cylinders are located between the inner boom’s front edge and
1
the rotation yoke’s upper section. The two cylinders are positioned di-
agonally and can therefore effectively dampen or control tilt motion.
The piston rod bracket is welded to the piston rod, which is threaded
in the piston head and locked with a lock screw. The cylinder head is
threaded in the cylinder pipe.
2 2
000535
1. Damping block
2. Tilt cylinder

page
–
7.7.8 Lift boom

Lift boom, general
page
–
See Lift boom, description page 35.
7.7.9 Rotation yoke

Rotation yoke, general
page
–
See group 7.6.7 Rotation yoke.

page
–

page
–

122 7 Load handling – 7.8 Levelling
7.8 Levelling
Hydraulic levelling, function description
page
–

value
D1
1
2
+ D790-1
D791-2
D797-R D791-3
3 7 9
D8
D9
D4
10 8
C6 14
P1 A
4 T1 B
11 12 13
5
C6
6
006888

1 Control lever (S815-P3) transmits a volt- Levelling right: US815/P3 Section 9 Frame, body, cab and accessories,
age signal proportional to lever move- = 0.5–2.0 V group 9.1 Controls and instruments
ment while control lever S815-T4 sends D1: Diagnostic menu, see section 8 Control
Zero position: US815/P3
voltage to the cab control unit (D790-1). system, group 8.4.9.1 ATTACH, menu 1
= 2.0–3.0 V
Levelling left: US815/P3
= 3.0–4.5 V
US815/T4 = 24 V

7 Load handling – 7.8 Levelling 123

2 The cab control unit (D790-1) transmits Checked by control Section 11 Common electrics, group 11.5.3.1
levelling left or right on the CAN bus. system, error shown Cab control unit
with error code.
vates the solenoid valve, engagement Control unit, frame rear
lics for top lift (Y6003) opens the con- page 58
nection between the pumps and the D4: Diagnostic menu, see section 8 Control
attachment’s control valve. system, group 8.4.5.6 HYD, menu 6
neously.
7 Control unit, attachment option U = 24 V Section 11 Common electrics, group 11.5.3.6

(D791-2) or activates solenoid valve, Control unit, attachment option or section 11
levelling (Y6034). Common electrics, group 11.5.3.7 Control
unit, attachment left jack pair
Machine with combi attachment
Control unit, attachment left jack pair system, group 8.4.9.18 ATTACH, menu 18
(D791-3) activates solenoid valve, level-
ling (Y6034).
8 The levelling control valve opens a con- - Levelling cylinders’ valve block, description
nection to the levelling cylinders in the page 128
levelling cylinders’ valve block.
9 Control unit, attachment option I = 400–650 mA Section 11 Common electrics, group 11.5.3.6
(D791-2) or control unit attachment, left Control unit, attachment option or section 11
jack pair (D791-3) activates servo valve, Common electrics, group 11.5.3.7 Control
levelling right (Y6035) or servo valve unit, attachment left jack pair
levelling left (Y6036). D9: Diagnostic menu, see section 8 Control
10 The servo valve for levelling right - Attachment control valve, description page
(Y6035) or levelling left (Y6036) is actu- 127
ates the levelling slide in the attachment D9: Diagnostic menu, see section 8 Control
control valve. system, group 8.4.9.19 ATTACH, menu 19
11 The control valve’s levelling slide - Attachment control valve, description page
changes position and pressurises the 127
levelling overcentre valve.

124 7 Load handling – 7.8 Levelling

12 The overcentre valve opens and directs - Overcentre valve, levelling, description page
pressure to the levelling cylinders’ valve 128
block.
13 The levelling cylinders’ valve block di- - Levelling cylinders’ valve block, description
rects pressure on to the levelling cylin- page 128
ders.
14 The levelling cylinders lock the attach- - Levelling cylinders, description page 129
ment’s inclination.

levelling

7 Load handling – 7.8 Levelling 125
Levelling lock, function description

page
–

value
D1
1 2 10
D790-1 D795
D791-2
D797-F
3 D791-3 7 D8
D4
8
C6
P1 A
9
4 T1 B
5
C6
Pos Explanation Signal description Reference 006889
1 The control lever (S815-T3.1) sends a US815-T3.1 = 24 V Section 9 Frame, body, cab and accessories,
levelling lock on the CAN bus. tem, error shown with Cab control unit
error code.
3 Control unit, frame rear (D797-R) acti- U = 24 V Valve block, top lift hydraulics, description
vates the solenoid valve, engagement of page 58


lics for top lift (Y6003) opens the connec- page 58
tion between the pumps and the D4: Diagnostic menu, see section 8 Control
attachment’s control valve. system, group 8.4.5.6 HYD, menu 6
neously.
6 The hydraulic oil pumps pump oil from See pressure plate on Section 10 Common hydraulics, group 10.4.2
the hydraulic oil tank. left frame beam. Axial piston pump with variable displacement
7 Control unit, attachment option (D791-2) U=0V Levelling cylinders’ valve block, description
stops activation solenoid valve, levelling page 128
(Y6034). D8: Diagnostic menu, see section 8 Control
Machine with combi attachment.
Control unit, attachment left jack pair
(D791-3) stops activation solenoid
valve, levelling (Y6034).
8 The levelling control valve (Y6034) - Levelling cylinders’ valve block, description
blocks the connections to the levelling page 128
cylinders in the levelling cylinders’ valve D8: Diagnostic menu, see section 8 Control
block. system, group 8.4.9.18 ATTACH, menu 18
9 The levelling cylinders change the at- - Levelling cylinders, description page 129
tachment’s inclination.
10 When tilt lock is activated, event menu - Section 11 Common electrics, group
shows tilt lock. 11.5.3.12 KID control unit
When levelling lock is activated, the ma-
chine’s speed is limited to max. 5 km/h.

levelling

page
–


page
–


page
–
Hydraulic levelling is regulated by a separate section in the attachment

Levelling slide
The valve slide controls the direction and speed of attachment level-
ling.
The valve slide is controlled by the servo valve for levelling right
(Y6035) and levelling left (Y6034).
Servo valve, levelling right

The servo valve for levelling right controls pressure to the levelling
slide so that it opens and pressurises the levelling cylinders.
The servo valve levelling right is controlled electrically by the solenoid
valve for levelling right (Y6035), which is activated by Control unit, at-
tachment option (D791-2). The servo valve directs servo pressure to
the tilt slide in proportion to the control current to the solenoid valve.
Servo valve, levelling left

The servo valve for levelling left controls pressure to the levelling slide
so that it opens and pressurises the levelling cylinders.
The servo valve levelling left is controlled electrically by the solenoid
valve for levelling left (Y6036), which is activated by Control unit, at-
tachment (D791-2). The servo valve directs servo pressure to the tilt
Passive levelling
The servo valves open a connection to the tank, in addition, hydraulic
oil can flow between right and left-hand side levelling cylinders, from
piston sides to rod sides, in accordance with inclination.
Active levelling
Levelling is monitored by the sequence valves in the valve block lev-
elling cylinder, which close when the feed pressure is high enough to
set all cylinders in bottom position. Following which, hydraulic oil is fed
to the rod sides on one side’s cylinders and the side lifts. When level-
ling, the other side will thus always be in its lowest position. This al-
ways gives maximal levelling travel.

page
–

7.8.4 Shuttle valve

page
–
7.8.5 Overcentre valve, levelling

Overcentre valve, levelling, description
page
–
The overcentre valve ensures that the levelling cylinders are com-
pletely extended. The valve is located to the right of the attachment
control valve on the rear edge of the side shift frame under the levelling
cylinders’ valve block.
Passive levelling
The over-centre valves allow flow of hydraulic oil between right and left
levelling cylinders, from piston sides to rod sides, in accordance with
inclination.
Active levelling
The over-centre valves close when the feed pressure is high enough
to put all levelling cylinders in bottom position. Then, hydraulic oil is
supplied through the levelling cylinder valve block to the rod sides on
one side’s (right or left) cylinders and the side lifts. When levelling, the
other side will thus always be in its lowest position. This always gives
maximal levelling travel.
001062
7.8.6 Valve block, levelling cylinders

Levelling cylinders’ valve block, description
page
–
The levelling cylinders’ valve block directs pressure from the attach-
ment control valve to the levelling cylinders. The valve block compris-
es lock valves that block the levelling when the levelling lock is
activated or if the machine is without power. The valve sits to the right
of the attachment control valve on the rear edge of the side shift frame
above the overcentre valve for levelling.
Lock valve
The lock valve is opened by Solenoid valve levelling (Y6034). When
the lock valve is closed the oil is blocked to and from the levelling cyl-
inders, and levelling is blocked. Solenoid valve levelling (Y6034) is
supplied with voltage by Control unit, attachment option (D791-2) or
Control unit, attachment right jack pair (D791-4).
001061

7 Load handling – 7.8.7 Levelling cylinders 129
7.8.7 Levelling cylinders

Levelling cylinders, description
page
–
On machines with hydraulic levelling there are four hydraulic cylinders

between the sideshift frame’s parts, see Side shift frame, description
page 129.
001860

page
–

page
–
The sideshift frame is available in two different versions, see Side shift
1 2 3 4
frame, description page 65.
Mechanical levelling
The sideshift frame is larger than the attachment’s main beam. The
main beam can move freely between the slide plates. This allows ap-
prox. 5° levelling.
001932
5 Hydraulic levelling
1. Main beam, attachment The sideshift frame is split in two. There are four levelling cylinders be-
2. Side shift frame upper section tween the two sections, see Levelling cylinders, description page 129.
3. Levelling cylinder The outer section is secured in the rotation yoke via the ring gear. The
4. Side shift frame lower section inner part holds the attachment’s main beam. The main beam slides
5. Side shift cylinder on slide plates. The hydraulic cylinders’ stroke makes levelling of the
main beam possible, approx. 5°. With hydraulically controlled levelling,
the angle of the main beam attachment can be controlled with the con-
trol lever.

page
–

page
–

130 7 Load handling – 7.9 Load carrier
7.9 Load carrier

7.9.1 Twistlocks
Twistlocks, function description
page
–

Safety switch Disengaged Section 11 Common electrics, group 11.5.1.4 Emergency stop switch volt-
age
Contact Full contact or bypass Section 9 Frame, body, cab and accessories, group 9.1 Controls and in-
activated struments
Section 8 Control system, group 8.2.2 Bypassing
D1
2 1
D18
8 7, 20
5, 21
D790-1 D790-2 D795
D2
D797-R D791-1
4, 6, 13,18, 19
9
D13
D8 D3
14 3
17
C12
D17
P1 A
10 16
T1 B
C12 15
11
12
006890

1 The switch for locking the twistlocks U = 24 V Section 9 Frame, body, cab and accessories,
(S1003) (automatic mode) sends a volt- group 9.1 Controls and instruments
age signal to the cab control unit (D790- D1: Diagnostic menu, see section 8 Control
1). system, group 8.4.9.3 ATTACH, menu 3

7 Load handling – 7.9.1 Twistlocks 131

2 The control lever (S815-T2) sends a US815/T2 = 24 V Section 9 Frame, body, cab and accessories,
(D790-1) for opening twistlocks. D2: Diagnostic menu, see section 8 Control
If Switch, lock twistlocks (S1003) is in system , group 8.4.9.3 ATTACH, menu 3
manual position no signal is needed
from the control lever to open twistlock.
3 The sensor for front left alignment Sensor directly opposite Sensor alignment, description page 140
(7202L), sensor for front right alignment indicator plate: U = 24 V D3: Diagnostic menu, see section 8 Control
(7202R), sensor for rear left alignment system, group 8.4.9.6 ATTACH, menu 6
(Y7203L) and sensor for rear right align-
ment (Y7203R) send a voltage signal to
the attachment control unit (D791).
4 The attachment control unit (D791) Checked by control sys- Section 11 Common electrics, group 11.5.3.5
transmits alignment on the CAN bus. tem, error shown with Control unit, attachment
error code.
5 The KID control unit (D795) activates - Section 11 Common electrics, group
the alignment event menu. 11.5.3.12 KID control unit
6 The attachment control module (D791) U = 24 V D18: Diagnostic menu, see section 8 Control
activates the alignment indicator light on system group 8.4.9.10 ATTACH, menu 10
the boom’s light panel.
7 The KIT control module (D790-2) acti- - Section 11 Common electrics, group
vates the alignment indicator light on the 11.5.3.11 Control unit KIT
cab light panel.
"open twistlocks" or "lock twistlocks" on tem, error shown with Cab control unit
vates the solenoid valve, engagement of Control unit, frame rear
sends a load signal to hydraulic oil system , group 8.4.5.6 HYD, menu 6
pump 2.
neously.

132 7 Load handling – 7.9.1 Twistlocks

13 The attachment control unit (D791) acti- U = 24 V Section 11 Common electrics, group 11.5.3.5
vates the "open twistlocks" servo valve Control unit, attachment
(Y6039) or "lock twistlocks" servo valve D12: Diagnostic menu, see section 8 Control
(Y6040). system, group 8.4.9.9 ATTACH, menu 9
14 The "open twistlocks" servo valve - Attachment control valve, description page
(Y6039) or "lock twistlocks" servo valve 135
(Y6040) pressurises the twistlocks slide D12: Diagnostic menu, see section 8 Control
with servo pressure. system, group 8.4.9.9 ATTACH, menu 9
15 The control valve’s twistlocks slide - Attachment control valve, description page
changes position and pressurises the 135
locks cylinders.
16 The lock cylinders rotate the twistlocks. - Lock cylinder, description page 136
17 The "unlocked twistlocks" sensor Sensor directly opposite Sensor twistlocks, description page 141
(B7204) or the "locked twistlocks" sen- indicator plate: U = 24 V D16: Diagnostic menu, see section 8 Control
sor (B7205) sends a signal to the attach- system, group 8.4.9.7 ATTACH, menu 7
ment control unit (D791).
18 The attachment control unit (D791) sup- U = 24 V D18: Diagnostic menu, see section 8 Control
plies voltage to the "unlocked twistlocks" system group 8.4.9.10 ATTACH, menu 10
indicator light (H562) or the "locked
twistlocks" indicator light (H563) on the
boom’s light panel.
19 The attachment control unit (D791) Checked by control sys- Section 11 Common electrics, group 11.5.3.5
transmits "twistlocks unlocked" or "twist- tem, error shown with Control unit, attachment
locks locked" on the CAN bus. error code.
20 The KIT control unit (D790-2) supplies - Section 11 Common electrics, group
voltage to the "unlocked twistlocks" indi- 11.5.3.11 Control unit KIT
cator light or the "locked twistlocks" indi-
cator light on the cab light panel.
the twistlocks event menu. 11.5.3.12 KID control unit

levelling

7 Load handling – 7.9.1 Twistlocks 133
Overheight jacks, function description

page
–

value
Safety switch Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage
Overload system Passive Section 8 Control system, group 8.2.1.1 Mechanical overload system
Twistlocks Open Twistlocks, function description page 130
13
1
2
D790-1
D797-R D791-2 7
3
8 12
D3
C6
P1
A
4 B 11
T1
10
9
C6 5
6
008218

1. The overheight jacks switch (S1031) sends U = 24 V Section 9 Frame, body, cab and accesso-
a voltage signal to the cab control unit ries, group 9.1 Controls and instruments
(D790-1).
2. Control unit cab (D790-1) sends a message Checked by control Section 11 Common electrics, group
to lower overheight jacks on the CAN bus. system, error shown 11.5.3.1 Cab control unit
with error code.
3. Control unit, frame rear (D797-R) activates U = 24 V Valve block, top lift hydraulics, description
the solenoid valve, engagement of hydrau- page 58
lics for top lift (Y6003). D3: Diagnostic menu, see section 8 Con-
trol system, group 8.4.5.6 HYD, menu 6

134 7 Load handling – 7.9.1.1 Hydraulic oil pump

4. Solenoid valve, engagement of hydraulics - Valve block, top lift hydraulics, description
for top lift (Y6003) opens and pressurises page 58
valve block top lift hydraulics and sends a
load signal to hydraulic oil pump 2.
5. The shuttle valve forwards the strongest - Section 10 Common hydraulics, group
load signal to the hydraulic oil pump 2 if sev- 10.5.3 Shuttle valve
eral functions are activated simultaneously.
6. Hydraulic oil pump 2 pumps oil from the hy- See pressure plate on Section 10 Common hydraulics, group
draulic oil tank. left frame beam. 10.4.2 Axial piston pump with variable dis-
placement
7. Control unit, attachment option (D791-2) ac- U = 24 V Attachment control valve, description page
tivates the servo valve overheight jacks up 135
(Y6070) or servo valve overheight jacks
down (Y6071).
8. Servo valve overheight jacks up (Y6070) or U = 24 V Attachment control valve, description page
servo valve overheight jack down (Y6071) 135
pressurises the overcentre valve for over-
height jacks.
9. Overcentre valve opens and pressurises hy- - Overcentre valve (product alternative over-
draulic cylinder overheight jacks. height jacks) page 142
10. Hydraulic cylinder overheight jacks lowers - Hydraulic cylinder, overheight jacks page
the overheight jacks. 142
11. Sensor overheight jacks up left (B7231-L) or Sensor directly oppo- Sensor, overheight-jacks page 143
sensor overheight jacks up right (B7231-R) site indicator plate: U =
sends a voltage signal to Control unit, at- 24 V
tachment option (D791-2).
12. Control unit, attachment option (D791-2) ac- Overheight jacks up: U Section 11 Common electrics, group
tivates the indicator lamp for overheight = 24 V 11.5.3.6 Control unit, attachment option
jacks up (H5001). Overheight jacks
down: U = 0 V
13 Indicator light, overheight jacks up (H5001) Overheight jacks up: U Section 9 Frame, body, cab and accesso-
illuminates when the jacks are completely = 24 V ries, group 9.1 Controls and instruments
raised. Overheight jacks
down: U = 0 V
7.9.1.1 Hydraulic oil pump

page
–

7.9.1.2 Valve block, top lift hydraulics

page
–

7 Load handling – 7.9.1.3 Control valve attachment 135
7.9.1.3 Control valve attachment

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

Twistlocks slide, description

The valve slide controls the direction and the lock cylinder.
The valve slide is controlled by two servo valves, lock twistlocks and
open twistlocks.
"Lock twistlocks" servo valve, description

The "lock twistlocks" servo valve directs pressure to the twistlocks
slide so that the slide opens and pressurises the lock cylinders.
The servo valve lock twistlocks is controlled electrically by the solenoid
valve for lock twistlocks (Y6040), which is activated by Control unit, at-
tachment (D791-1). The servo valve directs servo pressure to the
twistlocks slide in proportion to the control current to the solenoid
valve.
"Open twistlocks" servo valve, description

The "open twistlocks" servo valve directs pressure to the twistlocks
slide so that the slide opens and pressurises the lock cylinders.
The servo valve open twistlocks is controlled electrically by the sole-
noid valve for open twistlocks (Y6041), which is activated by Control
unit, attachment (D791-1). The servo valve directs servo pressure to
the twistlocks slide in proportion to the control current to the solenoid
valve.

page
–
7.9.1.4 Shuttle valve

page
–

136 7 Load handling – 7.9.1.5 Lock cylinder
7.9.1.5 Lock cylinder

Lock cylinder, description
page
–
The lock cylinder pulls the lock mechanism so that the twistlocks are
rotated. Two lock cylinders - one in the right and one in the left spread-
er beam - pull the lock mechanism. The lock cylinders are located in
the centre of the spreader beam’s longitudinal section.
000539

page
–
7.9.1.6 Lock mechanism

Lock mechanism, description
page
–
The lock mechanism transfers the force of the lock cylinders to the
twistlocks. Two lock mechanisms - one in the right and one in the left
spreader beam - actuate the twistlocks. The lock mechanism runs
along the longitudinal section of the spreader beam between the twist-
locks.
The lock mechanism consists of a rod with two spherical plain bear-
ings in the end. The rod is fastened in levers that rotate the twistlocks.
A retaining lug for the lock cylinder sits in the centre of the rod.
001863

7 Load handling – 7.9.1.7 Twistlocks 137
7.9.1.7 Twistlocks
Twistlocks, description
page
–
1
WARN IN G
Dropped load.
2 Fatal danger!
Twistlocks hold the load during load handling and
5 therefore it is very important that twistlocks are
checked according to instructions and are replaced at
the slightest sign of damage or wear.
4 3 Twistlocks secure the load and are located in the corners of the
spreader beam’s longitudinal part.
Twistlocks are manufactured from high-strength steel according to in-
ternational standards. The lift pins are marked with serial numbers.
Twistlocks are connected in pairs via a linkage system to a hydraulic
cylinder which in turn is controlled via a section in the attachment’s
control valve. Inductive sensors send signals when the twistlocks are
000536
locked and unlocked, respectively.
1. Lock mechanism
2. Sensor alignment
3. Contact pin
4. Lift pin
5. Lock guide

138 7 Load handling – 7.9.1.7 Twistlocks
Twistlock, replacement
page
–

2 Depressurise the brake and hydraulic systems, see section B
Safety.
3 Clean the twistlocks and the surrounding area.
4 Detach the centre nut of the twistlocks.
5 Tap on the nut so that the lift pin releases from the wedge.
6 Hold the lift pin while removing the centre nut.
WARN IN G
Dropped component.
Risk of pinch injury or product damage.
Twistlock weighs approx. 30 kg.
7 Remove the centre nut and lift away the twistlock.

8 Coat a new lift pin with grease and position it in the guide pin.
9 Place the lift pin and guide pin in the extension beam. Place the
guide pin so that the grease cup is accessible through the holes
in the extension beam.
NOTE
Do not forget the washer between the extension beam and
guide pin.
10 Position the wedge, bearing, lever, new locking washers and

new lock nuts on the lock pin.
Apply lubricating grease to the parts before fitting.
11 Check the positions of the parts and that the twistlock can move.
12 Tighten the lock nut to a torque of 300 Nm.
13 Lubricate the guide pin, lever and bearing arrangement with lubri-
cating grease.
14 Check that the twistlock mechanism can move.
15 Turn on the main electric power and start the machine.
16 Check that the twistlock is working.

7 Load handling – 7.9.1.7 Twistlocks 139
Twistlock, replacement (product alternative Collet type)

page
–
1 Machine in service position, see section B Safety in the Work-

shop Manual.
2 Depressurise the hydraulic systems, See section B Safety in the
Workshop Manual.
3 Clean the twistlocks and the surrounding area.
4 Slacken the screws of the clamp holding the twistlocks in place.
5 Hold the twistlock while removing the clamp halves.
WARN IN G
Dropped component.
Risk of pinch injury or product damage.
Twistlock weighs approx. 30 kg.

009958
6 Remove the clamp halves and lift away the twistlock.

7 Fit a new twistlock and secure it with the clamp halves.
NOTE
Remember the washer.
8 Check the positions of the parts and that the twistlock can move.
9 Tighten the screws of the clamp halves.
10 Lubricate the twistlock and lock mechanism with lubricating
grease.
11 Check that the twistlock mechanism can move.
12 Turn on the main electric power and start the machine.
13 Check that the twistlock is working.
009958

140 7 Load handling – 7.9.1.8 Sensor alignment
7.9.1.8 Sensor alignment

Sensor alignment, description
page
–
The alignment sensors detect when the attachment has contact with
the container. Four inductive sensors - one at each twistlock at the far
corner of the longitudinal section of the spreader beam - are used to
indicate alignment.
The sensor senses the position of a spring pin which is pressed in
when the attachment has contact up against the container. The sensor
is located above the pin. The position of the sensor can be adjusted so
that it gives a signal when the pin is pressed in and the head is level
with the lower edge of the spreader beam. The clearance between the
attachment and the container’s corner boxes means the sensors stop
sending signals when the attachment is lifted.
The sensors are supplied voltage by and send a 24 V signal to the at-
tachment control unit (D791) when the indicator pin is pressed in.
001451
Alignment sensor, checking

page
–

2 Check that the indicator pins in the corner boxes can freely move
up and down. 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 alignment event menu - and
that the alignment indicator lamp illuminates.
6 Lift the attachment slightly so that contact is just broken (unfilled
circles in the alignment event menu or alignment indicator lamp
000360
goes out).
Event menu, alignment 7 Check more must indicator pin movement is required to detect
contact. The movement must be 3–4 mm.
8 Adjust sensor position if necessary. See Position sensor, check-
ing and adjustment page 5.

page
–

7 Load handling – 7.9.1.9 Twistlock sensor 141
7.9.1.9 Twistlock sensor

Sensor twistlocks, description
page
–
Twistlocks sensors detect when the 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 the same way independently of one another. An
indicator plate is located on the lock mechanism at the lock cylinder.
When the lock mechanism is in the position that locks the twistlocks,
one of the sensors sends a signal to the attachment control unit
(D791). When the lock mechanism is in the position that unlocks the
001452
twistlocks, the other sensor sends a signal to the attachment control
unit (D791). No signals are sent if the lock mechanism stops midway.
The sensors are supplied voltage by and send a 24 V signal to the at-
tachment control unit (D791) when the indicator plate is in front of the
sensor.

page
–
7.9.1.10 Relief valve, attachment

page
–
7.9.1.11 Pipes and hoses

page
–

142 7 Load handling – 7.9.1.12 Overcentre valve
7.9.1.12 Overcentre valve

Overcentre valve (product alternative overheight jacks)
page
–
1
The overcentre valve prevents the overheight jacks lowering under
2 their own weight.
008219
1. Hydraulic cylinder, overheight jacks

2. Overcentre valve, overheight jacks
3. Sensor, overheight jacks up
(B7231-L and B7231-R)
7.9.1.13 Hydraulic cylinder, overheight jacks

Hydraulic cylinder, overheight jacks
page
–
1
The hydraulic cylinder lowers the overheight jacks. The hydraulic cyl-
2 inder is controlled by a separate section in the attachment control
valve, see Attachment control valve, description page 78.
3
008219

(B7231-L and B7231-R)

page
–

7 Load handling – 7.9.1.14 Sensor, overheight-jacks 143
7.9.1.14 Sensor, overheight-jacks

Sensor, overheight-jacks
page
–
1
Sensor, overheight jacks up, detects when the jacks are completely
2 raised.
Sensor, overheight jacks up left (B7231-L) detects the position of the
3 left jack pair and sends a voltage signal to Control unit, attachment op-
tion (D791-2) when the jack pair is fully folded up.
Sensor, overheight jacks up right (B7231-R) detects the position of the
left jack pair and sends a voltage signal to Control unit, attachment op-
tion (D791-2) when the jack pair is fully folded up.
008219

(B7231-L and B7231-R)

page
–

144 7 Load handling – 7.9.2 Lifting jacks
7.9.2 Lifting jacks

Raising/lowering of front lifting jacks, function
page
–
description

value
20
25
1, 29 D1 21, 22
D21
26, 27
A B A B A B A B A B
T1 D26
P1
19 24
2
D28 3, 18, 23
D790-1 D791-4 D18 D23
D797-R D791-3 D8 D13

3, 8, 13, 28
4
9 14
P1
T1
A B A B A B A B A B
D16
D4
D11 16, 17
5
15
6 11, 12
C7
7 10
013028

7 Load handling – 7.9.2 Lifting jacks 145

1 The switch for lowering the front jacks U = 24 V Section 9 Frame, body, cab and accesso-
(S1006) sends a voltage signal to the ries, group 9.1 Controls and instruments
cab control unit (D790-1). D1: Diagnostic menu, see section 8 Control
system , group 8.4.11.1 COMBI, menu 1
2 Control unit cab (D790-1) sends front Checked by control sys- Section 11 Common electrics, group
lifting jacks down or up on the CAN bus. tem, error shown with er- 11.5.3.1 Cab control unit
ror code.
3 Control unit, attachment left jack pair Checked by control sys- Section 11 Common electrics, group
(D791-3) and Control unit, attachment tem, error shown with er- 11.5.3.7 Control unit, attachment left jack
right jack pair (D791-4) send activate ror code. pair and section 11 Common electrics,
top hydraulics on the CAN bus. group 11.5.3.8 Control unit, attachment right
jack pair
vates the solenoid valve, engagement of 11.5.3.3 Control unit, frame rear
sends a load signal to hydraulic oil pump system, group 8.4.5.6 HYD, menu 6
2.
load signal to the hydraulic oil pumps if 10.5.3 Shuttle valve
neously.
7 Hydraulic oil pump 2 pumps oil from the See pressure plate on left Section 10 Common hydraulics, group
hydraulic oil tank. frame beam. 10.4.2 Axial piston pump with variable dis-
placement
8 Control unit, attachment left jack pair U = 24 V Section 11 Common electrics, group
(D791-3) activates solenoid valve front 11.5.3.7 Control unit, attachment left jack
knee out left (Y6056L). pair
9 Solenoid valve front knee out left - Control valve, lifting jacks, description page
(Y6056L) pressurises hydraulic cylinder 160
knee left front. D8: Diagnostic menu, see section 8 Control
10 Hydraulic cylinder knee left front lowers - Hydraulic cylinder knee/clamp, description
knee left front. page 165
11 Sensor front knee left (B7217L) sends a U = 24 V Sensor knee, description page 166
voltage signal to Control unit, attach- D11: Diagnostic menu, see section 8 Control
ment left jack pair (D791-3) when the system , group 8.4.11.1 COMBI, menu 4
knee is lowered.


12 Sensor front knee left (B7217L) stops U=0V Sensor knee, description page 166
sending a signal to Control unit, attach- D12: Diagnostic menu, see section 8 Control
ment left jack pair (D791-3). system , group 8.4.11.1 COMBI, menu 4
(D791-3) activates solenoid valve front 11.5.3.7 Control unit, attachment left jack
jack down left (Y6013L) when sensor pair
front knee left (B7217L) stops sending a D13: Diagnostic menu, see section 8 Control
signal. system , group 8.4.11.1 COMBI, menu 10
14 Solenoid valve front jack down left - Control valve, lifting jacks, description page
(Y6013L) pressurises Hydraulic cylinder 160
jack left front. D13: Diagnostic menu, see section 8 Control
15 Hydraulic cylinder jack left front lowers - Hydraulic cylinder, jack, description page
jack left front. 168
16 Sensor front jack left (B7219L) sends a U = 24 V Sensor, lifting jacks, description page 168
signal to Control unit, attachment left D16: Diagnostic menu, see section 8 Control
jack pair (D791-3) when the jack is low- system , group 8.4.11.1 COMBI, menu 4
ered.
17 Sensor front jack left (B7219L) stops U=0V Sensor, lifting jacks, description page 168
ment left jack pair (D791-3). system , group 8.4.11.1 COMBI, menu 4
18 Control unit, attachment right jack pair U = 24 V Section 11 Common electrics, group
(D791-4) activates solenoid valve front 11.5.3.8 Control unit, attachment right jack
knee out right (Y6056R) when sensor pair
front jack left (B7219L) stops sending a D18: Diagnostic menu, see section 8 Control
signal. system , group 8.4.11.1 COMBI, menu 10
19 Solenoid valve front knee out right - Control valve, lifting jacks, description page
(Y6056R) pressurises hydraulic cylinder 160
knee right front. D18: Diagnostic menu, see section 8 Control
20 Hydraulic cylinder knee right front low- - Hydraulic cylinder knee/clamp, description
ers knee right front. page 165
21 Sensor front knee right (B7217R) sends U = 24 V Sensor knee, description page 166
a voltage signal to Control unit, attach- D21: Diagnostic menu, see section 8 Control
ment right jack pair (D791-4) when the system , group 8.4.11.1 COMBI, menu 4
knee is lowered.
22 Sensor front knee right (B7217R) stops U=0V Sensor knee, description page 166
ment right jack pair (D791-4). system , group 8.4.11.1 COMBI, menu 4


(D791-4) activates solenoid valve front 11.5.3.8 Control unit, attachment right jack
jack down right (Y6013R) when sensor pair
front knee right (B7217R) stops sending D23: Diagnostic menu, see section 8 Control
a signal. system , group 8.4.11.1 COMBI, menu 10
24 Solenoid valve front jack down right - Control valve, lifting jacks, description page
(Y6013R) pressurises Hydraulic cylin- 160
der jack right front.
25 Hydraulic cylinder jack right front lowers - Hydraulic cylinder, jack, description page
jack right front. 168
26 Sensor front jack right (B7219R) sends U = 24 V Sensor, lifting jacks, description page 168
a signal to Control unit, attachment right D26: Diagnostic menu, see section 8 Control
jack pair (D791-4) when the jack is low- system , group 8.4.11.1 COMBI, menu 4
ered.
27 Sensor front jack right (B7219R) stops U=0V Sensor, lifting jacks, description page 168
ment right jack pair (D791-4) when the system , group 8.4.11.1 COMBI, menu 4
jack has reached the end position.
(D791-4) activates indicator lamp front 11.5.3.8 Control unit, attachment right jack
jack down (H580). pair
29 When the switch is released, activation of all solenoid valves is interrupted. Solenoid valves remain activated even
after the movement has been completed in order for it to be possible to complete the movement if the button is re-
leased when the lifting jack is in an intermediate position.

Raising/lowering of rear lifting jacks, function

page
–
description

value
D32 32
20
31
21
1, 33 D1 D21 22
D26 25
26 30 D30
27
A B A B A B A B A B
P1
T1
D23
24 19 29
2
3, 18, 23, 28 D18
D790-1 D791-4
D29
D797-R D791-3 3, 8, 13, 28 D8
4
D5 14 9 29
D13
P1
T1 A B A B A B A B A B
5 D16 16
17 30
15
C 6
11
D11 12
7 31
10 32
D32
013029


1 The rear jacks switch (S1007) sends a U = 24 V Section 9 Frame, body, cab and accesso-
voltage signal to the cab control unit ries, group 9.1 Controls and instruments
2 Control unit cab (D790-1) sends rear lift- Checked by control sys- Section 11 Common electrics, group
ing jacks down or up on the CAN bus. tem, error shown with 11.5.3.1 Cab control unit
error code.
3 Control unit, attachment left jack pair Checked by control sys- Section 11 Common electrics, group
(D791-3) and Control unit, attachment tem, error shown with 11.5.3.7 Control unit, attachment left jack
right jack pair (D791-4) send activate top error code. pair and section 11 Common electrics,
hydraulics on the CAN bus. group 11.5.3.8 Control unit, attachment right
jack pair
vates the solenoid valve, engagement of 11.5.3.3 Control unit, frame rear
lics for top lift (Y6003) opens and pressu- page 58
rises valve block lift cylinder and sends a D5: Diagnostic menu, see section 8 Control
load signal to hydraulic oil pump 2. system , group 8.4.5.6 HYD, menu 6
load signal to the hydraulic oil pumps if 10.5.3 Shuttle valve
several functions are activated simultane-
ously.
7 Hydraulic oil pump 2 pumps oil from the See pressure plate on Section 10 Common hydraulics, group
hydraulic oil tank. left frame beam. 10.4.2 Axial piston pump with variable dis-
placement
(D791-3) activates solenoid valve rear 11.5.3.7 Control unit, attachment left jack
knee out left (Y6058L). pair
9 Solenoid valve rear knee out left - Control valve, lifting jacks, description page
(Y6058L) pressurises hydraulic cylinder 160
knee left rear. D8: Diagnostic menu, see section 8 Control
10 Hydraulic cylinder knee left rear lowers - Hydraulic cylinder knee/clamp, description
knee left rear. page 165
11 Sensor rear knee left (B7218L) sends a U = 24 V Sensor knee, description page 166
voltage signal to Control unit, attachment D11: Diagnostic menu, see section 8 Con-
left jack pair (D791-3) when the knee is trol system , group 8.4.11.1 COMBI, menu 5
lowered.


12 Sensor rear knee left (B7218L) stops U=0V Sensor knee, description page 166
sending a signal to Control unit, attach- D11: Diagnostic menu, see section 8 Con-
ment left jack pair (D791-3). trol system , group 8.4.11.1 COMBI, menu 5
(D791-3) activates solenoid valve rear 11.5.3.7 Control unit, attachment left jack
jack down left (Y6014L), sensor rear knee pair
left (B7218L) stops sending a signal. D13: Diagnostic menu, see section 8 Con-
trol system , group 8.4.11.1 COMBI, menu
12
14 Solenoid valve rear jack down left - Control valve, lifting jacks, description page
(Y6014L) pressurises Hydraulic cylinder 160
jack left rear. D13: Diagnostic menu, see section 8 Con-
trol system , group 8.4.11.1 COMBI,
menu 12
15 Hydraulic cylinder jack left rear lowers - Hydraulic cylinder, jack, description page
jack left rear. 168
16 Sensor rear jack left (B7220L) sends a U = 24 V Sensor, lifting jacks, description page 168
signal to Control unit, attachment left jack D16: Diagnostic menu, see section 8 Con-
pair (D791-3) when the jack is lowered. trol system , group 8.4.11.1 COMBI, menu 5
17 Sensor rear jack left (B7220L) stops U=0V Sensor, lifting jacks, description page 168
ment left jack pair (D791-3) when sensor trol system , group 8.4.11.1 COMBI, menu 5
rear jack left (B7220L) stops sending a
signal.
(D791-4) activates solenoid valve rear 11.5.3.8 Control unit, attachment right jack
knee out right (Y6058R). pair
12
19 Solenoid valve rear knee out right - Control valve, lifting jacks, description page
(Y6058R) pressurises hydraulic cylinder 160
knee right rear. D18: Diagnostic menu, see section 8 Con-
12
20 Hydraulic cylinder knee/right rear lowers - Hydraulic cylinder knee/clamp, description

knee right rear. page 165
21 Sensor rear knee right (B7218R) sends a U = 24 V Sensor knee, description page 166
voltage signal to Control unit, attachment D21: Diagnostic menu, see section 8 Con-
right jack pair (D791-4) when the knee is trol system , group 8.4.11.1 COMBI, menu 5
lowered.


22 Sensor rear knee right (B7218R) stops U=0V Sensor knee, description page 166
ment right jack pair (D791-4) when the trol system , group 8.4.11.1 COMBI, menu 5
knee reaches the end position.
(D791-4) activates solenoid valve rear 11.5.3.8 Control unit, attachment right jack
jack down right (Y6014R) when sensor pair
rear knee right (B7218R) stops sending a D23: Diagnostic menu, see section 8 Con-
signal. trol system , group 8.4.11.1 COMBI, menu
12
24 Solenoid valve rear jack down right - Control valve, lifting jacks, description page
(Y6014R) pressurises Hydraulic cylinder 160
jack right rear. D23: Diagnostic menu, see section 8 Con-
12
25 Hydraulic cylinder jack right rear lowers - Hydraulic cylinder, jack, description page
jack right rear. 168
26 Sensor rear jack right (B7220R) sends a U = 24 V Sensor, lifting jacks, description page 168
signal to Control unit, attachment right D26: Diagnostic menu, see section 8 Con-
jack pair (D791-4) when the jack is low- trol system , group 8.4.11.1 COMBI, menu 5
ered.
27 Sensor rear jack right (B7220R) stops U=0V Sensor, lifting jacks, description page 168
ment right jack pair (D791-4). trol system , group 8.4.11.1 COMBI, menu 5
28 When both rear lifting jacks are complete- U = 24 V Section 11 Common electrics, group
ly lowered Control unit, attachment left 11.5.3.7 Control unit, attachment left jack
jack pair (D791-3) activates solenoid pair and section 11 Common electrics,
valve operating position left (Y6053L) and group 11.5.3.8 Control unit, attachment right
solenoid valve clamping left (Y6054L). jack pair
At the same time Control unit, attachment D29: Diagnostic menu, see section 8 Con-
right jack pair (D791-4) activates Solenoid trol system group 8.4.11.1 COMBI, menu
valve operating position right (Y6053R) 15 and 8.4.11.1 COMBI, menu 16
and Solenoid valve clamping right
(Y6054R).
29 Solenoid valve operating position left - Control valve, lifting jacks, description page
(Y6053L) closes the connection between 160
control valve and hydraulic cylinder D29: Diagnostic menu, see section 8 Con-
clamping left front. trol system group 8.4.11.1 COMBI, menu
Solenoid valve operating position right 15 and 8.4.11.1 COMBI, menu 16
(Y6053R) closes the connection between
control valve and hydraulic cylinder
clamping right front.


30 Solenoid valve clamping left (Y6054L) - Control valve, lifting jacks, description page
pressurises hydraulic cylinder clamp left 160
rear. D30: Diagnostic menu, see section 8 Con-
Solenoid valve clamping right (Y6054R) trol system , group 8.4.11.1 COMBI, menu
pressurises hydraulic cylinder clamp right 15
rear.
31 Hydraulic cylinder clamp presses knee - Hydraulic cylinder knee/clamp, description

down and thus presses the rear lifting page 165
jacks forward.
32 Sensor operating position left (B7212L) Sensor directly opposite Sensor operating position, description page
sends a voltage signal to Control unit, at- indicator plate: U = 24 V 165
tachment left jack pair (D791-3) and sen- D32: Diagnostic menu, see section 8 Con-
sor operating position right (B7212R) trol system , group 8.4.11.1 COMBI, menu 6
sends a voltage signal to Control unit at-
tachment right jack pair (D791-4) when
the jack pair is in the operating position.
33 When the switch is released, activation of all solenoid valves is interrupted. Solenoid valves remain activated even
after the movement has been completed in order for it to be possible to complete the movement if the button is re-
leased when a lifting jack is in an intermediate position.

Clamp with left jacks, function description

page
–

value
Lifting jacks Lowered Raising/lowering of front lifting jacks, function description page 144
Raising/lowering of rear lifting jacks, function description page 148
22 20 15 14
17 22
D1
1
D22 D20 D17
P1 B A B A B A B A B A
D22
T1
D21
D12
13
2, 25 3, 12, 18, 21
D790-1 D791-4
D797-R D791-3 D795

4 3, 8, 23 24
9
D23 D4 D8
P1
T1
A B A B A B A B A B
D22
5
D22 D16
D19
6
7 22 19 16 22
006894
11 10

1 The switch for clamp/release jacks U = 24 V Section 9 Frame, body, cab and accessories,
(S1008) sends a voltage signal to the cab group 9.1 Controls and instruments
control unit (D790-1). D1: Diagnostic menu, see section 8 Control
2 The cab control unit (D790-1) sends Checked by control Section 11 Common electrics, group 11.5.3.1
clamp or release jacks on the CAN bus. system, error shown Cab control unit
with error code.


3 Control unit, attachment left jack pair Checked by control Section 11 Common electrics, group 11.5.3.7
(D791-3) and Control unit, attachment system, error shown Control unit, attachment left jack pair and sec-
right jack pair (D791-4) send activate top with error code. tion 11 Common electrics, group 11.5.3.8
hydraulics on the CAN bus. Control unit, attachment right jack pair
vates the solenoid valve, engagement of Control unit, frame rear
lics for top lift (Y6003) opens and pressu- page 58
rises valve block lift cylinder and sends a D4: Diagnostic menu, see section 8 Control
load signal to hydraulic oil pump 2. system , group 8.4.5.6 HYD, menu 6
several functions are activated simultane-
ously.
8 Control unit, attachment left jack pair U = 24 V Section 11 Common electrics, group 11.5.3.7
(D791-3) activates solenoid valve clamp Control unit, attachment left jack pair
left (Y6054L) or solenoid valve clamp re- D8: Diagnostic menu, see section 8 Control
lease left (Y6055L). system , group 8.4.11.1 COMBI, menu 15
9 Solenoid valve clamp left (Y6054L) or so- - Control valve, lifting jacks, description page
lenoid valve clamp release left (Y6055L) 160
pressurises hydraulic cylinder clamp left D8: Diagnostic menu, see section 8 Control
front and hydraulic cylinder clamp left system , group 8.4.11.1 COMBI, menu 15
rear.
10 Hydraulic cylinder knee and clamp left - Hydraulic cylinder knee/clamp, description
front act on knee left front so that left lifting page 165
jacks clamp or release.
11 Hydraulic cylinder knee and clamp left - Hydraulic cylinder knee/clamp, description
rear act on knee left rear so that left lifting page 165
12 Control unit, attachment right jack pair U = 24 V Section 11 Common electrics, group 11.5.3.8
(D791-4) activates solenoid valve clamp Control unit, attachment right jack pair
right (Y6054R) or solenoid valve clamp D12: Diagnostic menu, see section 8 Control
release right (Y6055R). system , group 8.4.11.1 COMBI, menu 15
13 Solenoid valve clamp left (Y6054L) or so- - Control valve, lifting jacks, description page
lenoid valve clamp release left (Y6055L) 160
pressurises hydraulic cylinder clamp left D12: Diagnostic menu, see section 8 Control
front and hydraulic cylinder clamp left system , group 8.4.11.1 COMBI, menu 15
rear.


14 Hydraulic cylinder knee and clamp right - Hydraulic cylinder knee/clamp, description
front act on knee left front so that left lifting page 165
15 Hydraulic cylinder knee and clamp right - Hydraulic cylinder knee/clamp, description
rear act on knee left rear so that left lifting page 165
16 Sensor clamping position front jack left U = 24 V Sensor, clamping position, description page
(B7215L) sends a voltage signal to Con- 171
trol unit, attachment left jack pair D16: Diagnostic menu, see section 8 Control
(D791-3). system , group 8.4.11.1 COMBI, menu 2
17 Sensor clamping position front jack right U = 24 V Sensor, clamping position, description page
(B7215R) sends a voltage signal to Con- 171
trol unit, attachment right jack pair D17: Diagnostic menu, see section 8 Control
(D791-4) activates indicator light clamp- Control unit, attachment right jack pair
ing position front jack (H578). D21: Diagnostic menu, see section 8 Control
19 Sensor clamping position rear jack left U = 24 V Sensor, clamping position, description page
(B7216L) sends a voltage signal to Con- 171
trol unit, attachment left jack pair D19: Diagnostic menu, see section 8 Control
20 Sensor clamping position rear jack right U = 24 V Sensor, clamping position, description page
(B7216R) sends a voltage signal to Con- 171
trol unit, attachment right jack pair D20: Diagnostic menu, see section 8 Control
(D791-4) activates indicator light clamp- Control unit, attachment right jack pair
ing position rear jack (H579). D21: Diagnostic menu, see section 8 Control
22 When lifting is started, Sensor alignment U = 24 V Section 9 Frame, body, cab and accessories,
front jack left (B7213L) and Sensor align- group 9.1 Controls and instruments
ment rear jack left (B7214L) send a signal D22: Diagnostic menu, see section 8 Control
to Control unit, attachment left jack pair system , group 8.4.11.1 COMBI, menu 3
(D791-3). Sensor alignment front jack
right (B7213R) and Sensor alignment rear
jack right (B7214R) send a signal to Con-
trol unit, attachment right jack pair
(D791-4).
If it takes longer than 4 seconds between
the first sensor’s signal until all sensors
send signals, the lift function is blocked.


23 Control unit, attachment left jack pair U = 24 V Section 11 Common electrics, group 11.5.3.7
(D791-3) activates the alignment indica- Control unit, attachment left jack pair
tor light for the respective lifting jack. D23: Diagnostic menu, see section 8 Control
24 The KID control unit (D795) activates the - Section 11 Common electrics, group
event menu for alignment bottom lift. 11.5.3.12 KID control unit
25 When more than two sensors indicate Checked by control Section 8 Control system, group 8.2.5 Speed
alignment or clamping position, speed system, error shown limitation
limitation is activated. with error code.
Lifting jacks, checking and adjusting

page
–
If necessary, the lifting jacks can be operated manually, step by step

with the diagnosis menu Extra\\Combi menu 17, see section 8 Control
system, group 8.4.11.1 COMBI.
1 Start key in position I.

2 Check that all sensors have voltage. The LED on the sensor
should illuminate when the sensor indicates.
3 Check the distance between all sensors and their target surface,
the distance will be 4 ±1 mm when the sensor is in the centre of
the lug.
Sensor knee and Sensor jack should only be active during the
movement, not in the two end positions.
4 Check that the attachment hangs horizontally, adjust the tilt func-
tion if necessary.
5 Fully lower all jacks.
6 Check that the jacks are vertical in the lateral direction.
7 If necessary, adjust the position on the lowering cylinder’s rod
mounting by turning the piston.
After adjustment, the target surfaces for the jack sensors may
need to be precisely adjusted.
NOTE
Loosen the lock nuts on the piston head before adjustment.
8 Check the c-c measurement between right and left lifting jacks,
90˚ 90˚ the measurement should be approximately 4876 mm at the bot-
tom of the jacks.
c-c = 4876 mm
008205
Attachment, seen from the front

9 Operate the lifting jacks to clamping position.

10 Check that the lifting jacks are tilted 8.0° towards each other in
the longitudinal direction.
11 If necessary, adjust the position on the clamping cylinder’s rod
mounting by turning the piston.
After adjustment, the target surfaces for the knee sensors may
need to be precisely adjusted.
NOTE
Loosen the lock screws in the piston head before adjust-
8,0˚ 8,0˚ ment.
007458
Clamping position, max. retracted jacks

12 Operate the lifting jacks apart from clamping position.
13 Check that the rear lifting jacks are tilted 1.5° outwards (reverse).
14 Check that the front lifting jacks are tilted 9.0° outwards (forward).
9,0˚ 1,5˚
007459
Clamping position, max. extended jacks.

15 Press the top of the rear lowering button, the rear lifting jacks
should move to operating position. (Operate clamping position
apart to return to end position in order to test the operating posi-
tion again.)
16 Check that the lifting jacks stop at 1.0° inwards (forward).
1,0˚
007460
Operating position, rear jacks

17 Adjust the position by moving the sensor clamping position
laterally.
001856
Sensor, operating position

18 Press in the alignment lugs on a lifting jack one at a time and
check that the respective alignment indicator light is working.
If the light does not illuminate when the lug is pressed in, check
the lamp and alignment sensor, see Sensor alignment, descrip-
tion page 170.
008200
Indicator lights, alignment

7 Load handling – 7.9.2.1 Hydraulic oil pump 159
19 Press in the contact surfaces on the front and rear lifting jacks
and check that the indicator light for clamping position alignment
for the respective jack pair is working.
When both contact surfaces are pressed in the indicator light for
clamping position front and rear should illuminate.
If the light does not illuminate when the contact surfaces are
pressed in, check the lamp and clamping position sensor, see
Sensor, clamping position, description page 171.
008201
Indicator lights, clamping position
20 Check that the indicator light for front jacks lowered is illuminated
when the front lifting jacks are lowered.
008202
Indicator light, front jacks down

21 Operate the front lifting jacks up and check the indicator light for
front jacks lowered is switched off when the jacks are raised, and
that the indicator light for front jacks raised illuminates when the
front lifting jacks are completely raised.
22 Checks that the working lights on the attachment switch between
lighting the twistlocks and lighting the lifting jacks on the right and
left side when the rear lifting jacks on each respective side are
raised and lowered.
008204
Indicator light, front jacks up

page
–

7.9.2.2 Valve block, top lift hydraulics

page
–

160 7 Load handling – 7.9.2.3 Control valve, lifting jacks
7.9.2.3 Control valve, lifting jacks

Control valve, lifting jacks, description
page
–
The lifting jacks are controlled by two control valves: one for the left
1 2 3 4 5 6 7 8 9 10 jack pair and one for the right jack pair. The control valves are control-
led by separate control units: Control unit, attachment left jack pair
23 (D791-3) and Control unit, attachment right jack pair (D791-4). The
11 control valves are fitted crosswise (left front and right rear, respective-
22
ly) on the bracket for the knee on the attachment’s main beam.
12
21 The control valves are identical and have five sections each:
20 13 • Raising/lowering of front knee

• Raising/lowering of front jacks
19 14
• Raising/lowering of rear knee
18
15 • Raising/lowering of rear jacks
17 • Clamping position
16
have flow limits so that several functions can be activated
simultaneously.
000467
Valve slide front knee

1. Solenoid valve, rear knee out (Y6058) The valve slide controls the direction and speed of front knee lowering
2. Solenoid valve, rear knee in (Y6059) by controlling the hydraulic pressure to hydraulic cylinder knee and
3. Solenoid valve, clamp (Y6054) clamp.
4. Solenoid valve, clamp release (Y6055)
The valve slide is controlled by servo valve, front knee out and servo
5. Solenoid valve, front knee in (Y6057)
valve, front knee in.
6. Solenoid valve, front jack up (Y6060)
7. Solenoid valve, front jack down (Y6013)
Servo valve front knee out
8. Solenoid valve, front knee out (Y6056)
9. Drain to tank Servo valve front knee out, controls servo pressure to valve slide front
10. Connection, hydraulic cylinder for front jack knee so that it controls oil pressure for front knee out.
11. Connection, hydraulic cylinder for front knee Servo valve front knee is controlled electrically with Solenoid valve
12. Connection, hydraulic cylinder for front jack front knee out (Y6056) which is activated by Control unit, attachment
13.Connection, hydraulic cylinder for front knee left jack pair (D791-3) or Control unit, attachment right jack pair (D791-
14. Connection, hydraulic cylinder for clamping 4), depending on if it is the right or left jack.
15. Connection, hydraulic cylinder for rear knee The signal can be checked from the diagnostic menu, see section
16. Connection, hydraulic cylinder for rear jack 8 Control system , group 8.4.11.1 COMBI, menu 10.
17. Feed from hydraulic oil pumps
18. Tank return (through filter) Servo valve front knee in
19. Connection, hydraulic cylinder for rear jack
Servo valve front knee in, controls servo pressure to valve slide front
20. Connection, hydraulic cylinder for rear knee
knee so that it controls oil pressure for front knee in.
21. Connection, hydraulic cylinder for clamping
22. Solenoid valve, rear jack down (Y6014) Servo valve front knee is controlled electrically with Solenoid valve
23. Solenoid valve, rear jack up (Y6061) front knee in (Y6057) which is activated by Control unit, attachment left
jack pair (D791-3) or Control unit, attachment right jack pair (D791-4),
depending on if it is the right or left jack.
8 Control system , group 8.4.11.1 COMBI, menu 11.

7 Load handling – 7.9.2.3 Control valve, lifting jacks 161
Valve slide front jack

The valve slide controls the direction and speed of front jack lowering
by controlling the hydraulic pressure to hydraulic cylinder, jack.
The valve slide is controlled by servo valve front jack down and servo
valve front jack out.
Servo valve front jack down

Servo valve front jack down, controls servo pressure to valve slide
front jack so that it controls oil pressure for jack lowering.
Servo valve front jack is controlled electrically with Solenoid valve front
jack down (Y6013) which is activated by Control unit, attachment left
Servo valve front jack up

Servo valve front jack up, controls servo pressure to valve slide front
jack so that it controls oil pressure for jack raising.
Servo valve front jack is controlled electrically with Solenoid valve front
jack up (Y6060) which is activated by Control unit, attachment left jack
pair (D791-3) or Control unit, attachment right jack pair (D791-4), de-
pending on if it is the right or left jack.
8 Control system, group 8.4.11.1 COMBI, menu 11.
Valve slide clamp

Valve slide clamp controls the direction and speed of clamping with the
jack pair by controlling the hydraulic pressure to hydraulic cylinder
knee and clamp.
The valve slide is controlled by servo valve clamp and servo valve
clamp release.
Servo valve clamp

Servo valve clamp, controls servo pressure to valve slide clamp so
that it controls oil pressure for clamping.
Servo valve clamp is controlled electrically with Solenoid valve clamp
in (Y6054) which is activated by Control unit, attachment left jack pair
(D791-3) or Control unit, attachment right jack pair (D791-4), depend-
ing on if it is the right or left jack pair.

162 7 Load handling – 7.9.2.3 Control valve, lifting jacks
Servo valve clamp release

Servo valve clamp release, controls servo pressure to valve slide
clamping position so that it controls oil pressure for clamp release.
Servo valve clamp release is controlled electrically with Solenoid valve
clamp release in (Y6055) which is activated by Control unit, attach-
ment left jack pair (D791-3) or Control unit, attachment right jack pair
(D791-4), depending on if it is the right or left jack pair.
Valve slide rear knee

The valve slide controls the direction and speed of rear knee lowering
by controlling the hydraulic pressure to hydraulic cylinder knee and
clamp.
The valve slide is controlled by servo valve, rear knee out and servo
valve, rear knee in.
Servo valve rear knee out

Servo valve rear knee out, controls servo pressure to valve slide rear
knee so that it controls oil pressure for knee out.
Servo valve rear knee out is controlled electrically with Solenoid valve
rear knee out (Y6058) which is activated by Control unit, attachment
left jack pair (D791-3) or Control unit, attachment right jack pair (D791-
4), depending on if it is the right or left knee.
Servo valve rear knee in

Servo valve rear knee in, controls servo pressure to valve slide knee
so that it controls oil pressure for knee in.
Servo valve rear knee in is controlled electrically with Solenoid valve
rear knee in (Y6059) which is activated by Control unit, attachment left
depending on if it is the right or left knee.
Valve slide rear jack

The valve slide controls the direction and speed of rear jack lowering
by controlling the hydraulic pressure to hydraulic cylinder, jack.
The valve slide is controlled by servo valve rear jack down and servo
valve rear jack out.

7 Load handling – 7.9.2.4 Shuttle valve 163
Servo valve rear jack down

Servo valve rear jack down, controls servo pressure to valve slide front
jack so that it controls oil pressure for jack lowering.
Servo valve rear jack down is controlled electrically with Solenoid
valve rear jack down (Y6014) which is activated by Control unit, at-
tachment left jack pair (D791-3) or Control unit, attachment right jack
pair (D791-4), depending on if it is the right or left jack.
Servo valve rear jack up

Servo valve rear jack up, controls servo pressure to valve slide rear
jack so that it controls oil pressure for jack raising.
Servo valve rear jack up is controlled electrically with Solenoid valve
rear jack up (Y6061) which is activated by Control unit, attachment left

page
–
7.9.2.4 Shuttle valve

page
–

164 7 Load handling – 7.9.2.5 Valve, operating position
7.9.2.5 Valve, operating position

Valve operating position, description
page
–
The valve for operating position cuts off the pressure to the front hy-
draulic cylinder for clamping. The valve is located on the attachment’s
main beam by the hydraulic cylinder knee and clamp.
When the valve is activated, it cuts the hydraulic connection between
Control valve, attachment lifting jacks and hydraulic cylinder knee and
clamp front. This results in only the rear lifting jack being angled for-
ward.
Solenoid valve operating position (Y6053L/R) is activated by Control
unit, attachment left jack pair (D791-3) or Control unit, attachment right
jack pair (D791-4), depending on if it is the right or left jack.
001849
7.9.2.6 Main beam, attachment

page
–
The brackets for knee and hydraulic cylinder knee and clamp are lo-
cated on the attachment’s main beam.
7.9.2.7 Knee
Knee, description
page
–
The knee is located between the attachment’s main beam and lifting
jack. There are four knees, one at each lifting jack. The knee enables
folding in and clamping with the jacks. The knee is controlled by hy-
draulic cylinder knee and clamp.
Located on the knee joint is an indicator ring which is turned with the
lifting jack. The indicator ring is used together with Sensor, knee, to de-
termine whether the jack is raised, in intermediate position or lowered.
001851

7 Load handling – 7.9.2.8 Hydraulic cylinder knee and clamp 165
7.9.2.8 Hydraulic cylinder knee and clamp

Hydraulic cylinder knee/clamp, description
page
–
Hydraulic cylinder knee and clamp has two pistons in separate cylin-
1 2
ders. There are four hydraulic cylinders, one at each lifting jack. The
hydraulic cylinder is located between attachment and knee. One of the
hydraulic cylinder’s pistons folds the knee joint out. The other piston
clamps with the lifting jacks by angling the knee joint further.
001852
1. Hydraulic cylinder, clamp
2. Hydraulic cylinder, knee

page
–
7.9.2.9 Sensor, operating position

Sensor operating position, description
page
–
The sensor for operating position senses the position of the rear lifting
jacks’ hydraulic cylinder for knee and clamp. This is used to indicate
operating position for the rear lifting jacks. There are two sensors, one
on each side (right and left).
Sensor, operating position left (B7212L/R) provides a voltage signal
when the rear hydraulic cylinder lowering knee/clamp is in its inner end
position. The signal is used to stop activation of the solenoid valve for
operating position when the rear lifting jack is lowered.
001856

page
–

166 7 Load handling – 7.9.2.10 Sensor, knee
7.9.2.10 Sensor, knee

Sensor knee, description
page
–
Sensor knee senses the position of the knee joint, this is used to con-
trol lowering of the jacks. There are four sensors, one by each knee.
Sensor front knee (B7217) and Sensor rear knee (B7218) give voltage
signals when the knee is between either end-position. The signal goes
to 0 V when end-position is reached. This applies both when retracting
and extending. The signal is used to activate the next step in the se-
quence. If the signal does not go to 0 V, the jack is not lowered.
8 Control system , group 8.4.11.1 COMBI, menu 4 5.
001853

page
–

7 Load handling – 7.9.2.11 Lifting jacks 167
7.9.2.11 Lifting jacks

Lifting jacks, description
page
–
The lifting jacks grip around/under the load. In the lower end of the
jacks there are lifting shoes. The lifting jacks are raised and lowered
with the hydraulic cylinder for lifting jacks.
Located on the lifting jack’s joint is an indicator ring which is turned
with the lifting jack. The indicator ring is used together with Sensor,
jack, to determine whether the jack is raised, in intermediate position
or lowered.
001866

168 7 Load handling – 7.9.2.12 Hydraulic cylinder, jack
7.9.2.12 Hydraulic cylinder, jack

Hydraulic cylinder, jack, description
page
–
Hydraulic cylinder lifting jack is located between knee and lifting jack.
The hydraulic cylinder raises and lowers the lifting jacks.
001855

page
–
7.9.2.13 Sensor, lifting jacks

Sensor, lifting jacks, description
page
–
Sensor, lifting jacks, senses the position of the lifting jacks, this is used
to control lowering of the jacks. There are four sensors, one by each
lifting jack.
Sensor front jack (B7219) and Sensor rear lifting jack (B7220) give
voltage signals when the lifting jacks are between either end-position.
The signal goes down to 0 V when end-position is reached. This ap-
plies both when raising and lowering. The signal is used to activate the
next step in the sequence. If the signal does not go to 0 V, the knees
are not lowered.
8 Control system , group 8.4.11.1 COMBI, menu 4–5.
001859

page
–

7 Load handling – 7.9.2.14 Lifting shoe 169
7.9.2.14 Lifting shoe

Lifting shoe, description
page
–
The lifting shoe is located at the lower end of the lifting jacks. The lifting
shoe grips under the load. At each lifting shoe there are two sensors.
Sensor alignment senses when the lifting shoe has contact with the
load from above, see Sensor alignment, description page 170. Sensor
clamping position senses when the lifting shoe has horizontal contact
with the load, see Sensor, clamping position, description page 171.
3
001857
1. Indicator pin, clamping position sensor

2. Indicator pin, alignment sensor
3. Lifting shoe

170 7 Load handling – 7.9.2.15 Sensor alignment
7.9.2.15 Sensor alignment

Sensor alignment, description
page
–
The sensor for alignment (B7213L/R or B7214L/R) senses when the

lifting shoe has contact with the load from above. The sensor is located
behind the lifting shoe and senses the position on a linkage. The link-
age is affected by a pin in the middle of the lifting shoe which is
1 pressed down when the load is positioned correctly in the lifting shoe.
2
001858
1. Sensor clamping position (B7215L/R or B7216L/R)

2. Sensor alignment (B7213L/R or B7214L/R)

page
–

7 Load handling – 7.9.2.16 Sensor, clamping position 171
7.9.2.16 Sensor, clamping position

Sensor, clamping position, description
page
–
The sensor for clamping position (B7215L/R or B7216L/R) senses

when the lifting shoe has horizontal contact with the load. The sensor
is located behind the lifting shoe and is activated by a bolt mounted on
a spring-loaded plate on the lifting shoe.
1
Control system , group 8.4.11.1 COMBI, menu 2.
001858
1. Sensor clamping position (B7215L/R or B7216L/R)

2. Sensor alignment (B7213L/R or B7214L/R)

page
–
7.9.2.17 Relief valve, attachment

page
–

page
–

172 7 Load handling – 7.10 Other functions
7.10 Other functions

7.10.1 Support jacks
Support jacks, function description
page
–
Condition Reference val- Reference

ue
Safety switch Disengaged Section 10 Common hydraulics, group 10.4.2 Axial piston pump with varia-
ble displacement
Parking brake Released Section 4 Brakes, group 4.5 Parking brake system
Transmission Neutral position Section 2 Transmission
Machine stationary Speed = 0 km/h -
D1 D13
1
2, 13
D790-1 11
D795
D794 D797-O
4
D4 12
C8 D3
5
10 3
P
B
LS
7 T
C8 T1 A
8 6 9
013030

1 The support jacks switch (S1013) sends a U = 24 V Section 9 Frame, body, cab and accesso-
voltage signal to the cab control unit (D790- ries, group 9.1 Controls and instruments
1). D1: Diagnostic menu, see section 8 Control
system , group 8.4.11.3 SUPPORT JACKS,
menu 1
2 The cab control unit (D790-1) sends front Checked by control Section 11 Common electrics, group
support jacks down or up on the CAN bus. system, error shown 11.5.3.1 Cab control unit
with error code.

7 Load handling – 7.10.1 Support jacks 173

3 Sensor support jacks up (B7222) or Sensor Support jacks up or Sensor, support jacks up, description page
support jacks down (B7021) sends a volt- down: U = 24 V 179
age signal to Control unit, frame option Support jacks in inter- Sensor, support jacks down, description
(D797-O). mediate position: U = page 180
0V D3: Diagnostic menu, see section 8 Control
system , group 8.4.11.3 SUPPORT JACKS,
menu 2
4 Control unit, frame option (D797-O) acti- U = 24 V Section 11 Common electrics, group
vates the Solenoid valve support jacks 11.5.3.4 Control unit, frame option
down (Y6064) or Solenoid valve support D4: Diagnostic menu, see section 8 Control
jacks up (Y6063) and sends the status for system , group 8.4.11.3 SUPPORT JACKS,
the support jacks’ position on the CAN bus. menu 3
5 Solenoid valve support jacks down (Y6064) - Control valve, option frame, description
or Solenoid valve support jacks up (Y6063) page 174
pressurises the support jacks slide in Con- D4: Diagnostic menu, see section 8 Control
trol valve, option frame. system , group 8.4.11.3 SUPPORT JACKS,
menu 3
6 Control valve, option frame sends a load - Control valve, option frame, description
signal to shuttle valve, option frame and page 174
pressurises valve block, support jacks cylin-
der.
7 The shuttle valve sends pressure signal on - Section 10 Common hydraulics, group
to hydraulic oil pumps 1 & 2 10.5.3 Shuttle valve
8 Hydraulic oil pumps 1 & 2 pump oil from the See pressure plate on Section 10 Common hydraulics, group
hydraulic oil tank. left frame beam. 10.4.2 Axial piston pump with variable dis-
placement
9 Valve block support jacks pressurises hy- - Valve block, support jacks, description page
draulic cylinder support jacks. 180
10 The hydraulic cylinder lowers or raises the - Hydraulic cylinder, support jacks, description
support jack. page 178
11 Control unit KID (D795) activates the event - Section 11 Common electrics, group
menu for support jacks and blocks shifting 11.5.3.12 KID control unit
from neutral position.
12 Control unit, engine (D794) sends engine Checked by control Section 11 Common electrics, group
speed on the CAN bus. If the engine speed system, error shown 11.5.3.10 Engine control unit
is higher than 1000 rpm then the cab control with error code.
unit (D790-1) activates automatic lowering
of support jacks.

174 7 Load handling – 7.10.1.1 Hydraulic oil pump

13 The cab control unit (D790-1) activates the U = 24 V Section 11 Common electrics, group
indicator light for support jacks down. 11.5.3.1 Cab control unit
When support jacks are lowered the cab D13: Diagnostic menu, see section 8 Control
control unit (D790-1) changes the load system , group 8.4.11.3 SUPPORT JACKS,
curve (limit for overload protection sys- menu 4
tems).
When support jacks are raised the cab con-
trol unit (D790-1) allows shifting from neu-
tral position.

page
–

7.10.1.2 Control valve, option frame

Control valve, option frame, description
page
–
1
On machines with support jacks, the lowering/raising of support jacks
is controlled by a separate section in the control valve frame option.
6 2
The control valve is fitted on a bracket at the front end in the engine
compartment.
5 3
The control valve is controlled by Control unit, frame option (D797-O).
Control valve, option frame is made up of several sections, each sec-
4 tion controls one function. The following functions are controlled by
control valve, option frame.
• Support jacks
• Sliding cab/Cab lift
• Cab tilt
000624

1. Load signal (LS)
have flow limits so that several functions can be activated simultane-
3. Tank return (T1)
ously.
4. Connection, steering cylinder (B)
5. Tank return (TP)
Valve slide, support jacks
6. Connection, steering cylinder (A)
The valve slide controls the direction and speed of support jack lower-
ing by controlling the hydraulic pressure to hydraulic cylinder, support
jacks.
The valve slide is controlled by servo valve, support jacks up and ser-
vo valve, support jacks down.

7 Load handling – 7.10.1.2 Control valve, option frame 175
Servo valve, support jacks down

Servo valve, support jacks up controls servo pressure to valve slide
support jacks so that it controls oil pressure for support jacks up.
Servo valve support jacks down regulates electrically with the solenoid
valve support jacks down (Y6064), which is activated by Control unit,
frame option (D797-O).
Control system , group 8.4.11.3 SUPPORT JACKS, menu 3.
Servo valve, support jacks up

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 regulates electrically with the solenoid
valve support jacks up (Y6063), which is activated by Control unit,
Control system , group 8.4.11.3 SUPPORT JACKS, menu 3.
Control valve, option frame, replacement

page
–
NOTE
Safety.
Safety.

176 7 Load handling – 7.10.1.2 Control valve, option frame
1
NOTE
4
NOTE
tact and in place.
NOTE
000624

1. Load signal (LS)
up.
3. Tank return (T1) 7 Mark up the servo valves on the new control valve.
4. Connection, hydraulic cylinder (B) 8 Fit the valve.
5. Tank return (TP)
6. Connection, hydraulic cylinder (A)
marking.
with the marking.
NOTE
NOTE

7 Load handling – 7.10.1.2 Control valve, option frame 177
C AUTION
010475

C AUTION
product damage.

C AUTION


178 7 Load handling – 7.10.1.3 Hydraulic cylinder, support jacks
7.10.1.3 Hydraulic cylinder, support jacks

Hydraulic cylinder, support jacks, description
page
–
Hydraulic cylinder support jacks lowers the support jack up and down.
1 The hydraulic cylinder is located between support jacks and frame.
5
001870
7 6
1. Hydraulic cylinder, support jacks
2. Sensor, support jacks up (B7222)
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
7. Sensor, support jacks down (B7221)
7.10.1.4 Support jacks

Support jacks, description
page
–
The support jack consists of linkage and support. The linkage is de-
1 signed so that it locks automatically when it is loaded from below in its
lowered position.
2 The support jack is secured in the frame and in the drive axle’s attach-
ing bolts.
5
001870
7 6
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket

7 Load handling – 7.10.1.5 Sensor, raised support jacks 179
7.10.1.5 Sensor, raised support jacks

Sensor, support jacks up, description
page
–
Sensor, support jacks up (B7222) is located under hydraulic cylinder,

1 support jacks and senses when the support jack is raised. There is a
sensor for each support jack. The sensor indicates when the support
jack is fully raised. This is used to control the support jacks event
2 menu.
3 Control system , group 8.4.11.3 SUPPORT JACKS, menu 2.
Sensor, support jacks up (B7222) sends a voltage signal to Control
unit, frame option (D797-O) when the support jack is completely
4
raised.
5
001870
7 6
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket

page
–

180 7 Load handling – 7.10.1.6 Sensor, lowered support jacks
7.10.1.6 Sensor, lowered support jacks

Sensor, support jacks down, description
page
–
Sensor, support jacks down (B7221) is located under the support

1 jack’s upper mounting and detects when the support jack is lowered.
A sensor is fitted on each support jack. This is used to control the sup-
port jacks and the activation of the indicator light for support jacks
2 down.
3 Control system , group 8.4.11.3 SUPPORT JACKS, menu 2.
Sensor, support jacks down (B7221) sends a voltage signal to Control
unit, frame option (D797-O) when the support jack is completely low-
4
ered.
5
001870
7 6
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket

page
–

page
–
7.10.1.8 Shuttle valve, option

Shuttle valve, option description
page
–
See section 10 Common hydraulics, group 10.5.3 Shuttle valve.
7.10.1.9 Valve block, support jacks

Valve block, support jacks, description
page
–
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 Load handling – 7.10.2 Weight indicator 181
7.10.2 Weight indicator

Weight indicator, description
page
–
The weight indicator uses Sensor hydraulic pressure lift cylinder

(B768) and sensor boom angle to calculate the load. For more infor-
mation about sensors, see section 8 Control system , group 8.2.1
Overload system.
The pressure sensors can be checked from the diagnostic menu, see
tab 8 Control system , group 8.4.5.3 HYD, menu 3.
Fixed scale (only model year -2008)

The fixed scale weighs the load in a preset position on the boom by
measuring the pressure on the piston side in the lift cylinders. The
boom angle for the measuring position is indicated by a rod and mark-
ing on the left lift cylinder. The boom length for the measuring position
is indicated with an extra Sensor boom length (Position sensor boom
length 60 cm).
Dynamic scale
The dynamic scale weighs the load regardless of boom position. The
weight is calculated as a function of boom angle, boom length and the
pressure in the lift cylinders. The dynamic scale uses Sensor, hydrau-
lic pressure lift cylinder, Sensor, boom angle (analogue sensor) and
Sensor, boom length (analogue sensor).

182 7 Load handling – 7.10.2 Weight indicator
Weight indicator, function description (product

page
–
alternative fixed scale) (only model year -2008)

value
1 D1
3, 4
2 7, 12
D790-1 D795
D797-R 11 D797-F D791-1

6 9
D5 D10 D10 D8
10
006896
5 >˚ Pa Pa 8

1 The pistol trigger on the control lever US815/T4 = 24 V Section 9 Frame, body, cab and accesso-
sends a voltage signal to the cab control ries, group 9.1 Controls and instruments
unit (D790-1). D1: Diagnostic menu, see section 8 Control
system group 8.4.9.2 ATTACH, menu 2
weighing activated on the CAN bus. tem, error shown with 11.5.3.1 Cab control unit
error code.
3 Boom lowered to measuring position - Lifting/lowering, function description page 11

(when the boom is in measuring position
boom lowering is interrupted
automatically).
4 The boom is operated to 60 cm extension - Extension, function description (hydraulic oil

(when the boom is in measuring position pump alternative Rexroth) page 37
boom extension is interrupted
automatically).
5 Sensor, boom angle (B771) sends a volt- U = 0.5-4.5 V Section 8 Control system, group 8.2.1.5
age signal proportional to boom angle to Sensor, boom angle
Control unit, frame rear (D797-R). D5: Diagnostic menu, see section 8 Control
system, group 8.4.10.4 OP, menu
6 Control unit, frame rear (D797-R) trans- Checked by control sys- Section 11 Common electrics, group
mits boom angle on the CAN bus. tem, error shown with 11.5.3.3 Control unit, frame rear
error code. D5: Diagnostic menu, see section 8 Control
system, group 8.4.10.4 OP, menu


7 The KID control unit (D795) activates the - Section 11 Common electrics, group
event menu fixed scale (flashing). 11.5.3.12 KID control unit
8 Sensor, boom length 60 cm (B7224) U = 24 V Section 8 Control system, group 8.2.1.6

sends a signal to the attachment control Sensor, boom length
unit (D791-1). D8: Diagnostic menu, see section 8 Control
9 The attachment control unit (D791-1) Checked by control sys- Section 11 Common electrics, group
transmits Boom length 60 cm on the CAN tem, error shown with 11.5.3.5 Control unit, attachment
bus. error code. D8: Diagnostic menu, see section 8 Control
10 Sensor, hydraulic pressure lift cylinder U = 0.5 - 4.5 V Lift cylinder hydraulic pressure sensor, de-
piston side left (B768-L1) and Sensor hy- scription page 32
draulic pressure lift cylinder piston side D10: Diagnostic menu, see section 8 Con-
right (B768-R1) send a voltage signal to trol system, group 8.4.10.3 OP, menu 3
11 Control unit, frame front (D797-F) trans- Checked by control sys- Section 11 Common electrics, group
mits weight information on the CAN bus. tem, error shown with 11.5.3.2 Control unit, frame front
error code.
12 The KID control unit (D795) updates the - Section 11 Common electrics, group
weight information in the display (fixed 11.5.3.12 KID control unit
glow).

184 7 Load handling – 7.10.2 Weight indicator
Weight indicator, function description (product

page
–
alternative dynamic scale)

value
8
D790-1 D795
D797-F D797-R
7 3,5
D6
D2 D4
6
006897
Pa Pa Pa Pa 2 m <˚ 4

1 Operating menu dynamic scale is shown - Section 9 Frame, body, cab and accesso-
in the display. ries, group 9.1 Controls and instruments
2 Sensor, boom length (B777) sends a U = 0.5-4.5 V Section 8 Control system, group 8.2.1.6
voltage signal proportional to boom Sensor, boom length
length to Control unit, frame rear D2: Diagnostic menu, see section 8 Control
(D797-R). system, , group 8.4.10.4 OP, menu 4
mits boom length information on the CAN tem, error shown with er- 11.5.3.3 Control unit, frame rear
bus. ror code.
4 Sensor, boom angle (B771) sends a volt- U = 0.5-4.5 V Section 8 Control system, group 8.2.1.5
age signal proportional to boom angle to Sensor, boom angle
Control unit, frame rear (D797-R). D4: Diagnostic menu, see section 8 Control
system, , group 8.4.10.4 OP, menu 4
mits boom angle information on the CAN tem, error shown with er- 11.5.3.3 Control unit, frame rear
bus. ror code.


6 Sensor hydraulic pressure lift cylinder U = 0.5-4.5 V Lift cylinder hydraulic pressure sensor, de-
piston side left (B768-12), Sensor hy- scription page 32
draulic pressure lift cylinder rod side left D6: Diagnostic menu, see section 8 Control
(B768-11), Sensor hydraulic pressure lift system, group 8.4.10.3 OP, menu 3
cylinder piston side right (B768-10) and
Sensor hydraulic pressure lift cylinder
rod side right (B768-13) send voltage sig-
nals proportional to the hydraulic pres-
sure to Control unit, frame front
(D797-F).
7 Control unit, frame front (D797-F) calcu- Checked by control sys- Section 11 Common electrics, group
lates and sends the weight on the CAN tem, error shown with er- 11.5.3.2 Control unit, frame front
bus. The weight is calculated by a ma- ror code.
chine-unique load curve based on sensor
values for boom angle, boom length and
NOTE
The load curve is unique for each
machine.
8 The KID control unit (D795) shows - Section 11 Common electrics, group
weight information in the display. 11.5.3.12 KID control unit
Printer, description
page
–
Printer is an option for the dynamic scale function that makes it possi-
ble to save weights and print lists of saved weights.
The printer is connected to the KID control unit (D795) and is fitted on
a dashboard panel on the right side of the steering wheel.
The printer is controlled by the printer operating menu in the display,
where the driver selects the weights to be saved and what should be
printed.
004907
Printer location

186 7 Load handling – 7.10.2.1 Sensor hydraulic pressure lift cylinder
7.10.2.1 Sensor hydraulic pressure lift cylinder

Sensor hydraulic pressure lift cylinder, general
page
–
See Lift cylinder hydraulic pressure sensor, description page 32.
7.10.2.2 Sensor, boom angle

Sensor, boom angle, general
page
–
See section 8 Control system, group 8.2.1.2 Sensor, boom angle.
7.10.2.3 Sensor, boom length

Sensor, boom length, general
page
–
See section 8 Control system, group 8.2.1.3 Sensor, boom length.

7 Load handling – 7.10.3 Container counter 187
7.10.3 Container counter

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

counter has two counters that can be reset separately. The container
counter counts in different ways depending on whether the top lift
(twistlocks) or bottom lift (lifting jacks) is used.
Top lift
The container counter counts lifting when contact disappears with
locked twistlocks and twistlocks are not opened within 8 seconds.
Bottom lift
The container counter counts lifting when the clamp function is activat-
ed and lifting is started and unloading clamping position is not activat-
ed within 10 seconds.

188 7 Load handling – 7.10.3 Container counter
Container counter, function description (product

page
–
alternative top lift)

value
1, 4, 7
D1
10
D790-1 D795
D797-R D791-1
3, 6, 9
D5
D2
2, 8 5
006898

1 The attachment is positioned over a - Lifting/lowering, function description page 11
container with the functions 7.2 Lifting/ Extension, function description (hydraulic oil
lowering and 7.3 Extension. pump alternative Rexroth) page 37
system, group 8.4.8.1 BOOM, menu 1
2 The sensor for front left alignment Sensor directly oppo- Sensor alignment, description page 140
(7202L), sensor for front right alignment site indicator plate: U D2: Diagnostic menu, see section 8 Control
(7202R), sensor for rear left alignment = 24 V system, group 8.4.9.6 ATTACH, menu 6
ment (Y7203R) send a voltage signal to
the attachment control unit (D791-1).
3 The attachment control unit (D791-1) Checked by control Section 11 Common electrics, group 11.5.3.5
transmits alignment on the CAN bus. system, error shown Control unit, attachment
with error code.
4 Twistlocks are rotated to the locked po- - Twistlocks, function description page 130
sition and are closed with the 7.9.1
Twistlocks function.
5 The sensor for lock twistlocks left Sensor directly oppo- Sensor twistlocks, description page 141
(B7205L) and sensor for lock twistlocks site indicator plate: U D5: Diagnostic menu, see section 8 Control
right (B7205R) send a voltage signal to = 24 V system group 8.4.9.7 ATTACH, menu 7
the attachment control unit (D791-1).


transmits "locked twistlocks" on the system, error shown Control unit, attachment
CAN bus. with error code.
7 The container is lifted with the function - Lifting/lowering, function description page 11
7.2 Lift and lower.
8 The sensor for front left alignment U=0V Sensor alignment, description page 140
(7202L), sensor for front right alignment D2: Diagnostic menu, see section 8 Control
(7202R), sensor for rear left alignment system, group 8.4.9.6 ATTACH, menu 6
ment (Y7203R) stop sending a voltage
signal to the attachment control unit
(D791-1).
transmits no alignment on the CAN bus. system, error shown Control unit, attachment
with error code.
10 If the twistlocks remain locked for 8 sec- - Section 11 Common electrics, group 11.5.3.1
onds, the cab control unit (D790-1) adds Cab control unit
one lift to the container counter.

190 7 Load handling – 7.10.3 Container counter
Container counter, function description (product

page
–
alternative bottom lift)

value
Safety switch Disengaged Section 11 Common electrics , group 11.5.1.4 Emergency stop voltage (15E)
1 3 4
2, 7
D4
D3
D1
D2
10
D790-1 D795
6, 9 D791-3 D791-4 6, 9
D5 D8 D5
5 8 5 8 D8
006899
1 The attachment’s rear lifting jacks fold are - Raising/lowering of rear lifting jacks, function
lowered to operating position with the func- description page 148
tion 7.9.2 Lifting jacks. D1: Diagnostic menu, see section 8 Control
2 The attachment is positioned over a con- - Lifting/lowering, function description page 11

tainer with the functions 7.2 Lifting/lower- Extension, function description (hydraulic oil
ing and 7.3 Extension. pump alternative Rexroth) page 37
system , group 8.4.8.1 BOOM, menu 1
3 The front lifting jacks are lowered with the - Raising/lowering of front lifting jacks, function
function 7.9.2 Lifting jacks. description page 144
4 The lifting jacks clamp around the contain- - Clamp with left jacks, function description
er with the function 7.9.2 Lifting jacks. page 153


5 Sensor clamping position front jack left Sensor directly oppo- Sensor, clamping position, description page
(B7215L) and sensor clamping position site indicator plate: U 171
rear jack left (B7216L) send a voltage sig- = 24 V D5: Diagnostic menu, see section 8 Control
nal to Control unit, attachment left jack pair system , group 8.4.11.1 COMBI, menu 2
(D791-3).
Sensor clamping position front jack right
(B7215R) and sensor clamping position
rear jack right (B7216R) send a voltage
signal to Control unit, attachment right jack
pair (D791-4).
6 Control unit, attachment left jack pair Checked by control Section 11 Common electrics, group 11.5.3.7
(D791-3) and Control unit, attachment right system, error shown Control unit, attachment left jack pair
jack pair (D791-4) send clamping position, with error code. Section 11 Common electrics, group 11.5.3.8
lifting jacks on the CAN bus. Control unit, attachment right jack pair
7 The container is lifted with the function 7.2 - Lifting/lowering, function description page 11
Lift and lower.
8 Sensor alignment front jack left (B7213L) Sensor directly oppo- Sensor alignment, description page 170
and sensor alignment rear jack left site indicator plate: U D8: Diagnostic menu, see section 8 Control
(B7214L) send a voltage signal to Control = 24 V system , group 8.4.11.1 COMBI, menu 3
unit, attachment left jack pair (D791-3).
Sensor alignment front jack right (B7213R)
and sensor alignment rear jack right
(B7214R) send a voltage signal to Control
unit, attachment right jack pair (D791-4).
transmits alignment on the CAN bus. system, error shown Control unit, attachment
with error code.
10 If clamping position remains active for 10 - Section 9 Frame, body, cab and accessories,
seconds, the cab control unit (D790-1) group 9.1 Controls and instruments
adds one bottom lift to the container
counter.

192 7 Load handling – 7.10.4 Synchronised lift
7.10.4 Synchronised lift

Synchronised lift, function description
page
–

switch voltage
Height limitation
D1
+
2, 6
D790-1 D795
5 D797-R D797-F
D3 D4
006900
3 m <˚ 4

1 The control lever sends for lift or low- Lower: US815/P1 = 0.5–2.0 V Section 9 Frame, body, cab and accessories,
er and pistol trigger voltage signal to group 9.1 Controls and instruments
Lift: US815/P1 = 3.0–4.5 V
the cab control unit (D790-1). D1: Diagnostic menu, see section 8 Control
Pistol trigger: US815/T4 =
system , group 8.4.8.1 BOOM, menu 1 and
24 V 8.4.9.2 ATTACH, menu 2
2 The cab control unit (D790-1) trans- Checked by control system, Section 11 Common electrics, group
mits synchronised lift on the CAN error shown with error code. 11.5.3.1 Cab control unit
bus.
3 Sensor, boom angle (B771) sends a U = 0.5-4.5 V Section 8 Control system, group 8.2.1.5 Sen-
voltage signal to Control unit, frame sor, boom angle
rear (D797-R). D3: Diagnostic menu, see section 8 Control
system , group 8.4.10.1 OP, menu 1
4 Sensor, boom length (B777) sends a U = 0.5-4.5 V Section 8 Control system, group 8.2.1.6 Sen-
voltage signal to Control unit, frame sor, boom length
rear (D797-R). D4: Diagnostic menu, see section 8 Control
system, , group 8.4.10.4 OP, menu 4
5 Control unit, frame rear (D797-R) Checked by control system, Section 11 Common electrics, group
transmits length and angle informa- error shown with error code. 11.5.3.3 Control unit, frame rear
tion on the CAN bus.

7 Load handling – 7.10.4 Synchronised lift 193

6 The cab control unit (D790-1) control - Lifting/lowering, function description page 11
the functions 7.2 Lifting/lowering Extension, function description (hydraulic oil
and 7.3 Extension at the same time pump alternative Rexroth) page 37
so that the lifting movement is
vertical.

194 7 Load handling – 7.10.4 Synchronised lift

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

mm mm mm mm mm mm
8 Control system ............................................................................................... 3

8.1.4 Switch, bypass of load centre and height limitation ............................... 4
8.1.10 Error code menu .................................................................................... 4
8.2 Monitoring ................................................................................................... 7
8.2.1 Overload system .................................................................................... 7
8.2.2 Bypass ................................................................................................. 15
8.2.3 Load centre limitation ........................................................................... 16
8.2.4 Height limitation ................................................................................... 16
8.2.5 Speed limitation ................................................................................... 17
8.2.6 Service indicator .................................................................................. 17
8.4 Diagnostics ............................................................................................... 18
8.4.1 CAN/POWER ....................................................................................... 20
8.4.2 LIGHTS ................................................................................................ 40
8.4.3 CAB ..................................................................................................... 53
8.4.4 CLIMATE ............................................................................................. 62
8.4.5 HYD ..................................................................................................... 70
8.4.6 ENGINE ............................................................................................... 75
8.4.7 TRANSM .............................................................................................. 82
8.4.8 BOOM ................................................................................................ 101
8.4.9 ATTACH ............................................................................................ 109
8.4.10 OP ...................................................................................................... 132
8.4.11 EXTRA ............................................................................................... 137
8.4.13 RMI .................................................................................................... 166
8.5 Setup ...................................................................................................... 169
8.5.1 Initiation ............................................................................................. 169
8.5.2 Calibration .......................................................................................... 196

2 8 Control system

8 Control system 3
8 Control system
mm mm mm mm mm mm
Control system, general

page
–
In many cases the machines functions are controlled electrically. The

signals that control the machine are monitored to warn the operator or
limit the machine’s functions in case 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.
Diagnostic test is tool for performing service and troubleshooting with
menus in the machine’s display.
Settings is the tool for setting and adapting the machine’s functions.
The software creates the functions in the control system.

4 8 Control system – 8.1 Controls and instruments

8.1.4 Switch, bypass of load centre and
height limitation
Switch, bypass height limitation, description
page
–
Switches bypass height limitation (S1015) bypasses height limitation

and makes it possible to raise the boom above the limit for height lim-
itation, See Height limitation, description page 16.
The switch is supplied with voltage from and sends a voltage signal to
the Control unit, cab (D790-1) when the switch is activated.
008216
8.1.10 Error code menu

Error code menu, description
page
–
The control system’s display is divided into four fields that show infor-
C mation (see figure to the left).
D E • Field B: Error code level shown with a symbol.

• Field C: Indicates error code.
B
000389
• Field D: Indicates type of error.

• Field E: Indicates which function is affected by error code.
• The book symbol means that there's information in the operator's
manual.
Field B: Error code level

The control system gives error code information in three levels which
are indicated with a symbol in the lower left corner (B) on the display
unit.
• Stop
C Indicates a serious malfunction that may affect operator safety or
cause machine breakdown. The error code must be taken care of
D E
immediately. Stop working with the machine and contact service
immediately.
000350
The error code is shown automatically on the display.
• Warning
C Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine, con-
D E
tact service as soon as possible.
000351

8 Control system – 8.1.10 Error code menu 5
• Information
C Information to the operator that something should be taken care
of as soon as possible, e.g., defective light bulb. Take action to fix
D E the cause of the error code as soon as possible.
The error code is stored in the error code list under operating
000352
menu for service.
Field C: Error code number

The control system gives error codes from three sub-systems:
• Machine:
C
Shown with error code number XXX on display.
D E
B
000389
• Engine:
XXX/YY Shown with error code number XXX/YY on display.
D
NOTE
B If several error codes come from the engine, the error code
013390
level is shown for the most serious error code.
• Transmission:
XX/YY Shown with error code number XX/YY on display.
B
013391
Field D: Type of error

1. Too high/too low temperature.
1 2 3
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
4 5 6 5. Incorrect signal from control.

6. Incorrect signal to bulb.
7. Incorrect signal, for example, open circuit.
7
000396

6 8 Control system – 8.1.10 Error code menu
Field E: Affected function

1. Attachment
1 2 3
2. Rotation of attachment
3. Side shift-attachment
4. Length adjustment attachment
4 5 6 5. Levelling attachment
6. Twistlocks
7. Tilt attachment
7 8 9 8. Bottom lift-attachment
9. Bottom lift-attachment, clamping position
10. Bottom lift-attachment, jacks up/down
10 11 12 11. Boom up/down

12. Boom in/out
13. Pressure sensor lift cylinder (overload system, OP)
14. Overload system
13 14 15
15. Support jacks up/down
16. Hydraulic functions
17. Brake system
16 17 18
18. Steering
19. Engine
20. Transmission
19 20 21 21. Central lubrication
22. Control unit
23. Hardware-related error
22 23 24 24. Cab
25. Air conditioning system
26. Fuel system
25 26 27 27. Headlights
28. Windscreen wipers
29. Battery voltage
28 29 30 30. Bulb for lighting

000397

8 Control system – 8.2 Monitoring 7
8.2 Monitoring
8.2.1 Overload system
8.2.1.1 Mechanical overload system
Mechanical overload system, function description (model
page
–
year-2008)
3, 10
D795
4 2, 5, 7, 9 D797-R D793
8
D6
1 D1
006413
D4 >˚ 6

1 Sensor, steering axle load (B7221) Normal: U = 24 V Sensor, steering axle load, description page
sends a voltage signal to Control unit, Overload: U = 0 V 11
frame rear (D797-R) if the load on the D1: Diagnostic menu, see section 8 Control
steering axle is low. system , group 8.4.10.1 OP, menu 1
2 Control unit, frame rear (D797-R) sends Checked by control sys- Section 11 Common electrics, group
"Overload forward" on the CAN bus. tem; error indicated with 11.5.3.3 Control unit, frame rear
error code.
3 Control unit KID (D795) shows Event - Section 11 Common electrics, group
menu, overload forward. 11.5.3.12 KID control unit
4 Position sensor boom length 1.5 m Extension less than Sensor, boom length, description (position
(B777) sends a voltage signal to Control 1.5 m: U = 24 V sensor) page 13
unit, frame rear (D797-R) if the boom’s Extension more than D4: Diagnostic menu, see section 8 Control
extension is less than 1.5 m. 1.5 m: U = 0 V system , group 8.4.10.1 OP, menu 1
"boom length under 1.5m" on the CAN tem; error indicated with 11.5.3.3 Control unit, frame rear
bus. error code.
6 Sensor, boom angle (B771) sends a UB771/1 = 5 V Sensor, boom angle, description (angle sen-
voltage signal proportional to boom an- sor) page 12
UB771/2 = 0 V
gle to Control unit, frame rear (D797-R). D6: Diagnostic menu, see section 8 Control
UB771/3 = 0.5 - 4.5 V
"boom angle" on the CAN bus. tem; error indicated with 11.5.3.3 Control unit, frame rear
error code.
transmits speed information on the CAN tem; error indicated with 11.5.3.9 Control unit, transmission
bus. error code.

8 8 Control system – 8.2.1.2 Mechanical overload system with analogue position sensors

9 If both Position sensors, beam length Checked by control sys- Section 11 Common electrics, group
1.5 m (B777) send a voltage signal and tem; error indicated with 11.5.3.3 Control unit, frame rear
the boom angle is over 35 ° while the error code.
machine is operated faster than 10 km/h
then Control unit, frame rear (D797-R)
sends "Overload on steering axle" on
the CAN bus.
the Event menu for overload on steering 11.5.3.12 KID control unit
axle.
8.2.1.2 Mechanical overload system with

analogue position sensors
Mechanical overload system with analogue position
page
–
sensors, function description (model year-2008)
3, 8
D795
D797-R D793
D4 2, 7 6
4
m
D5
1 D1
006414
<˚ 5

1 Sensor, steering axle load (B7221) Normal: U = 24 V Sensor, steering axle load, description page
sends a voltage signal to Control unit, Overload: U = 0 V 11
frame rear (D797-R) if the load on the D1: Diagnostic menu, see section 8 Control
steering axle is low. system , group 8.4.10.1 OP, menu 1
"Overload forward" on the CAN bus. tem; error indicated with 11.5.3.3 Control unit, frame rear
error code.
3 Control unit KID (D795) activates Event - Section 11 Common electrics, group
menu, overload forward. 11.5.3.12 KID control unit
4 Sensor, boom length (R777) sends a UB777/1 = 5 V Sensor, boom length, description (analogue
voltage signal proportional to the boom sensor) page 14
UB777/2 = 0 V
(D797-R). UB777/3 = 0.5 - 4.5 V

8 Control system – 8.2.1.3 Electrical overload system 9

5 Sensor, boom angle (R771) sends a UB771/1 = 5 V Sensor, boom angle, description (angle sen-
voltage signal proportional to the boom sor) page 12
UB771/2 = 0 V
angle to Control unit, frame rear D6: Diagnostic menu, see section 8 Control
(D797-R). UB771/3 = 0.5 - 4.5 V
bus. error code.
7 If boom length is less than 1.5 m and Checked by control sys- Section 11 Common electrics, group
boom angle is greater than 35 ° while tem; error indicated with 11.5.3.3 Control unit, frame rear
the machine is operated faster than error code.
10 km/h then Control unit, frame rear
(D797-R) sends "Overload on steering
axle" on the CAN bus.
the Event menu for overload on steering 11.5.3.12 KID control unit
axle.
8.2.1.3 Electrical overload system

Electrical overload system, function description (standard
page
–
model year 2009-)
6
D795
D797-R D797-F D793

4 5, 8 2 7
m
D4 3 D3 D1 1
006415
<˚ Pa Pa

1 Sensor, hydraulic pressure lifting cylin- UB768-XX/1 = 5 V Section 8 Control system, group 8.2.1.7
der left (B768-L1 and B768-L2) trans- Sensor, hydraulic pressure lift cylinder
UB768-XX/2 = 0 V
mits a voltage signal proportional to the D1: Diagnostic menu, see section 8 Control
pressure in the left-hand lift cylinder to UB768-XX/3 = 0.5 - 4.5 V
Sensor, hydraulic pressure lifting cylin-
der right (B768-R1 and B768-R2) trans-
mits a voltage signal proportional to the
pressure in the right-hand lift cylinder to

10 8 Control system – 8.2.1.3 Electrical overload system

2 Control unit, frame front (D797-F) sends Checked by control sys- Section 11 Common electrics, group
pressure information on the CAN bus. tem; error indicated with 11.5.3.2 Control unit, frame front
error code.
3 Sensor, boom length (B777) sends a UB777/1 = 5 V Section 8 Control system, group 8.2.1.6
voltage signal proportional to the boom Sensor, boom length
UB777/2 = 0 V
(D797-R). UB777/3 = 0.5 - 4.5 V
Alternatively, Sensor, boom length
(B777) may have a position sensor for
none or maximum boom extension.
4 Sensor, boom angle (BR771) sends a UB771/1 = 5 V Section 8 Control system, group 8.2.1.5
voltage signal proportional to the boom Sensor, boom angle
UB771/2 = 0 V
angle to Control unit, frame rear D4: Diagnostic menu, see section 8 Control
(D797-R). UB771/3 = 0.5 - 4.5 V
5 Control unit, frame front (D797-F) calcu- Checked by control sys- Section 11 Common electrics, group
lates and sends the weight, which is cal- tem; error indicated with 11.5.3.2 Control unit, frame front
culated and compared with a machine error code.
unique load curve based on the sensor
values for boom angle, boom length and
NOTE
The load curve is unique for each
machine.
If the load is high then Control unit,
frame front (D797-F) sends Overload
forward on the CAN bus.
the event menu for overload, depending 11.5.3.12 KID control unit
on the load situation.
bus. error code.
8 In the event of overload on the steering Checked by control sys-

axle the speed is limited gradually with tem; error indicated with
the increasing load. error code

8 Control system – 8.2.1.4 Sensor, steering axle load 11
8.2.1.4 Sensor, steering axle load

Sensor, steering axle load, description
page
–
Sensors, steering axle load (B7221L and B7221R) detect when the
steering axle’s rear suspension decompresses. The sensors are fitted
on each side of the steering axle’s rear suspension.
Sensors, steering axle load, are inductive position sensors that are
supplied with voltage and send a voltage signal to Control unit, frame
rear (D797-R).
The sensor signals can be checked from the diagnostic menu, see
section 8 Control system , group 8.4.10.1 OP, menu 1.
005122
Location, Sensor, steering axle load (B7221L and

B7221R)

page
–
Sensor, steering axle load, replacement

page
–

2 Replace the sensor.
3 Adjust sensor position, see section 7 Load handling.
4 Turn on the main electric power and turn the ignition key to posi-
tion I.
5 Check the overload system, see section 8 Control system, group
8.2.1 Overload System.
005122

12 8 Control system – 8.2.1.5 Sensor, boom angle
8.2.1.5 Sensor, boom angle

Sensor, boom angle, description (angle sensor)
page
–
The boom’s angle is measured by a sensor that senses the boom’s an-
gle in relation to the frame. The sensor consists of a sensor housing,
potentiometer and arm. The sensor housing is mounted on the boom.
The arm is connected to the frame and turns the potentiometer when
the boom is angled.
The sensor is supplied with voltage by and sends a signal proportional
to the angle to Control unit, frame rear (D797-R).
001093
Sensor, boom angle (B771)
Sensor, boom angle, replacement (angle sensor)

page
–

tion I.
4 Calibrate Sensor, boom angle, see Weight indicator, calibration
(product alternative fixed scale) (only model year -2008) page
198 or Weight indicator, calibration (product alternative dynamic
scale) page 200.
5 Check that the end position damping is working in both outer and
inner end positions.

8 Control system – 8.2.1.6 Sensor, boom length 13
8.2.1.6 Sensor, boom length

Sensor, boom length, description (position sensor)
page
–
Sensor, boom length specifies the boom’s extension and is available

in two versions, position sensors or analogue sensors. Standard is
three inductive position sensors. As an option there is an extra position
sensor for fixed scale (60 cm extension).
Two inductive sensors, Sensor, damping boom in (B769-3) and Sen-
sor, damping boom out (769-4), are used to control the damping of
boom in and boom out. The sensors are located on the right-hand side
of the lift boom’s outer part.
The sensors are supplied with voltage by and send a negative signal
(grounding) to Control unit, frame rear (D797-R) when the boom’s in-
dicator plate passes the sensor. Each sensor has an LED that is acti-
vated when sensors sense the indicator plate. The LEDs can be used
1
to check the sensor’s function.
2 Position sensor damping extension sends a signal when the boom is

close to outer and inner end positions, this is used to activate damping,
3 see section 7 Load handling , group 7.3 Extension . The signal can be
checked from the diagnostic menu, see section 8 Control system ,
001203
4 group 8.4.8.8 BOOM, menu 8.

1. Position sensor, damping boom in (B769-3) Position sensor boom length 1.5 m (B777) sends a signal when the
2. Position sensor 1.5 m (B777) boom’s extension is 1.5 m. This signal is used for the overload system
3. Position sensor, damping boom out (B769-4) on the steering axle. The signal can be checked from the diagnostic
4. Position sensor, boom length 60 cm (B7224) menu, see section 8 Control system , group 8.4.10.1 OP, menu 1.
Position sensor boom length 60 cm (B7224) sends a signal when the
boom’s extension is in position for weighing on machines with fixed
scale, see section 7 Load handling , group 7.10.2 Weight indicator .

page
–
Sensor, boom length (position sensor), replacement

page
–

3 Adjust sensor position, see section 7 Load handling.
4 Check that the end position damping is working in both outer and
inner end positions.

14 8 Control system – 8.2.1.7 Sensor hydraulic pressure lift cylinder
Sensor, boom length, description (analogue sensor)

page
–
Sensor, boom length (R777) senses the lift boom’s extension and is
located in the rear edge of the boom on the left-hand side.
The sensor is connected to a spring-loaded wire that is connected to
a rotary potentiometer via a gearbox. The wire is connected to the in-
ner boom. When the boom is extended, the wire acts on the potenti-
ometer and the signal is changed.
The sensor is supplied with voltage by and sends a voltage signal pro-
portional to the length to Control unit, frame rear (D797-R).
000471 8 Control system , group 8.4.10.4 OP, menu 4.
Sensor, boom length (R777)
Sensor, boom length (analogue sensor), replacement

page
–

tion I.
4 Calibrate the sensor, see Weight indicator, calibration (product
alternative dynamic scale) page 200.
5 Check that the end position damping is working in both the outer
and the inner end positions.
8.2.1.7 Sensor hydraulic pressure lift cylinder

Sensor hydraulic pressure lift cylinder, general
page
–
See section 7 Load handling, group 7.2.9 Sensor, hydraulic pressure

lift cylinder.

8 Control system – 8.2.2 Bypass 15
8.2.2 Bypass
Bypassing, description
page
–
When the overload system engages and turns off the hydraulic con-
trols, it may take place in a situation where it is necessary to bypass
the safety system.
Bypass is activated with a switch, there are between one and three
switches depending on the machine’s equipment:
• Switch, bypass
• Switch, bypass height limitation
• Switch rotation stop

Bypassing the safety system makes the following possible:
• lower load at overload
• locking and opening twistlocks without full alignment
• spread 20’-40’ with locked twistlocks
• bottom lift without full alignment
• manual control of the recirculation damper for ECC or EHC
• release of parking brake in case of malfunction of Switch, parking
brake or Sensor, operator in seat
• lift above height limitation
• rotation past rotation stop
• load handling past limitation for load centre limitation.
• lift, lower and extension with active error on the overload system
• selection of travel direction in case of malfunction of Sensor, op-
erator in seat, speed is limited to 10 km/h
D ANGER
Bypassing the safety systems results in a risk of tip-
ping. Use at your own risk.

16 8 Control system – 8.2.3 Load centre limitation
8.2.3 Load centre limitation

Load centre limitation, description
page
–
Load centre limitation prevents the load from coming too close to the
machine. The load centre limitation is controlled by the control system
with signals from Sensor, boom angle, see Sensor, boom angle, de-
000358
scription (angle sensor) page 12 and Sensor, boom length, see Sen-
sor, boom length, description (analogue sensor) page 14. For
Event menu, load centre limitation.
example, this is used in connection with cab lift to prevent the contain-
er damaging the cab.
For details about lift, lower and extension, see section 7 Load han-
dling, group 7.2 Lifting/lowering and section 7 Load handling, group
7.3 Extension.
Load centre limitation reaches its limit, synchronised lift is activated
(see section 7 Load handling, group 7.10.4 Synchronised lift) this
function can be temporarily disengaged using Switch, bypass (see By-
passing, description page 15).
Load centre limitation values can be checked from the diagnostic
menu, see 8 Control system , group 8.4.10.5 OP, menu 5.
8.2.4 Height limitation

Height limitation, description
page
–
Height limitation is a part of the control system and prevents the ma-
chine lifting higher than a preset height, without the operator being in-
formed.
Height limitation is controlled by the control system with signals from
Sensor, boom angle, and Sensor, boom length. When boom angle
and extension indicate that permitted height is reached, lift and exten-
sion are blocked and display information height limitation is activated.
For details about lift, lower and extension, see section 7 Load han-
dling, group 7.2 Lifting/lowering and section 7 Load handling, group
7.3 Extension.
Height limitation can be temporarily disengaged using Switch, bypass
of load centre and height limitation (S1015), see Switch, bypass height
limitation, description page 4.
Height limitation values can be checked from the diagnostic menu, see

8 Control system – 8.2.5 Speed limitation 17
8.2.5 Speed limitation

Speed limitation, description
page
–
Speed limitation prevents the machine’s speed from exceeding pre-

set value by limiting gear position and engine rpm.
Speed limitation is set via the initiation menu; see section 8 Control
system , group 8.5.1.5 INIT DRIVE-TRAIN, menu 9.
8.2.6 Service indicator

Service indicator, resetting
page
–

2 First navigate to the service menu and press Enter.
000056
3 Enter the code for service indicator reset.

Code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060
The code determines which service menu shall be activated

(Service, Diagnostics, Initiation or Calibration).
4 Reset the service indicator by pressing Enter. NEXT SERVICE is
SERVICE INTERVALL changed to indicated interval.
NEXT SERVICE XXXXh
SERVICE INTERVALL To change duration of the service interval, set the desired interval
STORED XXXXh with the plus or minus key.
004908
PRESENT XXXXh

18 8 Control system – 8.4 Diagnostics
8.4 Diagnostics
Diagnostic test, general
page
–
The machine has built-in functions for troubleshooting called diagnos-

DIAGNOSIS tic test. The diagnostic test consists of several menus shown on the
CAN/POWER LIGHTS CAB display. The menus are grouped for faster access. The following pag-
CLIMATE HYD ENGINE
es describe the menu figures content and which functions that can be
TRANSM BOOM ATTACH
009268
controlled.
OP EXTRA RMI
The diagnostic test is divided into the following groups:
• Voltage feed and communication for the Control system, CAN/
POWER, description page 20.
• Lighting, LIGHTS, description page 40.
• Cab functions, CAB, description page 53.
• Air conditioning, CLIMATE, description page 62.
• Hydraulic functions, HYD, description page 70.
• Engine, ENGINE, description page 75.
• Transmission, TRANSM, description page 82.
• Boom functions, BOOM, description page 101.
• Attachment functions, ATTACH, description page 109.
• Overload system, OP, description page 132.
• Optional functions, EXTRA, description page 137.
– Bottom lift, COMBI, menu 1 page 137.
– Hydraulic sliding/vertically adjustable cab, SLIDING-CAB,
menu 1 page 154.
– Support jacks, SUPPORT-JACKS, menu 1 page 158
– Mini-wheel or lever steering, EL-STEERING, menu 1 page
161
• RMI (Remote Machine Interface), RMI, description page 166
Diagnostic menu, description

page
–
Diagnostic tests show how the control units interpret input signals as
1 2 3 4
well as which signals that the control units send.
7 DIAG CAB 2(10)

FRONT WIPER
SWITCH (1-3) 2
6 OUTPUT 11 5
004856
FEEDBACK 0
1. DIAG = Diagnostic menus
2. Menu group
3.Menu number
4.Total number of menus in the loop
5.Signal value
6.Variable
7. Menu heading

8 Control system – 8.4 Diagnostics 19
DIAG Indicates that diagnostic tests are selected.
Menu group Indicates which menu group is selected, these groups are:
CAN/POWER, description page 20.
LIGHTS, description page 40.
CAB, description page 53.
CLIMATE, description page 62.
HYD, description page 70.
ENGINE, description page 75.
TRANSM, description page 82.
BOOM, description page 101.
ATTACH, description page 109.
EXTRA, description page 137.
Menu number Number of current menu. Every menu group consists of several menus in a loop.
Number of Total number of menus in the group.

menus
Variable The signal that is measured. Different signals are designated in different ways:
SWITCH: a digital input signal, e.g., a switch.
OUTPUT: a digital output signal, e.g., feed to a motor.
INPUT: an analogue input signal, e.g., from a sensor.
REFERENCE: status for an analogue output signal.
REQUIRED: triggered output signal for a control current
FEEDBACK: either feedback signal from a motor or measured current on the minus side for an analogue
output signal.
Signal value Measurement value or status for signal for variable. On the same row there are different types that are
interpreted in different ways.
SWITCH: 1 or 0 where 1 means closed circuit.
OUTPUT: two characters where the first number is 1 if the output signal is active. The second number is
status for the circuit, 1=circuit OK, 0=open circuit or short-circuiting.
INPUT: numerical value corresponding to the signal.
REFERENCE: two characters where the first number is 1 if the input signal is active. The second number
is status for the circuit, 1=circuit OK, 0=open circuit or short-circuiting.
REQUIRED: numerical value corresponding to the signal.
FEEDBACK: numerical value corresponding to the signal.
Menu heading Description of the function for which the menu reads signals.

20 8 Control system – 8.4.1 CAN/POWER
8.4.1 CAN/POWER
CAN/POWER, description
page
–
This group handles redundant voltage feed to control units and CAN
DIAGNOSIS bus communication.
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE Confirm selection with function key for Enter.
TRANSM BOOM ATTACH
009268
OP EXTRA RMI
8.4.1.1 CAN/POWER, menu 1

PRESENT REDCAN STATUS, COMMUNICATION MODE
page
–
Description: Indicates communications status for the redundant CAN-

DIAG CAN/POWER 1(20) bus.
PRESENT REDCAN STATUS
COMMUNICATION MODE X Circuit diagram: -
NUMBERS OF UNITS X Connection: -
003177
SEGMENT ERROR X
Function: 11.6.2 Redundant CAN-bus
Signal value:
3 Ok.
2 Segment check
0 Error.
PRESENT REDCAN STATUS, NUMBER OF UNITS

page
–
Description: Indicates the number of nodes on the redundant CAN bus

DIAG CAN/POWER 1(20) that should be on the machine in question, excluding Control unit, cab
PRESENT REDCAN STATUS (D790-1) and Control unit, KID (D795). (Control unit, transmission
COMMUNICATION MODE X (D793) and Control unit, engine (D794) are connected to a separate
NUMBERS OF UNITS X
CAN bus and are therefore not counted).
003177
SEGMENT ERROR X
Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
CAN BUS ATT group, 11.6
Connection: -
Signal value:
X Number of nodes that should be in the machine. Number of

nodes dependent on installed options.

8 Control system – 8.4.1.2 CAN/POWER, menu 2 21
PRESENT REDCAN STATUS, SEGMENT ERROR

page
–
Description: Indicates if there is open circuit on the redundant CAN

DIAG CAN/POWER 1(20) bus. And if there is, where the first open circuit is. If there is open cir-
PRESENT REDCAN STATUS cuit, it is indicated with a number that corresponds to the incorrect seg-
COMMUNICATION MODE X ment on the redundant CAN bus.
NUMBERS OF UNITS X
003177
SEGMENT ERROR X Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
Connection: -
Signal value:
0 No open circuit.
>0 If X is separated from 0, the first segment is indicated as

missing contact. A 1 means that the first segment is incorrect,
that is, that contact between first and second control unit is
cut off.
To see which control units are installed on the machine along
with their order, use diagnostic menu CAN/POWER, menu 2,
see PRESENT REDCAN STATUS, RED.CON.CITIES page
21.

PRESENT REDCAN STATUS, RED.CON.CITIES
page
–
Description: Indicates which control units have contact with the cab
DIAG CAN/POWER 2(20) control unit (D790-1) via the redundant CAN bus. Note that certain
PRESENT REDCAN STATUS control units are optional and may not be installed on the machine.
RED.CON.CITIES
XYXYXYXY Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
000087
1234ROFD CAN BUS ATT group, 11.6

Connection:
D790-1: K13:4, K13:5, K13:7 and K13:8
D795: K1:10, K1:11, K1:12 and K1:13
D797-F, D797-R, D797-O, D791-1, D791-2, D791-2, D791-3,
D797-4: K2:2, K2:3, K2:4 and K2:5
Function: 11.5.3.1 Control unit, cab, 11.5.3.2 Control unit, frame front,
11.5.3.3 Control unit, frame rear, 11.5.3.4 Control unit, frame option,
11.5.3.5 Control unit, attachment, 11.5.3.6 Control unit, attachment
option, 11.5.3.7 Control unit, attachment left jack pair, 11.5.3.8 Control
unit, attachment right jack pair, 11.5.3.12 Control unit KID, 11.6.2 Re-
dundant CAN bus

22 8 Control system – 8.4.1.3 CAN/POWER, menu 3
Signal value:
1 Communication with the node is OK.
0 No communication and/or there is some node error.
Position 1: Control unit, attachment (D791-1)
Position 2: Control unit, attachment option (D791-2)
Position 3: Control unit, attachment left jack pair (D791-3)
Position 4: Control unit, attachment right jack pair (D791-4)

Position R: Control unit, frame rear (D797-R)
Position O: Control unit, frame option (D797-O)

Position F: Control unit, frame front (D797-F)
Position D: Control unit, KID (D795)

PRESENT DRIVE-TRAIN CAN BUS STATUS, ENGINE
page
–
Description: Indicates status for engine in drivetrain’s CAN bus.

DIAG CAN/POWER 3(20) Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
PRESENT DRIVE-TRAIN
CAN BUS STATUS engine Volvo 1240&1250, group 1.0, Circuit engine Cummins
ENGINE X group 1.0
000088
TRANSMISSION X Connection:
Volvo TWD1240VE: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/1 and 2
Volvo TAD1250VE: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/1 and 2
Cummins QSM11: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/46 and 37
Function: 11.6.3 Communication
Signal value:
NOTE
The cable harness for CAN bus drivetrain is common to the en-
gine and transmission from the cab electronic box to the frame
electronic box. The cable branches in the frame electronic box. If
communication with both the engine and transmission is cut off,
start troubleshooting at the cable harness between the cab elec-
tronic box and the frame electronic box. If there is communication
(either engine or transmission), this rules out a fault in the cable
harness between the cab electronic box and the frame electronic
box.

PRESENT DRIVE-TRAIN CAN BUS STATUS,

page
–
TRANSMISSION
Description: Indicates status for transmission in drivetrain’s CAN bus
DIAG CAN/POWER 3(20) Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
PRESENT DRIVE-TRAIN
CAN BUS STATUS Dana TE 32000 group 2.0, Circuit Dana TE 32000FF group 2.0
ENGINE X Connection: CAN J1939 from D790-1/K13:1 and K13:2 to D793/L2
000088
TRANSMISSION X and M2
Function: 11.6.3 Communication
Signal value:
NOTE
The cable harness for CAN bus drivetrain is common to the en-
gine and transmission from the cab electronic box to the frame
electronic box. The cable branches in the frame electronic box. If
communication with both the engine and transmission is cut off,
start troubleshooting at the cable harness between the cab elec-
tronic box and the frame electronic box. If there is communication
(either engine or transmission), this rules out a fault in the cable
harness between the cab electronic box and the frame electronic
box.

IGNITION, KEY IN
page
–
Description: Indicates if ignition is on (key in ignition).

DIAG CAN/POWER 4(X)
Circuit diagram: Circuit Power group 11.5
INGNITION
KEY IN X Connection: signal from S150/15 to D790-1/K11:1
RELAY K315-1 XY
Function: 11.5.1.3 Ignition voltage
006859
RELAY K315-2 XY
Signal value:
1 Input signal active.
0 No signal.

IGNITION, RELAY K315-1

page
–
Description: Control current to Relay ignition voltage (K315-1),

DIAG CAN/POWER 4(X) 15-voltage.
INGNITION
KEY IN X Circuit diagram: Circuit Power group 11.5
RELAY K315-1 XY Connection: signal from D790-1/K10:10 to K315-1/86
006859
RELAY K315-2 XY
Function: 11.5.1.3 Ignition voltage (15)
Signal value:
00 No output signal and open circuit in the circuit.
01 Normal mode function off.

No output signal, circuit OK. It can also be a short circuit as
this is only detected when the output signal is active.
10 Output signal active, short-circuiting.
11 Normal mode function on.

Output signal active, circuit OK. It can also be an open circuit
as this can only be detected when the output signal is miss-
ing.
IGNITION, RELAY K315-2

page
–
Description: Control current to Relay ignition voltage (K315-2), 15-volt-

DIAG CAN/POWER 4(X) age.
INGNITION
KEY IN X Circuit diagram: Circuit Power group 11.5
RELAY K315-1 XY Connection: signal from D790-1/K10:16 to K315-2/86
006859
RELAY K315-2 XY
Signal value:


as this can only be detected when the output signal is
missing.


EMERGENCY STOP, SW
page
–
Description: Indicates if switch, control switch, is activated.

DIAG CAN/POWER 5(X)
EMERGENCY STOP, SW X
RELAY K3009-1 XY Connection: signal from S250/12 to D790-1/K8:4
FEEDBACK X
Function: 11.5.1.4 Emergency stop switch voltage (15E)
006860
RELAY K3009-2 XY
Signal value:
0 No signal.
EMERGENCY STOP, RELAY K3009-1

page
–
Description: Status for control current to Relay K2, for emergency stop
DIAG CAN/POWER 5(X) switch voltage (K3009-1), 15E voltage.
RELAY K3009-1 XY Circuit diagram: Circuit Power group 11.5
FEEDBACK X Connection: signal from D790-1/K10:11 to K3009-1/86
006860
RELAY K3009-2 XY
Signal value:


missing.
EMERGENCY STOP, FEEDBACK

page
–
Description: Feedback signal from emergency stop switch voltage re-

DIAG CAN/POWER 5(X) lay (K3009-1); indicates that relay is working normally.
FEEDBACK X Connection: signal from K3009-1/87 via F58-3/8 to digital in D790-1/
006860
RELAY K3009-2 XY K11:13

Signal value:
0 No signal.

EMERGENCY STOP, RELAY K3009-2

page
–
Description: Status of control current to emergency stop switch volt-

DIAG CAN/POWER 5(X) age relay (K3009-2), 15E-voltage.
FEEDBACK X Connection: signal from D790-1/K10:12 to K3009-2/86
006860
RELAY K3009-2 XY
Signal value:


missing.

790-1 CAB, POWER
page
–
Description: Ignition voltage (15) to cab control unit (D790-1).

DIAG CAN/POWER 6(20)
790-1 CAB
POWER XX.XXV Connection: 15-voltage from K315-1/87 via F54/4 and F58-5/1 to
5V REF X.XXV D790-1/K1:2, D790-1/K1:3 and D790-1/K1:4
000091
Function: 11.5.1 Voltage feed

Signal value: XX.XXV = voltage on the connection. The signal value
should be 22-30 V (battery voltage).
790-1 CAB, 5V REF

page
–
Description: Reference voltage 5 V to controls in cab.

Circuit diagram: Circuit Climate system group 9.4 (contact 1, 2), Circuit
790-1 CAB
POWER XX.XXV Drivetrain group 1.1 (contact 3), Circuit Joystick group 7.1 (contact 4)
5V REF X.XXV Connection:
000091
1. signal from digital out D790-1/K4:5 to Y672/10 and Y673/10

2. signal from digital out D790-1/K5:11 to S118/1, S 139/1 and
S117/1
3. signal from digital out D790-1/K5:13 to B690-1/1 and B697/1
4. signal from digital out D790-1/K7:2 to S815/9
Function: 9.4 Heating, ventilation and air conditioning (contact 1
and 2); 1 Engine and 2 Transmission (contact 3); 7 Load handling
(contact 4)
Signal value: X.XXV = 5.00 V, Important that the signal value is stable
(not varying).


790-1 CAB, 24V SENSOR SUPPLY
page
–
Description: 24 V voltage feed to components in cab.

Circuit diagram:
790-1 CAB
24V SENSOR SUPPLY XY 1. Circuit Wiper group 9.5
24V SUPPLY,RPM>500 XY
003178
2. Circuit Extra equipment group 9.1, Circuit Drivetrain group 2.1,
Circuit Cab driver’s seat group 9.3, Circuit Lighting group 9.6, Cir-
cuit Working lights group 9.6 and Circuit Extra Sensor Instr. group
9.1
3. Circuit Joystick group 7.1
4. Circuit Power group 11.5, Circuit Brake group 4.0, Circuit Bypass
group 8.2, Circuit Sliding/Vertically adjustable Cab group 9.10,
Circuit Hyd Support jacks group 7.10, Circuit Twistlocks group
7.9, Circuit Spreading Sensor group 7.5, Circuit Extra equipment
group 9.1
5. Circuit Combi Att group 7.9
6. -
7. Circuit Sliding/Vertically adjustable Cab group 9.10
8. Circuit Alarm, audible signals group 9.7
9. Circuit Wiper group 9.5
10. Circuit Wiper group 9.5
Connection:
1. signal from digital out D790-1/K4:14 to M650-1/53a
2. signal from digital out D790-1/K5:1 to S199-1/5, S199-3/5, S199-
4/5, S220-2/1, S143/5, S100/5, S110/5, S105-3/5, S105-2/5,
S105-1/5
4. signal from digital out D790-1/K8:16 to S250/11, S107/5, S1005/
5, S1015/5, S1014/5, S177/3, S1013/3, S1003/3, S1003/4,
S1004/5, S199-2/5
5. signal from digital out D790-1/K9:1 to S1006/3, S1007/3, S1008/3
6. signal from digital out D790-1/K9:7 not connected
7. signal from digital out D790-1/K10:1 to B769-2/1

Function:
1. 9.5.5 Wiper motor front
2. 2.0 Transmission, 9.3 Seat, 9.6 Lighting
3. 7.1.1 Control lever
4. 11.5.1.4 Emergency stop voltage, 4.5 Parking brake system, 8.2.2
Bypass, 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab,
7.10.1 Support jacks, 7.9.1 Twistlocks
5. 7.9.2 Lifting jacks
6. -
7. 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab
8. 9.3.10 Sensor operator in seat
9. 9.5.7 Wiper motor rear
10. 9.5.6 Wiper motor roof
Signal value:

No output signal. It can also be a short circuit in the circuit as
this fault can only be detected when the output signal is ac-
tive.
10 Output signal active, short-circuit. It can also be open circuit

as this cannot be detected.

Output signal active, circuit OK or open circuit. Open circuit
cannot be detected.
790-1 CAB, 24V SUPPLY, RPM >500

page
–
Description: Voltage feed at engine speed is higher than 500 rpm.

Circuit diagram: Circuit Sensor instr. group 9.1
790-1 CAB
24V SENSOR SUPPLY XY Connection: signal from digital out D790-1/K10:9 to P708/+ and K358/
24V SUPPLY,RPM>500 XY 86
003178
Function: 9.3.6 Compressor air-suspension seat, 11.1.1 Hour meter

Signal value:


missing.


797-F FRAME, POWER
page
–
Description: Ignition voltage (15) to Control unit, frame front (D797-F).

797-F FRAME
POWER XX.XXV Connection: 15 voltage from K315-1/87 via F54/4 and F58-2/1 to
RED.POWER Le X Ri X D797-F/K2:1, D797-F/K2:9 and D797-F/K2:10
000093
EME STOP POWER X
797-F FRAME, RED. POWER

page
–
Description: Redundant voltage to Control unit, frame front (D797-F).

Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6
797-F FRAME
POWER XX.XXV Connection:
RED.POWER Le X Ri X
000093
Le: redundant feed to D797-F/K2:7

EME STOP POWER X
Ri: redundant feed to D797-F/K2:8
Function: 11.5.1.2 Redundant voltage feed of control units
Signal value:
1 Feed active.
0 No feed.
797-F FRAME, EME STOP POWER

page
–
Description: Emergency stop voltage to Control unit, frame front

DIAG CAN/POWER 8(20) (D797-F).
797-F FRAME
POWER XX.XXV Circuit diagram: Circuit Power group 11.5
RED.POWER Le X Ri X Connection: 15E-voltage from K3009-1787 via K3009-2/87 and
000093
EME STOP POWER X F58-3/2 to D797-F/K2:11

Signal value:
1 Feed active.
0 No feed.


797-F FRAME, 24V SENSOR SUPPLY
page
–
Description: Voltage feed 24 V to sensors connected to Control unit,

DIAG CAN/POWER 9(20) frame front (D797-F) (pressure switches).
797-F FRAME
24V SENSOR SUPPLY XY Circuit diagram: Circuit Brake system group 4.0, Circuit Drivetrain
5V REF X.XXV group 2.1, Circuit Lighting group 9.6
000094
Connection: signal from digital out D797-F/K1:39 to S, 200, S204,
S216 and S220
Function: 9.6.4 Brake light, 2.2.6 NO (normally open) switch declutch,
4.3.7 NO (normally open) switch brake pressure, 4.3.8 NO (normally
open) switch brake light 4.5.5 NO (normally open) switch parking
brake
Signal value:


ing.
797-F FRAME, 5V REF

page
–
Description: Reference voltage 5 v to sensors connected to Control

DIAG CAN/POWER 9(20) unit, frame front (D797-F) (voltage feed to pressure sensors).
797-F FRAME
24V SENSOR SUPPLY XY Circuit diagram: Circuit OP + Scale group 8.2
5V REF X.XXV Connection: digital out from 797-F/K1:8 to B768-R1, B768-R2,
000094
B768-L1 and B768-L2

Function: 7.2.9 Sensor hydraulic pressure lift cylinder
Signal value: X.XXV = 5.00 V. Important that signal value is stable (not
varying).

797-R FRAME, POWER
page
–
Description: Ignition voltage (15) to Control unit, frame rear (D797-R).

Circuit: Circuit Power group 11.5
797-R FRAME
POWER XX.XXV Connection: 15 voltage from K315-1/87 via F54/4 and F58-2/3 to
RED.POWER Le X Ri X D797-R/K2:1 and D797-R/K2:9
000095


797-R FRAME, RED. POWER

page
–
Description: Redundant voltage to Control unit, frame rear (D797-R).

797-R FRAME
POWER XX.XXV Connection:
RED.POWER Le X Ri X
Le: redundant feed to D797-R/K2:7
000095
Ri: redundant feed to D797-R/K2:8
Signal value:
1 Feed active.
0 No feed.

797-R FRAME, 24V SENSOR SUPPLY
page
–
Description: Voltage feed 24 V to sensors connected to Control unit,

DIAG CAN/POWER 11(20) frame rear (D797-R).
797-R FRAME
5V REF X.XXV Connection: digital out from D797-R/K1:2 to B7221
000096
Function: 8.2.1.1 Sensor, steering axle load

Signal value:


missing.
797-R FRAME, 5V REF

page
–
Description: Reference voltage 5 V to sensors connected to Control

DIAG CAN/POWER 11(20) unit, frame rear (D797-R).
797-R FRAME
5V REF X.XXV Connection: digital out from 797-R/K1:8 to B771/1 and B777/1
000096
Function: 8.2.1.2 Sensor, boom angle (angle sensor), 8.2.1.3 Sensor,

boom length (analogue sensor)
Signal value: X.XXV = 5.00 V. Important that signal value is stable (not
varying).


797-O FRAME, POWER
page
–

797-O FRAME Description: Ignition voltage (15) to Control unit frame option
POWER XX.XXV (D797-O).
RED.POWER Le X Ri X
000097
EME STOP POWER X Circuit diagram: Circuit Power group 11.5
Connection: 15-voltage from K315-1/30 via F54/4 and 58-2/4 to
D797-O/K2:10
797-O FRAME, RED. POWER

page
–

797-O FRAME Description: Redundant voltage to Control unit frame option (D797-O).
POWER XX.XXV Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6
RED.POWER Le X Ri X
000097
EME STOP POWER X Connection:

Le: redundant feed to D797-O/K2:7
Ri: redundant feed to D797-O/K2:8
Signal value:
1 Feed active.
0 No feed.
797-O FRAME, EME STOP POWER

page
–

797-O FRAME Description: Emergency stop voltage (15E) to Control unit frame op-
POWER XX.XXV tion (D797-O).
RED.POWER Le X Ri X
000097
EME STOP POWER X Circuit diagram: Circuit Power group 11.5

Connection: 15E-voltage from K3009-1/87 via K3009-2/87 and F58-3/
4 to D797-O/K2:11
Signal value:
1 Feed active.
0 No feed.


797-O FRAME, 24V SENSOR SUPPLY
page
–

797-O FRAME Description: Battery voltage to sensor.
24V SENSOR SUPPLY XY Circuit diagram: Circuit Hyd Support jacks group 7.10, Circuit Tiltable
5V REF X.XXV
000098
cab group 9:10
Connection: digital out D797-O/K1:9 to B7222L, B7222R, B7223L,
B7223R
Function: 7.10.1.5 Sensor, raised support jacks, 7.10.1.6 Sensor, low-
ered support jacks
Signal value:


ing.
790-O FRAME, 5V REF

page
–

797-O FRAME Description: not connected
24V SENSOR SUPPLY XY Circuit diagram: -
5V REF X.XXV
000098
Connection: digital out from D797-O/K1:8, not connected

Function: -
Signal value: -

795 DISPLAY, RED. POWER
page
–
Description: Redundant voltage to KID control unit (D795).

795 DISPLAY
Connection:
RED.POWER Le X Ri X
000099
Le: redundant feed to D790/K1:8

Ri: redundant feed to D790/K1:7
Signal value:
1 Feed active.
0 No feed.


793 TRANSMISSION, POWER
page
–
Description: Battery voltage (30) to transmission control unit (D793).

Circuit diagram: Circuit Power group 11.5, Circuit Dana TE 32000
793 TRANSMISSION
POWER XX.XXV group 2.0, Circuit Dana TE 32000FF group 2.0
IGNITION POWER XX.XXV Connection: 30-voltage from F54/2 via F58-1/5 to D793/A1
000100
SENSOR SUPPLY XX.XXV
Function: 11.5.1.1 Battery voltage (30)
793 TRANSMISSION, IGNITION POWER

page
–
Description: Ignition voltage (15) to transmission control unit (D793).

Circuit diagram: Circuit Power group 11.5, Circuit Dana TE 32000
793 TRANSMISSION
POWER XX.XXV group 2.0, Circuit Dana TE 32000FF group 2.0
IGNITION POWER XX.XXV Connection: 15-voltage from K315/87 via F54/4 and F58-2/5 to D793/
000100
SENSOR SUPPLY XX.XXV S2

793 TRANSMISSION, SENSOR SUPPLY

page
–
Description: voltage feed to sensors on transmission, reference volt-

DIAG CAN/POWER 15(20) age of 5 V.
793 TRANSMISSION
POWER XX.XXV Circuit diagram: Circuit Dana TE 32000 group 2.0, Circuit Dana TE
IGNITION POWER XX.XXV 32000FF group 2.0
000100
SENSOR SUPPLY XX.XXV Connection:

Dana: 5V analogue Ref from D793/M1 to S221/1
Dana full flow: 5V analogue Ref from D793/M1 to S2210/1
Function: 2.9 Control system, transmission
Signal value: XX.XXV = voltage on connection. The signal value
should be 8 V, stable (not vary).

791-1 ATTACHMENT, POWER
page
–
Description: Battery voltage to Control unit, attachment (D791-1).

791-1 ATTACHMENT
POWER XX.XXV Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1
RED.POWER Le X Ri X
00003179
and F52-1 to D791-1/K2:1, K2:9, K2:10, K2:11


791-1 ATTACHMENT, RED. POWER

page
–
Description: Redundant voltage feed to attachment control unit

DIAG CAN/POWER 16(20) (D791-1).
791-1 ATTACHMENT
POWER XX.XXV Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
RED.POWER Le X Ri X CAN BUS ATT group, 11.6
00003179
Connection:
Le: redundant voltage feed to D791/K2:7
Ri: redundant voltage feed to D791/K2:8
Signal value:
1 Feed active.
0 No feed.

page
–

791-2 ATTACHMENT Description: Battery voltage to Control unit, attachment option
POWER XX.XXV (D791-2).
RED.POWER Le X Ri X
000102
Circuit diagram: Circuit Power group 11.5, Circuit Power att. group
11.5
Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1
and F52-1 to D791-2/K2:1, K2:11

page
–

791-2 ATTACHMENT Description: Redundant voltage to Control unit, attachment option
RED.POWER Le X Ri X
000102
Connection:
Le: redundant feed to D791-2/K2:7
Ri: redundant feed to D791-2/K2:8
Signal value:
1 Feed active.
0 No feed.


page
–

Description: Battery voltage to Control unit, attachment left jack pair
791-3 ATTACHMENT
RED.POWER Le X Ri X Circuit diagram: Circuit Power group 11.5, Circuit Combi Att group 7.9
000103
and F52-2 to D791-3/K2:1, K2:11
should be 22-30V (battery voltage).

page
–

Description: Redundant voltage to Control unit, attachment left jack
791-3 ATTACHMENT
POWER XX.XXV pair (D791-3).
RED.POWER Le X Ri X Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
000103

Connection:
Signal value:
1 Feed active.
0 No feed.

page
–

791-4 ATTACHMENT Description: Battery voltage to Control unit, attachment right jack pair
RED.POWER Le X Ri X
000104
Circuit diagram: Circuit Power group 11.5, Circuit Combi Att group 7.9
and F52-2 to D791-4/K2:1, K2:11
should be 22-30V (battery voltage).


page
–

791-4 ATTACHMENT Description: Redundant voltage to Control unit, attachment right jack
POWER XX.XXV pair (D791-4).
RED.POWER Le X Ri X
000104
Connection:
Signal value:
1 Feed active.
0 No feed.

24V SENS. SUP 791-1
page
–
Description: Voltage feed to position sensors connected to Control

DIAG CAN/POWER 20(20) unit, attachment (D791-1).
24V SENS.SUP 791-1 XY
24V SENS.SUP 791-2 XY Circuit diagram: Circuit Spreading Valves group 7.5
24V SENS.SUP 791-3 XY Connection: digital out from D791/K1:10 to B769, B777-3, B7224,
003180
24V SENS.SUP 791-4 XY B7225, B7202L, B7202R, B7203L, B7203R, B7204L, B7204R,
B7205L and B7205R
Function: 7.5.10 Position sensor spreading, 7.6.10 Sensor rotation
stop, 7.9.1.8 Sensor alignment, 7.9.1.9 Sensor twistlocks, 8.2.1.6
Sensor, boom length
Signal value:


missing.

24V SENS. SUP 791-2

page
–

24V SENS.SUP 791-1 XY Description: Voltage feed to position sensors connected to Control
24V SENS.SUP 791-2 XY unit, attachment (D791-2).
003180
24V SENS.SUP 791-4 XY Circuit diagram: Circuit Over Height group 7.9
Connection: digital out from D791/K1:10 to B7231L and B7231R
Function: 7.9.1 Twistlocks
Signal value:


missing.
24V SENS. SUP 791-3

page
–

24V SENS.SUP 791-1 XY Description: Battery voltage to position sensor for left jack pair on com-
24V SENS.SUP 791-2 XY bi attachment.
003180
24V SENS.SUP 791-4 XY Circuit diagram: Circuit Combi Att group 7.9
Connection: digital out from D791-3/K1:26 to B7212L, B7213L,
B7214L, B7215L, B7216L, B7217L, B7218L, B7219L and B7220L
Function: 7.9.2.9 Sensor operating position, 7.9.2.10 Sensor knee,
7.9.2.13 Sensor lifting jacks, 7.9.2.15 Sensor alignment, 7.9.16 Sen-
sor clamping position
Signal value:


missing.

24V SENS. SUP 791-4

page
–

24V SENS.SUP 791-1 XY Description: Battery voltage to position sensor for right jack pair on
24V SENS.SUP 791-2 XY combi attachment.
003180
24V SENS.SUP 791-4 XY Circuit diagram: Circuit Combi Att group 7.9
Connection: digital out from D791-4/K1:26 to B7212R, B7213R,
B7214R, B7215R, B7216R, B7217R, B7218R, B7219R and B7220R
Function: 7.9.2.9 Sensor operating position, 7.9.2.10 Sensor knee,
7.9.2.13 Sensor lifting jacks, 7.9.2.15 Sensor alignment, 7.9.16 Sen-
sor clamping position
Signal value:


missing.

REDCAN STATUS CHECK
page
–
Description: Control function from the redundant CAN bus. Control

DIAG CAN/POWER 21(X) unit, attachment (D791-1) creates a virtual fault in the redundant CAN
REDCAN STATUS CHECK bus in order to determine whether all control units have contact and
PRESS ENTER are connected in the right order. The control system indicates the fault
by numbering the cables between the control units (segments) from 1
006861
SEGMENT ERROR X
onwards. Segment 1 is always between Control unit, cab (D790-1)
and Control unit, attachment(D791-1). The last segment is always be-
tween Control unit, KID (D795) and Control unit, cab (D790-1). The
segments in between vary depending on machine configuration.
D791-4 D791-3 D791-2 D791-1
CAN R CAN L CAN R CAN L CAN R CAN L CAN R CAN L Connection:
4 3 2
5 D790-1 D790-2 D795 Signal value:

CAN R CAN L CAN R CAN L
1 9 8
0 No errors.
6 7
CAN L CAN R CAN L CAN R CAN L CAN R
>0 X > 0, the number indicates incorrect segment. Use circuit di-
006883
D797-R D797-O D797-F

agram to find the incorrect segment.
Segment numbering with maximum number of control
units. Control units marked with dashes are optional.

40 8 Control system – 8.4.2 LIGHTS
8.4.2 LIGHTS
LIGHTS, description
page
–
This group covers lighting.

DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selection with function key for Enter.
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
012083
OP EXTRA RMI
8.4.2.1 LIGHTS, menu 1

WORKING LIGHT CAB, SWITCH
page
–
Description: Signal from switch working lights cab roof.

DIAG LIGHTS 1(13)
Circuit diagram: Working lights group 9.6
WORKING LIGHT CAB
SWITCH X Connection: from S105-1/1 to digital in D790-1/K6:10
OUTPUT LE XY RI XY
Function: 9.6 Lighting system
000107
Signal value:
0 No signal.
WORKING LIGHT CAB, OUTPUT

page
–
Description: Voltage feed to working lights cab roof.

DIAG LIGHTS 1(13)
WORKING LIGHT CAB
SWITCH X Connection:
OUTPUT LE XY RI XY
LE: digital out from D790-1/K2:7 to E404-1L
000107
RI: digital out from D790-1/K2:6 to E404-1R

Function: 9.6.9 Working lights cab
Signal value:

No output signal. It can also be a fault in the circuit as this fault
can only be detected when the output signal is active.
10 Output signal active, short-circuiting or open circuit.

Output signal active, circuit OK.

8 Control system – 8.4.2.2 LIGHTS, menu 2 41

WORKING LIGHT ATTACH, SWITCH
page
–
Description: Signal from switch working lights attachment.

DIAG LIGHTS 2(13)
WORKING LIGHT ATTACH
SWITCH X Connection: signal from S105-2/1 to digital in D790-1/K6:2
OUTPUT LE XY RI XY
012084
OPT OUTPUT (2X) XY
Signal value:
0 No signal.
WORKING LIGHT ATTACH, OUTPUT

page
–
Description: Voltage feed to working light, attachment, feed.

DIAG LIGHTS 2(13)
WORKING LIGHT ATTACH
OUTPUT LE XY RI XY
LE: digital out from D791/K1:15 to E404-2L
012084
OPT OUTPUT (2X) XY

RI: digital out from D791/K1:1 to E404-2R
Function: 9.6.11 Working lights attachment
Signal value:


missing.

42 8 Control system – 8.4.2.3 LIGHTS, menu 3
WORKING LIGHT ATTACH, OPT OUTPUT (2X)

page
–
DIAG LIGHTS 2(13)

WORKING LIGHT ATTACH Description: Voltage feed to the extra working lights on the
SWITCH X attachment.
OUTPUT LE XY RI XY
012084
OPT OUTPUT (2X) XY Circuit diagram: Circuit Extra Wor.li. Att group 9.6
Connection: digital out from D791/K1:42 to E404-4R and E404-4L
Function: 9.6.11 Working lights attachment
Signal value:


missing.

WORKING LIGHT BOOM, SWITCH
page
–
Description: Signal from switch working light boom.

DIAG LIGHTS 3(13)
WORKING LIGHT BOOM
SWITCH X Connection: from S105-3/1 to digital in D790-1/K6:3
OUTPUT LE XY RI XY
000109
OPTIONAL OUTPUT XX
Signal value:
0 No signal.

WORKING LIGHT BOOM, OUTPUT

page
–
Description: Voltage feed to working light boom.

DIAG LIGHTS 3(13)
WORKING LIGHT BOOM
OUTPUT LE XY RI XY
LE: digital out from D797-R/K1:1 to E404-3L
000109
OPTIONAL OUTPUT XX
RI: digital out from D797-R/K1:15 to E404-3R
Function: 9.6.10 Working light boom
Signal value:


missing.
WORKING LIGHT BOOM, OPTIONAL OUTPUT

page
–
DIAG LIGHTS 3(13)

WORKING LIGHT BOOM Description: Voltage feed to extra working lights on the boom.
SWITCH X Circuit diagram: Circuit Extra Wor.li. Boom group 9.6
OUTPUT LE XY RI XY
000109
OPTIONAL OUTPUT XX Connection: digital out from D790-1/K10:8, via relay K304/87 to
H404-5L and H404-5R
Function: 9.6.10 Working light boom
Signal value:


missing.


MAIN LIGHT, SWITCH
page
–
Description: Signal from headlights switch.

DIAG LIGHTS 4(13)
Circuit diagram: Circuit Lighting group 9.6
MAIN LIGHT
SWITCH X Connection: from S100/1 to digital in D790-1/K6:5
000110
Signal value:
0 No signal.

PRESENT OUTPUT SIGNAL, SIDE F
page
–
Description: Voltage feed to side lights front.

DIAG LIGHTS 5(13)
PRESENT OUTPUT SIGNAL
SIDE-F LE XY RI XY Connection:
SIDE-R LE XY RI XY
LE: digital out from D797-F/K1:25 to H416-1
000111
REAR LE XY RI XY
RI: digital out from D797-F/K1:29 to H417-1
Function: 9.6.2 Running lights
Signal value:


missing.

PRESENT OUTPUT SIGNAL, SIDE R

page
–
Description: Voltage feed to side lights rear.

DIAG LIGHTS 5(13)
SIDE-R LE XY RI XY
LE: digital out from D797-R/K1:7 to H416-2
000111
REAR LE XY RI XY
RI: digital out from D797-R/K1:9 to H417-2
Function: 9.6.2 Running lights
Signal value:


missing.
PRESENT OUTPUT SIGNAL, REAR

page
–
Description: Voltage feed to rear lights.

DIAG LIGHTS 5(13)
SIDE-R LE XY RI XY
LE: digital out from D797-R/K1:10 to H412L
000111
REAR LE XY RI XY
RI: digital out from D797-R/K1:25 to H412R
Function: 9.6.3 Rear lights
Signal value:


missing.


HEADLIGHTS, SWITCH
page
–
Description: Lighting headlights front, switch.

DIAG LIGHTS 6(13)
HEAD LIGHTS
SWITCH X Connection: from S162/56A to digital in D790-2/K3:9
HEAD LE XY RI XY
000112
DIMMED XY
Signal value:
0 No signal.
HEAD LIGHTS, HEAD

page
–
Description: Voltage feed to headlights, high beam. If the machine is

DIAG LIGHTS 6(13) equipped with extra working lights front then they are connected in
HEAD LIGHTS parallel with the high beams.
SWITCH X
HEAD LE XY RI XY Circuit diagram: Circuit Lighting group 9.6 and Circuit Extra Wor.Li.
000112
DIMMED XY Frame group 9.6

Connection:
LE: digital out from D797-F/K1:1 to E402L ( E404-7L and

E404-8L)
RI: digital out from D797-F/K1:15 to E402R ( E404-7R and

E404-8R)
Function: 9.6.1 Headlights
Signal value:


missing.

HEAD LIGHTS, DIMMED

page
–
Description: Voltage feed to headlights, low beams.

DIAG LIGHTS 6(13)
HEAD LIGHTS
SWITCH X Connection: digital out from D797-F/K1:42 to E400L and E400R
HEAD LE XY RI XY
Function: 9.6.1 Headlights
000112
DIMMED XY
Signal value:


missing.

PRESENT INPUT SIGNAL, HAZARD SWITCH
page
–
Description: Signal from switch flashing hazard lights (Hazard).

DIAG LIGHTS 7(13)
Circuit diagram: Circuit Direction indicators, Hazard flashers,
HAZARD SWITCH X group 9.7
FLASH.SW. LE X RI X Connection: from S109/1 to digital in D790-1/K5:6
000113
Function: 9.7 Signalling system

Signal value:
0 No signal.
PRESENT INPUT SIGNAL, FLASH.SW.

page
–
Description: Signal from switch direction indicators.

DIAG LIGHTS 7(13)
HAZARD SWITCH X group 9.7
FLASH.SW. LE X RI X Connection:
000113
LE: from S161/1 to digital in D790-2/K8:9

RI: from S161/6 to digital in D790-2/K8:8
Signal value:
0 No signal.


PRESENT OUTPUT SIGNAL HAZARD/FLASHER, FRONT
page
–
Description: Voltage feed to direction indicators front.

DIAG LIGHTS 8(13)
HAZARD/FLASHER group 9.7
FRONT LE XY RI XY Connection:
000114
REAR LE XY RI XY
LE: digital out from D797-F/K1:9 to H422
RI: digital out from D797-F/K1:10 to H423
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
(Hazard)
Signal value:


missing.
PRESENT OUTPUT SIGNAL HAZARD/FLASHER, REAR

page
–
Description: Voltage feed to direction indicators rear.

DIAG LIGHTS 8(13)
HAZARD/FLASHER group 9.7
FRONT LE XY RI XY Connection:
000114
REAR LE XY RI XY
LE: digital out from D797-R/K1:29 to H426
RI: digital out from D797-R/K1:39 to H427
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
(Hazard)
Signal value:


missing.


ROTATING BEACON, SWITCH
page
–
Description: Signal from switch rotating beacon.

DIAG LIGHTS 9(13)
ROTATION BEACON
SWITCH X Connection: from S110/1 to digital in D790-1/K6:4
OUTPUT XY
000115
Signal value:
0 No signal.
ROTATING BEACON, OUTPUT

page
–
Description: Voltage feed to rotating beacon.

DIAG LIGHTS 9(13)
ROTATION BEACON
SWITCH X Connection: digital out D790-1/K2:5 to H428
OUTPUT XY
Function: 9.6.8 Rotating beacon
000115
Signal value:



PRESENT INPUT SIGNAL, BRAKE LIGHT SWITCH
page
–
Description: Signal from make-contact brake lights.

DIAG LIGHTS 10(13)
BRAKE LIGHT SWITCH X Connection: from S216/2 to digital in D797-F/K1:13
REVERSE LIGHT SIGNAL X
Function: 4.3.8 Make-contact brake lights
013260
Signal value:
0 No signal.

PRESENT INPUT SIGNAL, REVERSE LIGHT SIGNAL

page
–
Description: Signal from transmission control unit (D793) when re-

DIAG LIGHTS 10(13) verse gear is activated.
BRAKE LIGHT SWITCH X Circuit diagram: Circuit Lighting group 9.6
REVERSE LIGHT SIGNAL X Connection: -
013260
Function: 9.6.5 Back-up light
Signal value:
1 Input signal active. Output signal "reverse gear active" from

transmission control unit (D793).
0 No signal.

PRESENT OUTPUT SIGNAL, BRAKE LIGHT
page
–
Description: Voltage feed to brake lights.

DIAG LIGHTS 11(13)
BRAKE LIGHT LEXY RIXY Connection:
REVERSE LGT LEXY RIXY
000117
REVERSE ALARM XY
Function: 9.6.4 Brake lights
Signal value:


missing.

PRESENT OUTPUT SIGNAL, REVERSE LGT

page
–
Description: Voltage feed to brake lights.

DIAG LIGHTS 11(13)
BRAKE LIGHT LEXY RIXY Connection:
000117
REVERSE ALARM XY
Function: 9.6.5 Back-up light
Signal value:


missing.
PRESENT OUTPUT SIGNAL, BACK-UP (REVERSE)

page
–
ALARM
Description: Voltage feed to back-up alarm.
DIAG LIGHTS 11(13)
Circuit diagram: Circuit Reverse alarm group 9.7
BRAKE LIGHT LEXY RIXY Connection: digital out from D797-R/K1:30 to H965
Function: 9.7.5 Back-up alarm
000117
REVERSE ALARM XY
Signal value:


missing.


CAB LIGHT, MANUAL SWITCH
page
–
Description: Signal from switch lighting cab.

DIAG LIGHTS 12(13)
CAB LIGHT
MANUAL SWITCH X Connection: from KIT, D790-2/K8:11 to digital in D790-1/K11:2
DOOR SWITCH X
000118
OUTPUT XXX
Signal value:
0 No signal.
CAB LIGHT, DOOR SWITCH

page
–
Description: Signal from contact breaking door.

DIAG LIGHTS 12(13)
CAB LIGHT
MANUAL SWITCH X Connection: from S266LE or S266RE (connected in parallel) to digital
DOOR SWITCH X in D790-1/K11:3
000118
OUTPUT XXX
Function: 9.10.2 Doors
Signal value:
0 No signal.
CAB LIGHT, OUTPUT

page
–
Description: Voltage feed to interior light cab.

DIAG LIGHTS 12(13)
CAB LIGHT
MANUAL SWITCH X Connection: from D790-1/K11:6 to E434
DOOR SWITCH X
Function: 9.6.12 Interior lighting cab
000118
OUTPUT XXX
Signal value: XXX = 0-255 = 0-24 V (255 means 24 V which corre-
sponds to battery voltage).

SWITCH LIGHTS, OUTPUT
page
–
Description: Voltage feed to background lights in switches, panels and

DIAG LIGHTS 13(13) keys.
SWITCH LIGHTS Circuit diagram: -
OUTPUT XXX Connection: -

000119
Function: 9.6.12 Interior lighting cab

Signal value:
50 Means 4-5 V.
170 Means 15-16 V.

8 Control system – 8.4.3 CAB 53
8.4.3 CAB
CAB, description
page
–
This group covers functions in the cab.

DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
012086
OP EXTRA RMI
8.4.3.1 CAB, menu 1

WASHER, SWITCH
page
–
Description: Signal from gear and multi-function lever switch washer.

DIAG CAB 1(X)
Circuit diagram: Circuit Wipers group 9.5
WASHER
SWITCH X Connection: signal from S162/53C to digital in D790-2/K3:4
OUTPUT FRONT XY
Function: 9.5 Wiping and cleaning of windows
012087
OUTPUT REAR/ROOF XY
Signal value:
0 No signal.
WASHER, OUTPUT
page
–
Description: Voltage feed to windscreen washer motor.

DIAG CAB 1(X)
WASHER
SWITCH X Connection: digital out D790-1/K10:13 to M651-1 and M651-2
OUTPUT FRONT XY
Function: 9.5.4 Washer motor and reservoir
012087
OUTPUT REAR/ROOF XY
Signal value:



54 8 Control system – 8.4.3.2 CAB, menu 2
WASHER, OUTPUT REAR/ROOF

page
–
Description: Grounding of motor washer roof and rear window. The

DIAG CAB 1(X) motor is supplied with voltage parallel with Motor windscreen washing,
WASHER activation is controlled by controlling grounding of the motor. The mo-
SWITCH X tor is grounded at windscreen washing if the wiper motor roof or rear
OUTPUT FRONT XY
012087
OUTPUT REAR/ROOF XY window is activated.
Connection: PWM out D790-1/K5:4 to M651-2
Function: 9.5.4 Washer motor and reservoir
Signal value:


missing.
8.4.3.2 CAB, menu 2

FRONT WIPER, SWITCH (1-3)
page
–
Description: Signal from multi-function lever switch wiper function.

DIAG CAB 2(10)
FRONT WIPER
SWITCH (1-3) X Connection:
OUTPUT XY
X = 1 Interval slow: signal from S162/J1 to digital in D790-2/K3:6
000122
FEEDBACK X
X = 2 Interval less slow: signal from S162/J2, digital in D790-2/
K3:7
X = 3 Interval continuous: signal from S162/53, digital in D790-2/
K3:8
Signal value:
1 Long interval.
2 Normal interval.
3 Continuous operation.

8 Control system – 8.4.3.3 CAB, menu 3 55
FRONT WIPER, OUTPUT

page
–
Description: Voltage feed to wiper front.

DIAG CAB 2(10)
FRONT WIPER
SWITCH (1-3) X Connection: digital out D790-1/K2:1 to M650-1/53
OUTPUT XY
Function: 9.5.5 Wiper motor front
000122
FEEDBACK X
Signal value:


FRONT WIPER, FEEDBACK

page
–
Description: Signal from motor wiper front, indicates when wiper mo-
DIAG CAB 2(10) tion is completed.
FRONT WIPER
SWITCH (1-3) X Circuit diagram: Circuit Wipers group 9.5
OUTPUT XY Connection: from M650-1/31b to digital in D790-1/K4:13
000122
FEEDBACK X
Function: 9.5.5 Wiper motor front
Signal value:
1 Input signal active (wiper sweep).
0 No signal (home position).
8.4.3.3 CAB, menu 3

REAR WIPER, SWITCH
page
–
Description: Status of rear window wiper switch on KIT control unit

DIAG CAB 3(10) (D790-2).
REAR WIPER
SWITCH X Circuit diagram: -
OUTPUT XY Connection: -
000123
FEEDBACK X
Signal value:
1 Input signal active. Key for continuous/interval pressed down.
0 No signal.

REAR WIPER, OUTPUT

page
–
Description: Voltage feed to direction windscreen wiper rear.

DIAG CAB 3(10)
REAR WIPER
SWITCH X Connection: digital out from D790-1/K2:4 to M650-2/53
OUTPUT XY
Function: 9.5.7 Wiper motor rear
000123
FEEDBACK X
Signal value:


REAR WIPER, FEEDBACK

page
–
Description: Signal from motor windscreen wiper rear, indicates when

DIAG CAB 3(10) wiper motion is completed.
REAR WIPER
SWITCH X Circuit diagram: Circuit Wipers group 9.5
000123
FEEDBACK X
Function: 9.5.7 Wiper motor rear
Signal value:
8.4.3.4 CAB, menu 4

ROOF WIPER, SWITCH
page
–
Description: Signal from switch wiper roof.

DIAG CAB 4(10)
Circuit diagram: -
ROOF WIPER
SWITCH X Connection: -
OUTPUT XY
000124
FEEDBACK X
Signal value:
1 Input signal active. Key for continuous/interval pressed down.
0 No signal.

ROOF WIPER, OUTPUT

page
–
Description: Voltage feed to wiper roof.

DIAG CAB 4(10)
ROOF WIPER
SWITCH X Connection: digital out D790-1/K10:14 to M650-3/53
OUTPUT XY
Function: 9.5.6 Wiper motor roof
000124
FEEDBACK X
Signal value:


missing.
ROOF WIPER, FEEDBACK

page
–
Description: Signal from motor wiper roof, indicates when wiper mo-
DIAG CAB 4(10) tion is completed.
ROOF WIPER
SWITCH X Circuit diagram: Circuit Wipers group 9.5
000124
FEEDBACK X
Function: 9.5.6 Wiper motor roof
Signal value:
8.4.3.5 CAB, menu 5

HORN, SWITCH
page
–
Description: Signal from switch horn.

DIAG CAB 5(10)
Circuit diagram: Circuit Alarm, audible signals group 9.7
HORN
SWITCH X Connection: signal from S162/H to digital in D790-2/K3:2
OUTPUT XY
Function: 9.7 Signal system
013382
SWITCH JOYSTICK X
Signal value:
0 No signal.

HORN, OUTPUT
page
–
Description: Voltage feed to horn.

DIAG CAB 5(10)
HORN
SWITCH X
Connection: digital out D790-1/K11:11 to H850/8 ( for compressor
OUTPUT XY
013382
SWITCH JOYSTICK X horn, signal to relay K3016/86)
Function: 9.7.1 Horn
Signal value:


SWITCH JOYSTICK
page
–
Description: Signal from the switch open twistlocks on the control le-
DIAG CAB 5(10) ver. The signal is used to activate the horn when there is no alignment.
HORN
SWITCH X Circuit diagram: Circuit Joystick group 7.1
OUTPUT XY Connection: signal from S815/20 to digital in D790-1/K7:15
013382
SWITCH JOYSTICK X
Function: 9.7 Signal system
Signal value:
0 No signal.

8.4.3.6 CAB, menu 6

BUZZER
page
–
Description: Voltage feed to buzzer for alarm indication panel, feed.

DIAG CAB 6(10)
BUZZER XY
SWITCH SEAT X Connection: digital out D790-1/K11:5 to H853/1
ALARM X
Function: 9.3 Seat, 1 Engine, 8.2.1 Overload system
000126
OP X
Signal value:


ing.
SWITCH SEAT
page
–
Description: Signal from sensor operator in seat.

DIAG CAB 6(10)
BUZZER XY
SWITCH SEAT X Connection: signal from S230/1 to D790-1/K11:14
ALARM X
Function: 9.3.9 Sensor operator in seat
000126
OP X
Signal value:
1 Input signal active. Operator in seat.
0 No signal. No operator in seat.
ALARM
page
–
Description: Status for alarm indication panel, warning from control

DIAG CAB 6(10) system.
BUZZER XY
SWITCH SEAT X Circuit diagram: -
ALARM X Connection: -
000126
OP X
Function: 8.1.2 Information display
Signal value:
1 Conditions for activation of buzzer from seat switch and park-

ing brake are fulfilled
0 Conditions for activation of buzzer are not fulfilled.

OP
page
–
Description: Status for overload warning from the control system.

DIAG CAB 6(10)
Circuit diagram: Circuit OP + Scale group 8.2
BUZZER XY
SWITCH SEAT X Connection: -
ALARM X
Function: 8.2.1 Overload system
000126
OP X
Signal value: X = 1,
1 Conditions for activation of buzzer fulfilled, that is, overload

system is indicating.
0 Conditions for activation of buzzer are not fulfilled.
8.4.3.7 CAB, menu 7

FUEL, SENSOR VALUE
page
–
Description: Signal from sensor fuel level.

DIAG CAB 7(10)
FUEL
SENSOR VALUE XXXOHM Connection: analogue rheostat signal from B757/1 signal to D797-R/
PROC XXX K2:15
000127
Function: 1.2.2 Sensor fuel level

Signal value: XXXOHM = Current resistance value from sensor fuel
level in ohm.
FUEL, PROC
page
–
Description: the control system’s interpretation of signal from fuel tank

DIAG CAB 7(10) sensor.
FUEL
SENSOR VALUE XXXOHM Circuit diagram: Circuit Sensor instr. group 9.1
PROC XXX Connection: -
000127
Function: 1.2.2 Sensor fuel level

Signal value: XXX = 0-100 = 0-100% = Fuel volume in tank.
8.4.3.8 CAB, menu 8

SEAT HEATER, SWITCH
page
–
DIAG CAB 8(10)

SEAT HEATER Description: Signal from seat heating switch.
SWITCH X Circuit diagram: Circuit Cab driver’s seat group 9.3
OUTPUT XY
000128
Connection: signal from S143/1 to digital in D790-1/K6:6

Function: 9.3 Seat
Signal value:
0 No signal.

SEAT HEATER, OUTPUT

page
–
DIAG CAB 8(10)

SEAT HEATER Description: Control voltage to seat heating relay.
SWITCH X Circuit diagram: Circuit Cab driver’s seat group 9.3
OUTPUT XY
000128
Connection: digital out D790-1/K10:7 to K383/86
Function: 9.3.3 Heating coil
Signal value:


ing.
8.4.3.9 CAB, menu 9

AUT. LUBRICATION CHASSIS, OUTPUT
page
–
DIAG CAB 9(X)

AUT LUBRICATION Description: Voltage feed to central lubrication chassis. Central lubri-
CHASSI cation is only supplied with voltage when the machine is operating.
006863
OUTPUT XY Circuit diagram: Circuit Central lubrication group 9.14

Connection: digital out D797-F/K1:28 to M693-1
Function: 9.14 Central lubrication
Signal value:


missing.

8.4.3.10 CAB, menu 10

AUT. LUBRICATION ATTACHMENT, OUTPUT
page
–
DIAG CAB 10(X)

AUT LUBRICATION Description: Central lubrication attachment, feed. Central lubrication is
ATTACHMENT only supplied with voltage when the machine is operating.
006864
OUTPUT XY Circuit diagram: Circuit Central lubrication group 9.14
Connection: digital out D791/K1:14 to M693-2
Function: 9.14 Central lubrication
Signal value:


8.4.4 CLIMATE
CLIMATE, description
page
–
This group covers the cab’s climate control system.

DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
012088
OP EXTRA RMI
8.4.4.1 CLIMATE, menu 1

PRESENT INPUT SIGNAL, REQUIRED TEMP
page
–
Description: Set value for desired temperature.

DIAG CLIMATE 1(8)
Circuit diagram: Circuit Climate system group 9.4
REQUIRED TEMP XXX Connection: signal from S139/3 to analogue in D790-1/K5:8
PRESENT TEMP XXX
Function: 9.4 Heating, ventilation and air conditioning
000132
WATER VALVE FEEDB. XXX

Signal value: XXX = 160-280 = 16-28 °C Preset temperature shown in
tenths of degrees and adjusted in increments of half degrees (200 =
20 °C). Test by increasing or decreasing temperature with the temper-
ature switch on the panel.

8 Control system – 8.4.4.2 CLIMATE, menu 2 63
PRESENT INPUT SIGNAL, PRESENT TEMP

page
–
Description: Signal from sensor cab temperature.

DIAG CLIMATE 1(8)
REQUIRED TEMP XXX Connection: signal from B775-1/2 to input D790-1/K4:8
PRESENT TEMP XXX
Function: 9.4.17 Sensor cab temperature
000132
Signal value: XXX = Cab’s interior temperature in tenths of degrees
(200 = 20 °C).
PRESENT INPUT SIGNAL, WATER VALVE FEEDB.

page
–
Description: Water valve’s position (opening in percent).

DIAG CLIMATE 1(8)
REQUIRED TEMP XXX Connection: signal from Y673/9 to analogue in D790-1/K10:4
PRESENT TEMP XXX
Function: 9.4.5 Water valve
000132

Signal value: XXX = 0-100 = 0-100% = Water valve’s opening in %. 0
= Closed. 100 = Fully open.

TEMP COIL
page
–
Description: Temperature of the air out from the fan. The sensor is lo-
DIAG CLIMATE 2(8) cated in the air distributor.
TEMP COIL XXX
TEMP COOLANT XXX Circuit diagram: Circuit Climate system group 9.4
TEMP AMBIENT XXX Connection: signal from B775-2/2 to input D790-1/K4:10
000133
TEMP DE-ICE XXX

Function: 9.4.16 Sensor temperature outlet fan
Signal value: XXX = Temperature of the air blown into the cab in tenths
of degrees (200 = 20 °C).
TEMP COOLANT
page
–
Description: Coolant temperature, temperature of the engine’s cool-

DIAG CLIMATE 2(8) ant. Signal is retrieved from the engine via CAN bus drivetrain.
TEMP COIL XXX
TEMP COOLANT XXX Circuit diagram: Circuit Climate system group 9.4
TEMP AMBIENT XXX Connection: from engine via CAN bus, see PRESENT INPUT SIG-
000133
TEMP DE-ICE XXX NAL, COOLANT TEMP page 80.

Function: 1.7.9 Sensor coolant temperature
Signal value: XXX = Engine temperature in tenths of degrees (200 =
20 °C).
TEMP AMBIENT
page
–
Description: Outdoor temperature. Heat radiation from engine and sun

DIAG CLIMATE 2(8) may affect the value since the sensor is located on the rear of the cab
TEMP COIL XXX roof.
TEMP COOLANT XXX
TEMP AMBIENT XXX Circuit diagram: Circuit Climate system group 9.4
000133
TEMP DE-ICE XXX Connection: signal from B774/2 to input D790-1/K7:9

Function: 9.4.18 Sensor ambient temperature
Signal value: XXX = Outdoor temperature in tenths of degrees (200 =
20 °C).

64 8 Control system – 8.4.4.3 CLIMATE, menu 3
TEMP DE-ICE
page
–
Description: Temperature in refrigerant circuit.

DIAG CLIMATE 2(8)
TEMP COIL XXX
TEMP COOLANT XXX Connection: signal from B775-3/2 to input D790-1/K4:11
TEMP AMBIENT XXX
Function: 9.4.12 Sensor temperature refrigerant
000133
TEMP DE-ICE XXX
Signal value: XXX = Refrigerant temperature in tenths of degrees (200
= 20 °C).

PRESENT INPUT SIGNAL, PRESSURE SWITCH
page
–
Description: Signal from refrigerant pressure switch.

DIAG CLIMATE 3(X)
PRESSURE SWITCH X Connection: signal from S246/2 to digital in D797-R/K1:37
OPT DOOR SWITCH X
Function: 9.4.10 Pressure switch
006865
Signal value:
1 Input signal active. Press Ok.
0 No signal, too high or too low pressure.
PRESENT INPUT SIGNAL, OPT DOOR SWITCH

page
–
DIAG CLIMATE 3(X)

PRESENT INPUT SIGNAL Description: Signal from the driver’s door switch. On machines with the
PRESSURE SWITCH X option of automatic shutdown of AC with open door this signal is used
OPT DOOR SWITCH X to control the shutdown.
006865

Connection: signal from S266-LE or S266-RI to digital in D790-1/
K11:3
Signal value:
1 Input signal active. Door open.
0 No signal. Doors closed.

PRESENT INPUT SIGNAL, WATER VALVE
page
–
Description: Signal from water valve, the voltage is a measure of the

DIAG CLIMATE 4(8) position.
WATER VALVE XX.XXV Circuit diagram: Circuit Climate system group 9.4
DRAUGHT VALVE XX.XXV Connection: signal from Y673/9 to analogue in D790-1/K10:4
000135

Signal value: XX.XXV = 0.50 - 4.50 V

PRESENT INPUT SIGNAL, DRAUGHT VALVE

page
–
Description: Signal from the engine to the air distributor. Voltage is a

DIAG CLIMATE 4(8) measure of the valve’s position.
WATER VALVE XX.XXV Circuit diagram: Circuit Climate system group 9.4
DRAUGHT VALVE XX.XXV Connection: signal from Y672/9 to analogue in D790-1/K4:7
000135
Function: 9.4.14 Air distributor
Signal value: XX.XXV = 0.50 - 4.50 V

PRESENT INPUT SIGNAL, REQUIRED TEMP
page
–
Description: Signal from switch temperature. Voltage when switch is

DIAG CLIMATE 5(8) pressed in voltage level indicates increase or decrease of the temper-
PRESENT INPUT SIGNAL ature.
REQUIRED TEMP XX.XXV
REQ. DRAUGHT XX.XXV Circuit diagram: Circuit Climate system group 9.4
000136
REQ. FAN SPEED XX.XXV Connection: signal from S139/3 to analogue in D790-1/K5:8
Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Increase / - / decrease.
PRESENT INPUT SIGNAL, REQ. DRAUGHT

page
–
Description: Signal from switch air distribution, voltage when switch is

DIAG CLIMATE 5(8) pressed in. The voltage level indicates change of air control against
PRESENT INPUT SIGNAL windscreen (up) or floor (down). The valve’s position changes in steps
REQUIRED TEMP XX.XXV between windscreen - floor.
REQ. DRAUGHT XX.XXV
000136
REQ. FAN SPEED XX.XXV Circuit diagram: Circuit Climate system group 9.4
Connection: signal from S117/3 to analogue in D790-1/K5:9
Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Up / - / down.
PRESENT INPUT SIGNAL, FAN SPEED

page
–
Description: Signal from switch fan speed, switch controls increase or

DIAG CLIMATE 5(8) decrease of fan speed. Speed is endless adjustable. The voltage level
PRESENT INPUT SIGNAL indicates if the speed should be increased or decreased.
REQUIRED TEMP XX.XXV
REQ. DRAUGHT XX.XXV Circuit diagram: Circuit Climate system group 9.4
000136
REQ. FAN SPEED XX.XXV Connection: signal from S118/2 to analogue in D790-1/K5:7
Function: 9.4 Heating, ventilation and climate control unit
Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Increase / - / decrease.


PRESENT OUTPUT SIGNAL, FAN SPEED
page
–
Description: Current control of fan motor, speed is controlled with

DIAG CLIMATE 6(8) PWM-control of grounding (of fan motor).
FAN SPEED XXX Circuit diagram: Circuit Climate system group 9.4
RECIRKULATION XY Connection: analogue out from D790-1/K2:2 to M657/31
000137
COMPRESSOR XY
Function: 9.4.3 cab fan
Signal value: XXX = 0-255 = Fan speed (255 = max. fan speed).
PRESENT OUTPUT SIGNAL, RECIRCULATION

page
–
Description: Control voltage to motor for fresh air and recirculation

DIAG CLIMATE 6(8) damper.
FAN SPEED XXX Circuit diagram: Circuit Climate system group 9.4
RECIRKULATION XY Connection: digital out from D790-1/K2:3 to M612
000137
COMPRESSOR XY
Function: 9.4.2 Fresh air and recirculation damper
Signal value:


PRESENT OUTPUT SIGNAL, COMPRESSOR

page
–
Description: Voltage feed of AC compressor’s electromagnetic clutch.

DIAG CLIMATE 6(8) Controls cut-in and cut-out of the compressor. Two outputs are con-
PRESENT OUTPUT SIGNAL nected in parallel to handle the current.
FAN SPEED XXX
RECIRKULATION XY Circuit diagram: Circuit Climate system group 9.4
000137
COMPRESSOR XY Connection: digital out from D797-R/K1:34 and K1:35 to M645/1

Function: 9.4.7 Compressor
Signal value:


ing.


OUTPUT WATER VALVE, CLOCKWISE
page
–
Description: Voltage feed to water valve, for opening. The valve is con-
DIAG CLIMATE 7(8) nected to an H-bridge. The signal can only be diagnosed when the
OUTPUT WATER VALVE valve’s position changes. The valve’s opening and closing is control-
CLOCKWISE XY XY led by the climate control unit’s software depending on desired tem-
ANTI-CLOCKWISE XY XY perature, outside temp. cab temperature and coolant temperature, so
it may be difficult to determine whether the valve is working as it
should.
24V
Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from
D790-1/K4:2 via R4 to Y673/6
M Signal value: motor runs clockwise row 1: 11 11 row 2: 00 11

000138
0V
H-bridge this is only detected when the output signal is active.

ing.

OUTPUT WATER VALVE, COUNTER-CLOCKWISE

page
–
Description: Voltage feed to water valve, for closing. The valve is con-
DIAG CLIMATE 7(8) nected to an H-bridge. The signal can only be diagnosed when the
OUTPUT WATER VALVE valve’s position changes. The valve’s opening and closing is control-
CLOCKWISE XY XY led by the climate control unit’s software depending on desired tem-
ANTI-CLOCKWISE XY XY perature, outside temp. cab temperature and coolant temperature, so
it may be difficult to determine whether the valve is working as it
should.
24V
D790-1/K4:2 via R4 to Y673/6
M Signal value: motor runs counter-clockwise row 1: 00 11, row 2: 11 11

000138
0V
H-bridge this is only detected when the output signal is active.

ing.

OUTPUT DRAUGHT VALVE, CLOCKWISE
page
–
Description: Voltage feed to motor for the air distributor, rotation clock-
DIAG CLIMATE 8(8) wise. Is connected to an H-bridge. Signal can only be diagnosed when
OUTPUT DRAUGHT VALVE the air distributor’s position changes.
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY Circuit diagram: Circuit Climate system group 9.4
D790-1/K4:4 via R6 to Y672/6
24V
Signal value: motor runs clockwise row 1: 11 11, row 2: 00 11
M 01 Normal mode function off.


000139
0V 11 Normal mode function on.

H-bridge
ing.

OUTPUT DRAUGHT VALVE, COUNTER-CLOCKWISE

page
–
Description: Voltage feed to motor for the air distributor, rotation coun-
DIAG CLIMATE 8(8) ter-clockwise. Motor is connected to an H-bridge. Signal can only be
OUTPUT DRAUGHT VALVE diagnosed when the air distributor’s position changes.
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY Circuit diagram: Circuit Climate system group 9.4
D790-1/K4:4 via R6 to Y672/6
24V
Signal value: motor runs counter-clockwise row 1: 00 11, row 2: 11 11
M 01 Normal mode function off.


000139
0V 11 Normal mode function on.

H-bridge
ing.

70 8 Control system – 8.4.5 HYD
8.4.5 HYD
HYD, description
page
–
This group covers the hydraulic functions.

DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
009272
OP EXTRA RMI
8.4.5.1 HYD, menu 1

HYDRAULIC OIL, TEMP
page
–
Description: Signal from sensor hydraulic oil temperature.

DIAG HYD 1(6)
Circuit diagram: Circuit Hydraulics group 10.0
HYDRAULIC OIL
TEMP XXX Connection: signal from B776/1 for input D797-R/K2:13
FAN XY
Function: 10.6.3 Sensor, hydraulic oil temperature
000141
Signal value: XXX = Temperature in tenths of degrees (200 = 20 °C).
HYDRAULIC OIL, FAN

page
–
Description: Voltage feed cooling fan hydraulic oil.

DIAG HYD 1(6)
Circuit diagram: Circuit Hydraulics group 10.0
HYDRAULIC OIL
TEMP XXX Connection: digital out from D797-R/K1:14 to M668/1
FAN XY
Function: 10.6.4 Cooling fan
000141
Signal value:


8.4.5.2 HYD, menu 2

BRAKE COOLANT OIL, TEMP
page
–
Description: Signal from sensor for oil temperature, brake system.

DIAG HYD 2(6)
Circuit diagram: Circuit Brake system group 4.0
BRAKE COOLANT OIL
TEMP XXX Connection: signal from B762/1 for input D797-F/K2:13
FAN XY
Function: 4.8.10 Sensor oil temperature, brake system
000142
Signal value: XXX = Temperature in tenths of degrees (200 = 20 °C).

8 Control system – 8.4.5.3 HYD, menu 3 71
BRAKE COOLANT OIL, FAN

page
–
Description: Voltage feed to cooling fan for brake system fluid.

DIAG HYD 2(6)
BRAKE COOLANT OIL
TEMP XXX Connection: digital out from D797-F/K1:14 to M674/1
FAN XY
Function: 4.8.8 Cooling fan
000142
Signal value:


8.4.5.3 HYD, menu 3

PRESSURE LIFTING CYL, C-
page
–
DIAG HYD 3(6)

PRESSURE LIFTING CYL Description: Pressure on the lift cylinders’ rod side (C-). For voltage
Le Ri value, see OP, description page 132.
C- XXX XXX
C+ XXX XXX Circuit diagram: Circuit OP + Scale group 8.2
Connection: See PRESENT INPUT SIGNAL LIFT CYL LE RI, C- page
134
C- Signal value: XXX = 0-250 = Hydraulic pressure 0 - 25 MPa. (255 =
incorrect signal.)
NOTE
You can quickly test the sensors by lifting max. and running the
C+
lifting function against end-position (overflow). All 4 sensors (C+
and C-) will then show the same pressure ±0.1 MPa.
000143

72 8 Control system – 8.4.5.4 HYD, menu 4
PRESSURE LIFTING CYL, C+

page
–
Description: Pressure on the lift cylinders’ piston side (C+). For voltage
DIAG HYD 3(6) value, see OP, description page 132. The sensor on the right-hand lift
PRESSURE LIFTING CYL
Le Ri cylinder is optional .
C- XXX XXX Circuit diagram: Circuit OP + Scale group 8.2
C+ XXX XXX
Connection: See PRESENT INPUT SIGNAL LIFT CYL LE RI, C+
page 134
C- Signal value: XXX = 0-250 = Hydraulic pressure 0 - 25 MPa. (255 =

incorrect signal.)
NOTE
You can quickly test the sensors by lifting max. and running the
C+ lifting function against end-position (overflow). All 4 sensors (C+
and C-) will then show the same pressure ±0.1 MPa.
000143
8.4.5.4 HYD, menu 4

PRESSURE SWITCHES, BRAKE PRESSURE
page
–
Description: Signal from the NC switch for oil pressure, brake system.
DIAG HYDRAULIC 4(X)
PRESSURE SWITCHES
BRAKE PRESSURE X Connection: signal from S204/2 to analogue in D797-F/K1:20
BRAKE LIGHT PRESS. X
Function: 4.3.7 NC switch oil pressure, brake system
012403
DECLUTCH PRESSURE X
Signal value:
0 No signal.
PRESSURE SWITCHES, BRAKE LIGHT PRESS.

page
–
Description: Signal from make-contact brake lights.

DIAG HYDRAULIC 4(X)
PRESSURE SWITCHES
BRAKE PRESSURE X Connection: from S216/2 to analogue in D797-F/K1:13
Function: 4.3.8 Make-contact brake lights
012403
DECLUTCH PRESSURE X
Signal value:
0 No signal.

8 Control system – 8.4.5.5 HYD, menu 5 73
PRESSURE SWITCHES, DECLUTCH PRESSURE

page
–
Description: Signal from NO switch declutch.

DIAG HYDRAULIC 4(X)
Circuit diagram: Circuit Drivetrain group 2.1
PRESSURE SWITCHES
BRAKE PRESSURE X Connection: from S220-2/2 to analogue in D797-F/K1:41
Function: 2.8.2 NO switch, declutch
012403
DECLUTCH PRESSURE X
Signal value:
0 No signal.
8.4.5.5 HYD, menu 5

P-BRAKE, SWITCH
page
–
Description: Signals from switch parking brake. Two signals, one for
DIAG HYDRAULIC 5(X) released parking brake and one for applied parking brake. Both sig-
P-BRAKE nals must be valid to enable release of parking brake.
SWITCH X/Y
FEEDBACK SWITCH X Circuit diagram: Circuit Brake system group 4.0
012404
VALVE XY Connection: signal from S107/1 to digital in D790-1/K8:13 and from

S107/7 to digital in D790-1/K8:5
Function: 4.1.2 Switch parking brake
Signal value:
1/0 Open, parking brake released.
0/1 On, parking brake applied.
P-BRAKE, FEEDBACK SWITCH

page
–
Description: Signal from break-contact parking brake.

DIAG HYDRAULIC 5(X)
P-BRAKE
SWITCH X/Y Connection: signal from S200/2 analogue in D797-F/K1:27
FEEDBACK SWITCH X
Function: 4.5.5 NC switch, parking brake
012404
VALVE XY
Signal value:
0 No signal.

74 8 Control system – 8.4.5.6 HYD, menu 6
P-BRAKE, VALVE
page
–
Description: Voltage feed to Solenoid valve parking brake.

DIAG HYDRAULIC 5(X)
P-BRAKE
SWITCH X/Y Connection: digital out D797-F/K1:7 to Y642/1
FEEDBACK SWITCH X
Function: 4.5.3 Solenoid valve parking brake
012404
VALVE XY
Signal value:


ing.
8.4.5.6 HYD, menu 6

PRESENT OUTPUT SIGNAL, PRESSURE TO ATTACHM.
page
–
VALVE
Description: Voltage feed to Solenoid valve, engagement of hydraulics
DIAG HYD 6(6) for top lift.
PRESSURE TO ATTACHM. Circuit diagram: Circuit Rotation, group 7.6
VALVE XY Connection: digital out D797-R/K1:31 to Y6003/1
000146
Function: 7.4 Side shift, 7.5 Spreading, 7.6 Rotation, 7.7 Tilt, 7.8 Lev-
elling 7.9.1 Twistlock, 7.9.2 Lifting jacks
Signal value:


ing.

8 Control system – 8.4.6 ENGINE 75
8.4.6 ENGINE
ENGINE, description
page
–
This group covers engine functions.

DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
012093
OP EXTRA RMI

PRESENT INPUT SIGNAL, ACCELERATOR
page
–
Description: Signal from accelerator pedal.

DIAG ENGINE 1(X)
ACCELERATOR X.XXV Connection: signal from R690/2 to analogue in D790-1/K6:11
REQUIRED SPD PROC XXX
Function: 1 Engine
006866
REQUIRED SPD RPM XXXX

Signal value: X.XXV = 0.50-4.50 V
PRESENT INPUT SIGNAL, REQUIRED SPD PROC

page
–
Description: Required engine speed (in percent) which is sent from the
DIAG ENGINE 1(X) cab control unit (D790-1) to the engine control unit (D794) via the CAN
PRESENT INPUT SIGNAL bus drivetrain.
ACCELERATOR X.XXV
REQUIRED SPD PROC XXX Circuit diagram: -
006866
REQUIRED SPD RPM XXXX Connection: -

Function: 1.9 Control system, engine
Signal value: XXXX = 0-100%
PRESENT INPUT SIGNAL, REQUIRED SPD TCU

page
–
Description: Required engine speed in rpm which is sent from Control

DIAG ENGINE 1(X) unit, transmission (D793) to the engine control unit (D794) via the CAN
PRESENT INPUT SIGNAL bus drivetrain.
ACCELERATOR X.XXV
REQUIRED SPD PROC XXX Circuit diagram: -
006866
REQUIRED SPD RPM XXXX Connection: -

Signal value: XXXX = 0-2010 rpm

PRESENT INPUT SIGNAL, ENGINE SPEED EDC
page
–
Description: Engine speed from engine control unit (D794) to the cab
DIAG ENGINE 2(X) control unit (D790-1) via the CAN bus drivetrain. The actual value for
PRESENT INPUT SIGNAL engine speed.
ENGINE SPEED EDC XXXX
ENGINE SPEED TCU XXXX Circuit diagram: -
009281
Connection: -
Function: 1.9.2 Sensor engine rpm
Signal value: XXXX = Active speed in rpm.

76 8 Control system – 8.4.6.3 ENGINE, menu 3
PRESENT INPUT SIGNAL, ENGINE SPEED TCU

page
–
Description: Engine speed from transmission control unit (D793) to the

DIAG ENGINE 2(X) cab control unit (D790-1) via the CAN bus drivetrain. The actual value
PRESENT INPUT SIGNAL for engine speed.
ENGINE SPEED EDC XXXX
ENGINE SPEED TCU XXXX Circuit diagram: -
009281
Connection: -
Function: 2.2.5 Sensor engine rpm and oil temperature transmission
Signal value: XXXX = Active speed in rpm.

PRESENT INPUT SIGNAL, PRESENT TORQUE
page
–
Description: Actual torque from engine control unit (D794). Percent-

DIAG ENGINE 3(X) age torque use of engine’s capacity.
PRESENT TORQUE XXX Circuit diagram: -
PRESENT TORQUE XXX Connection: -
006867
PRES TORQUE @ RPM XXX

Signal value: XXX = 0-100%
PRESENT INPUT SIGNAL, REQUIRED TORQUE

page
–
Description: Requested torque from cab control unit (D790-1) to en-

DIAG ENGINE 3(X) gine control unit (D794).
PRESENT TORQUE XXX Circuit diagram: -
006867

PRESENT INPUT SIGNAL, PRES TORQUE @ RPM

page
–
Description: Available torque at current engine speed.

DIAG ENGINE 3(X)
Circuit diagram: -
PRESENT TORQUE XXX
006867


8 Control system – 8.4.6.4 ENGINE, menu 4 77

PRESENT INPUT SIGNAL, PREHEAT SWITCH
page
–
DIAG ENGINE 4(X)

PRESENT INPUT SIGNAL Description: Signal from ignition, preheating position. Only used on
PREHEAT SWITCH X machines with Volvo engines.
CRANK ENGINE SWITCH X
009282
D+ X Circuit diagram: Circuit Power group 11.5
Function: 1 Engine, 1.10.1 Preheating
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, CRANK ENGINE SWITCH

page
–
Description: Signal from ignition, start position.

DIAG ENGINE 4(X)
PREHEAT SWITCH X Connection: signal from S150/50 to digital in D790-2/K2:1
CRANK ENGINE SWITCH X
Function: 1.1.1 Engine, 1.11 Start and stop
009282
D+ X
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, D+

page
–
Description: Signal from alternator, indicates if alternator supplies cur-

DIAG ENGINE 4(X) rent.
PREHEAT SWITCH X Circuit diagram: Circuit Power group 11.5
CRANK ENGINE SWITCH X Connection: from G660/D+ to digital in D797-R/K2:16
009282
D+ X
Function: 11.4.1 Alternator
Signal value:
0 No signal.


PRESENT OUTPUT SIGNAL, PREHEAT
page
–
Description: Status for preheating of induction air.

DIAG ENGINE 5(10)
Circuit diagram: -
PREHEAT X Connection:
CRANK ENGINE X
Volvo: software signals on CAN-bus drivetrain
000152
Cummins: controlled by engine’s control system.
Function: 1.10.1 Preheating
Signal value:
1 Output signal active.
0 No output signal.
PRESENT OUTPUT SIGNAL, CRANK ENGINE

page
–
Description: Status for Voltage feed starter motor.

DIAG ENGINE 5(10)
PREHEAT X Connection:
CRANK ENGINE X
Volvo: software signals on CAN-bus drivetrain
000152
Cummins: digital out D797-R/K1:36 to K360/86

Function: 1.11 Start and stop
Signal value:


ing.


PRESENT INPUT SIGNAL, OIL PRESSURE
page
–
Description: Engine oil pressure. CAN bus message from engine con-
DIAG ENGINE 6(X) trol unit (D794) to cab control unit (D790-1).
OIL PRESSURE XXX Circuit diagram: see supplier documentation, engine
BOOST PRESSURE XXX Connection:
006868
OIL LEVEL XXX
Volvo TWD1240VE: signal from "43 Sensor, oil temperature/pres-
sure" to Control unit, engine (D794) "black connector" sleeve 14
Volvo TAD1250VE: signal from "28 Sensor, oil temperature and
oil pressure" to Control unit, engine (D794) "Connector B" sleeve
11
Cummins QSM11: signal from "oil pressure/temperature sensor"
to engine control unit (D794) "Sensor connector" sleeve 44
Function: 1.8.3 Sensor oil pressure engine
Signal Value: XXX = 10 corresponds to 100 kPa.
PRESENT INPUT SIGNAL, BOOST PRESSURE

page
–
Description: Charge air pressure. CAN bus message from engine con-
DIAG ENGINE 6(X) trol unit (D794) to cab control unit (D790-1).
OIL PRESSURE XXX Circuit diagram: See supplier documentation, engine
BOOST PRESSURE XXX Connection:
006868
OIL LEVEL XXX

Volvo TWD1240VE: signal from "36 Sensor, charge air pressure/
charge air temperature" to Control unit, engine (D794) "black con-
nector" sleeve 2
Volvo TAD1250VE: signal from "23 Sensor, charge air pressure/
charge air temperature" to Control unit, engine (D794) "connector
A" sleeve 22
Cummins QSM11: signal from "Intake manifold (boost) pressure
sensor" to engine control unit (D794) "Sensor connector" sleeve
39
Function: 1.6.5 Sensor boost pressure
Signal Value: XXX = 10 corresponds to 100 kPa.
PRESENT INPUT SIGNAL, OIL LEVEL

page
–
DIAG ENGINE 6(X)

PRESENT INPUT SIGNAL Only for engine alternative Volvo TAD1250VE
OIL PRESSURE XXX Description: Engine oil level. CAN bus message from engine control
BOOST PRESSURE XXX
006868
OIL LEVEL XXX unit (D794) to cab control unit (D790-1).

Circuit diagram: See supplier documentation, engine
Connection: Volvo TAD1250VE: signal from "15 Sensor, oil level" to
Control unit, engine (D794) "connector A" sleeve 3
Function:
Signal value: XXX = 0-100 = 0-100% = Oil level in percent.


PRESENT INPUT SIGNAL, OIL TEMP
page
–
Description: Engine oil temperature. CAN bus message from engine

DIAG ENGINE 7(X) control unit (D794) to cab control unit (D790-1).
OIL TEMP XXX Circuit diagram: see supplier documentation, engine
COOLANT TEMP XXX Connection:
009284
INTAKE MAIN.TEMP XXX
Volvo TWD1240VE: signal from "43 Sensor, oil temperature/pres-
sure" to Control unit, engine (D794) "black connector" sleeve 1
Volvo TAD1250VE: signal from "28 Sensor, oil temperature and
oil pressure" to Control unit, engine (D794) "connector A" sleeve
31
Cummins QSM11: signal from "Oil pressure/temperature sensor"
sleeve 4 to Control unit, engine (D794) "Sensor connector" sleeve
42
Function: 1.8.7 Sensor oil temperature
Signal value: XXX = 200 equals 20 °C.
PRESENT INPUT SIGNAL, COOLANT TEMP

page
–
Description: Coolant temperature. CAN bus message from engine

009284

Volvo TWD1240VE: signal from "35 Sensor, coolant temperature"
to Control unit, engine (D794) "black connector" sleeve 25
Volvo TAD1250VE: signal from "16 coolant temperature sensor"
to engine control unit (D794) "Connector B" sleeve 27
Cummins QSM11: signal from "Coolant temperature sensor" to
engine control unit (D794) "Sensor connector" sleeve 02
Function: 1.7.9 Sensor coolant temperature
PRESENT INPUT SIGNAL, INTAKE MAIN.TEMP

page
–
Description: Charge air temperature. CAN bus message from engine

009284

Volvo TWD1240VE: signal from "36 Sensor, charge air pressure/
charge air temperature." to Control unit, engine (D794) "black
connector" sleeve 2
Volvo TAD1250VE: signal from "23 charge air pressure/tempera-
ture sensor" to engine control unit (D794) "connector A" sleeve 47
Cummins QSM11: signal from "Intake manifold (boost) tempera-
ture sensor" to engine control unit (D794) "Sensor connector"
sleeve 38
Function: 1.6.6 Sensor charge-air temperature


PRESENT EDC ERROR, NO. OF ACT ERROR
page
–
Description: Number of active error codes from Control unit, engine

DIAG ENGINE 8(X) (D794).
PRESENT EDC ERROR
NR OF ACT ERROR XX Circuit diagram: -
SPN XXXX Connection: -
009279
FMI XX
Function: 1.9 Control system
Signal value: XX = number of active error codes.
PRESENT EDC ERROR, SPN

page
–
Description: SPN number for the first error code from engine control
DIAG ENGINE 8(X) unit (D794). SPN indicates the malfunction area, i.e. what component
PRESENT EDC ERROR or signal is defective. Error codes are shown with SPN/FMI in error
NR OF ACT ERROR XX code menus.
SPN XXXX
009279
FMI XX Circuit diagram: -

Connection: -
Function: 8.3 Error codes
Signal value: XXXX = error code number. Use the error code list; see
section D Error codes.
PRESENT EDC ERROR, FMI

page
–
Description: FMI number for the first error code from the engine control
DIAG ENGINE 8(X) unit (D794). FMI indicates error type, e.g. short circuit or low value. Er-
PRESENT EDC ERROR ror codes are shown with SPN/FMI in error code menus.
NR OF ACT ERROR XX
SPN XXXX Circuit diagram: -
009279
FMI XX Connection: -
Function: 8.3 Error codes
Signal value: XX = fault type number. Use the error code list; see sec-
tion D Error codes.

FUEL CONSUMPTION, MOMENTARILY l/h
page
–
Description: Current fuel consumption in litres/hour.

DIAG ENGINE 9(X)
Circuit diagram: -
FUEL CONSUMTION
MOMENTARILY l/h XXX Connection: -
Function: 1.2 Fuel system
009280
Signal value: XXX = fuel consumption in l/h.

82 8 Control system – 8.4.7 TRANSM
8.4.7 TRANSM
TRANSM, description
page
–
This group covers the transmission function.

DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
009274
OP EXTRA RMI
8.4.7.1 TRANSM, menu 1

PRESENT INPUT SIGNAL, BRAKE PEDAL
page
–
DIAG TRANSM. 1(15)

PRESENT INPUT SIGNAL Description: Not used.
BRAKE PEDAL X.XXV Circuit diagram: Circuit Drivetrain group 2.1
DECLUTCH SWITCH X
000159
DECLUTCH PRESS SW. X Connection: signal from B697/3 to analogue in on D790-1/K6:12

Function: -
Signal value: X.XXV = 0.00 - 5.00 V
PRESENT INPUT SIGNAL, DECLUTCH SWITCH

page
–
Description: Signal from declutch pedal.

DIAG TRANSM. 1(15)
BRAKE PEDAL X.XXV Connection: signal from S220-1/2 to digital in D790-1/K6:14
DECLUTCH SWITCH X
Function: 2.1.2 Declutch pedal
000159
DECLUTCH PRESS SW. X

Signal value:
1 Input signal active. Declutch pedal pressed down.
0 No signal.
PRESENT INPUT SIGNAL, DECLUTCH PRESS SW.

page
–
Description: Signal from NO switch declutch (pressure switch).

DIAG TRANSM. 1(15)
BRAKE PEDAL X.XXV Connection: signal from S220-2/2 to digital in D797-F/K1:41
DECLUTCH SWITCH X
Function: 2.8.2 NO switch, declutch
000159
DECLUTCH PRESS SW. X

Signal value:
0 No signal.

8 Control system – 8.4.7.2 TRANSM, menu 2 83

SWITCHES, FORWARD
page
–
Description: Signal from gear and multi-function lever (forward).

DIAG TRANSM. 2(15)
SWITCHES
FORWARD X Connection: from S162/F to digital in 790-2/K3:11
REVERSE X
Function: 2 Transmission
000160
SHIFT MODE X
Signal value:
1 Input signal active. Travel direction forward selected.
0 No signal.
SWITCHES, REVERSE
page
–
Description: Signal from gear and multi-function lever (reverse).

DIAG TRANSM. 2(15)
SWITCHES
FORWARD X Connection: from S162/R to digital in 790-2/K3:12
REVERSE X
000160
SHIFT MODE X
Signal value:
1 Input signal active. Travel direction reverse selected.
0 No signal.
SWITCHES, SHIFT MODE

page
–
Description: Signal from shifting program switch. Status on CAN bus

DIAG TRANSM. 2(15) from KIT control unit (D790-2). The switches are integrated in the KIT
SWITCHES control unit (D790-2).
FORWARD X
REVERSE X Circuit diagram: -
000160
SHIFT MODE X Connection: -

Signal value:
1 Shifting program 1 selected.
2 Shifting program 2 selected.
4 Automatic shifting selected.

84 8 Control system – 8.4.7.3 TRANSM, menu 3

PRESENT VALUE, FORWARD
page
–
Description: Status for forward direction of travel from transmission

DIAG TRANSM. 3(15) control unit (D793). Indicates if forward drive is activated in the trans-
PRESENT VALUE mission.
FORWARD X
000161
GEAR X Connection: -
Signal value:
1 Output signal for travel direction forward active.
0 No output signal.
PRESENT VALUE, REVERSE

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Description: Status for rearward direction of travel from transmission

DIAG TRANSM. 3(15) control unit (D793). Indicates if rearward drive is activated in the trans-
PRESENT VALUE mission.
FORWARD X
000161
GEAR X Connection: -
Signal value:
1 Output signal for travel direction reverse active.
0 No output signal.
PRESENT VALUE, GEAR

page
–
Description: Current gear, status from transmission control unit

DIAG TRANSM. 3(15) (D793). Shows which gear is activated in the transmission.
PRESENT VALUE
FORWARD X Circuit diagram: -
REVERSE X Function: 2.8 Control system, transmission
000161
GEAR X
Connection: -
Signal value: X = current gear.

OPERATING STATE, AUT/MAN MODE
page
–
Description: Shows which shifting program is selected automatic or

DIAG TRANSM. 4(15) manual.
OPERATING STATE
AUT/MAN MODE X Circuit diagram: -
WARNING X Connection: -
000162
OPERATING MODE X
Signal value:
1 Automatic.
0 Manual.

OPERATING STATE, WARNING

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–
Description: Warning for serious malfunction in transmission from

DIAG TRANSM. 4(15) transmission control unit (D793).
OPERATING STATE
000162
OPERATING MODE X
Signal value:
1 Active error.
0 No errors.
OPERATING STATE, OPERATING MODE

page
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Description: Operating mode status for transmission control unit

DIAG TRANSM. 4(15) (D793); also shown in control unit display.
OPERATING STATE
000162
OPERATING MODE X
Signal value:
0 Not used.
1 Manual or automatic shifting, standard mode shown during

operation.
2 Not used.
3 Not used.
4 Limp-home, reduced capacity due to malfunction in transmis-

sion.
5 Shut-down, serious transmission malfunction control unit

shuts down, likely that malfunction cannot be shown as CAN
bus.
6 Calibration of transmission in progress.

OPERATING STATE, SHIFT IN PROGRESS
page
–
Description: Status for transmission function during operation, shifting

DIAG TRANSM. 5(15) in progress. Active during shifting.
OPERATING STATE
SHIFT IN PROGRESS X Circuit diagram: -
FAULT X Connection: -
000163
OLD FAULT X
Signal value:
1 Shifting in progress.
0 No activity.

OPERATING STATE, FAULT

page
–
Description: Status for transmission’s function during operation, active

DIAG TRANSM. 5(15) error codes present.
OPERATING STATE
000163
OLD FAULT X
Signal value:
1 Active error code.
0 No error codes.
OPERATING STATE, OLD FAULT

page
–
Description: Status for transmission’s function during operation, there

DIAG TRANSM. 5(15) are inactive error codes that have not been acknowledged.
OPERATING STATE
000163
OLD FAULT X
Signal value:
1 There are inactive error codes that have not been acknowl-
edged.
0 No unacknowledged error codes.

DRUM SPEED (transmission alternative Dana)
page
–
Description: Signal from sensor rpm drum (position 1).

DIAG TRANSM. 6(15)
Circuit diagram: Circuit Dana TE 32000 group 2.0
DRUM SPEED XXXXHz
OUTPUT SPEED XXXXHz Connection: signal from B752 till D793/B3 and D793/C3
ENGINE SPEED XXXXHz
Function: 2.3.7 Sensor rpm drum
TURBINE SPEED XXXXHz
Signal value: XXXXHz = frequency, indicates pulses from the sensor
in Hz (pulses /second). To convert to rpm, divide frequency by number
1 2 3
of teeth on drum gear.
5
000164
4
1. Sensor, drum rpm (B752)
2.Temperature switch, torque converter (S221)
3.Sensor, engine speed and transmission tempera-
ture (B758/766)
4.Sensor, turbine rpm transmission (B751)
5.Sensor rpm output shaft (B758)

OUTPUT SPEED (transmission alternative Dana)

page
–
Description: Signal from sensor rpm output shaft (propeller shaft) (po-
DIAG TRANSM. 6(15) sition 5).
DRUM SPEED XXXXHz
OUTPUT SPEED XXXXHz Circuit diagram: Circuit Dana TE 32000 group 2.0
ENGINE SPEED XXXXHz Connection: signal from B758 till D793/ D3 and D793/ E3
Function: 2.3.9 Sensor rpm output shaft
1 2 3
of teeth on output shaft’s gear.
5 000164
4
ture (B758/766)
ENGINE SPEED (transmission alternative Dana)

page
–
Description: Rpm signal from sensor rpm engine speed (position 3).
DIAG TRANSM. 6(15)
DRUM SPEED XXXXHz
OUTPUT SPEED XXXXHz Connection: signal from B7558/766 to D793/H3
ENGINE SPEED XXXXHz
1 2 3
of teeth on input shaft’s gear.
5
000164
4
ture (B758/766)

TURBINE SPEED (transmission alternative Dana)

page
–
Description: Signal from sensor rpm turbine transmission (position 4).

DIAG TRANSM. 6(15)
DRUM SPEED XXXXHz
OUTPUT SPEED XXXXHz Connection: signal from B751 to D793/R2
ENGINE SPEED XXXXHz
Function: 2.3.6 Sensor rpm turbine
1 2 3
of teeth on turbine’s gear.
5
000164
4
ture (B758/766)
ENGINE SPEED (transmission alternative Dana full flow)

page
–
Description: Rpm signal from sensor rpm engine speed (position 3).
DIAG TRANSM. 6(15)
Circuit diagram: Circuit Dana TE 32000FF group 2.0
ENGINE SPEED XXXXrpm
TURBINE SPEED XXXXrpm Connection: signal from B7530 to D793/F3 and D793/K3
DRUM SPEED XXXXrpm
OUTPUT SPEED XXXXrpm
Signal value: XXXXrpm = rotation speed.
1 2 3
5
013149
4
3.Sensor, engine speed (B7530)
6. Sensor temperature (B7660)

TURBINE SPEED (transmission alternative Dana full flow)

page
–
Description: Signal from sensor rpm turbine transmission (position 4).

DIAG TRANSM. 6(15)
TURBINE SPEED XXXXrpm Connection: signal from B7510 to D793/G3 and D793/K3
DRUM SPEED XXXXrpm
Function: 2.3.6 Sensor rpm turbine
1 2 3
5
013149
4
DRUM SPEED (transmission alternative Dana full flow)

page
–
Description: Signal from sensor rpm drum (position 1).

DIAG TRANSM. 6(15)
TURBINE SPEED XXXXrpm Connection: signal from B7520 till D793/B3 and D793/C3
DRUM SPEED XXXXrpm
Function: 2.3.7 Sensor rpm drum
1 2 3
5
013149
4

OUTPUT SPEED (transmission alternative Dana full flow)

page
–
Description: Signal from sensor rpm output shaft (propeller shaft) (po-
DIAG TRANSM. 6(15) sition 5).
TURBINE SPEED XXXXrpm Circuit diagram: Circuit Dana TE 32000FF group 2.0
DRUM SPEED XXXXrpm Connection: signal from B7580 till D793/ D3 and D793/ E3
Function: 2.3.9 Sensor rpm output shaft
1 2 3
5
013149
4

OUTPUT STATUS, RSP DRIVE (transmission alternative
page
–
Dana)
Description: Status high and low side for control of solenoid valve RSP
DIAG TRANSM. 7(15) Drive.
OUTPUT STATUS
RSP DRIVE X X Circuit diagram: Circuit Dana TE 32000 group 2.0
2/4 VFS SELECTION X Connection: signal from D793/K1 and D793/K2 to Y6066
000165
1/3 VFS SELECTION X

11 Activated high and low side.
10 High side activated, low side no signal.
01 High side no signal, low side activated.
00 No signal.

OUTPUT STATUS, 2/4 VFS SELECTION (transmission

page
–
alternative Dana)
Description: Status of feed to solenoid valve VFS 2ND/4TH.
DIAG TRANSM. 7(15)
OUTPUT STATUS
RSP DRIVE X X Connection: digital out from D793/D1 and D793/E1 to Y6069
2/4 VFS SELECTION X
000165
1/3 VFS SELECTION X
Signal value:
1 Activated.
0 No signal.
OUTPUT STATUS, 1/3 VFS SELECTION (transmission

page
–
alternative Dana)
Description: Status of feed to solenoid valve VFS 1 ST/3 RD.
DIAG TRANSM. 7(15)
OUTPUT STATUS
RSP DRIVE X X Connection: signal from D793/ H1 and D793/ J1 to Y6067
2/4 VFS SELECTION X
000165
1/3 VFS SELECTION X

Signal value:
1 Activated.
0 No signal.
FWD SELECTION (transmission alternative Dana full flow)

page
–
Description: Status of the feed to solenoid valve FWD selection.

DIAG TRANSM. 7(15)
FWD SELECTION X
REV SELECTION X Connection: signal from D793/K1 and D793/S3 to Y6066F
2/4 SELECTION X
013178
1/3 SELECTION X
1 Activated.
0 No signal.
REV SELECTION (transmission alternative Dana full flow)

page
–
Description: Status of the feed to solenoid valve FWD selection.

DIAG TRANSM. 7(15)
FWD SELECTION X
REV SELECTION X Connection: signal from D793/E2 and D793/S3 to Y6066R
2/4 SELECTION X
013178
1/3 SELECTION X
Signal value:
1 Activated.
0 No signal.

2/4 SELECTION (transmission alternative Dana full flow)

page
–
Description: Status of feed to solenoid valve 2ND/4TH SELECTION.

DIAG TRANSM. 7(15)
FWD SELECTION X
REV SELECTION X Connection: signal from D793/K2 and D793/R2 to Y6074
2/4 SELECTION X
013178
1/3 SELECTION X
Signal value:
1 Activated.
0 No signal.
1/3 SELECTION (transmission alternative Dana full flow)

page
–
Description: Status of feed to solenoid valve 1ST/3 RD SELECTION.

DIAG TRANSM. 7(15)
FWD SELECTION X
REV SELECTION X Connection: signal from D793/F2 and D793/S3 to Y60675
2/4 SELECTION X
013178
1/3 SELECTION X
Signal value:
1 Activated.
0 No signal.

FWD SUPPLY (transmission alternative Dana)
page
–
Description: Status for control current to clutch pack forward.

DIAG TRANSM. 8(15)
FWD SUPPLY X
REV SUPPLY X Connection: signal from D793/B1 to Y630
2/4 SUPPLY X
Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
000166
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.

REV SUPPLY (transmission alternative Dana)

page
–
Description: Status for control current to clutch pack reverse.

DIAG TRANSM. 8(15)
FWD SUPPLY X
REV SUPPLY X Connection: signal from D793/F1 to Y631
2/4 SUPPLY X
000166
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.
2/4 SUPPLY (transmission alternative Dana)

page
–
Description: Status for control current to clutch pack 2/4.

DIAG TRANSM. 8(15)
FWD SUPPLY X
REV SUPPLY X Connection: signal from D793/E2 to Y6074
2/4 SUPPLY X
000166
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.
1/3 SUPPLY (transmission alternative Dana)

page
–

DIAG TRANSM. 8(15)
FWD SUPPLY X
REV SUPPLY X Connection: signal from D793/F2 to Y6075
2/4 SUPPLY X
000166
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.
FWD/REV SUPPLY (transmission alternative Dana full

page
–
flow)
Description: Status for control current to clutch pack forward and re-
DIAG TRANSM. 8(15) verse.
SUPPLY
FWD/REV SUPPLY X Circuit diagram: Circuit Dana TE 32000FF group 2.0
2/4 SUPPLY X Connection: digital out from D793/B1 and D793/C1 to Y6300
013252
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.

2/4 SUPPLY (transmission alternative Dana full flow)

page
–

DIAG TRANSM. 8(15)
SUPPLY
FWD/REV SUPPLY X Connection: digital out from D793/F1 and D793/G1 to Y6069
2/4 SUPPLY X
013252
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.
1/3 SUPPLY (transmission alternative Dana full flow)

page
–

DIAG TRANSM. 8(15)
SUPPLY
FWD/REV SUPPLY X Connection: digital out from D793/ D1 and D793/ E1 to Y6067
2/4 SUPPLY X
013252
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.

FWD FEEDBACK (transmission alternative Dana)
page
–
Description: Present control current to solenoid valve clutch pack for-

DIAG TRANSM. 9(X) ward.
FWD FEEDBACK XXXXmA
REV FEEDBACK XXXXmA Circuit diagram: Circuit Dana TE 32000 group 2.0
2/4 FEEDBACK XXXXmA Connection: signal from D793/B1 to Y630
006869
1/3 FEEDBACK XXXXmA

transmission
Signal value: XXXX = Measured value in mA.
REV FEEDBACK (transmission alternative Dana)

page
–
Description: Present control current to solenoid valve clutch pack re-

DIAG TRANSM. 9(X) verse
FWD FEEDBACK XXXXmA
REV FEEDBACK XXXXmA Circuit diagram: Circuit Dana TE 32000 group 2.0
2/4 FEEDBACK XXXXmA Connection: signal from D793/F1 to Y631
006869
1/3 FEEDBACK XXXXmA

transmission

2/4 FEEDBACK (transmission alternative Dana)

page
–
Description: Present control current to solenoid valve clutch pack 2/4.

DIAG TRANSM. 9(X)
FWD FEEDBACK XXXXmA
REV FEEDBACK XXXXmA Connection: signal from D793/D1 to Y6069
2/4 FEEDBACK XXXXmA
006869
1/3 FEEDBACK XXXXmA
transmission
1/3 FEEDBACK (transmission alternative Dana)

page
–

DIAG TRANSM. 9(X)
FWD FEEDBACK XXXXmA
REV FEEDBACK XXXXmA Connection: signal from D793/H1 to Y6067
2/4 FEEDBACK XXXXmA
006869
1/3 FEEDBACK XXXXmA

transmission
ANALOGUE OUTPUTS, FWD/REV FEEDBACK

page
–
(transmission alternative Dana full flow)

Description: Present control current to solenoid valve clutch pack for-
DIAG TRANSM. 9(X) ward and reverse.
ANALOG OUTPUTS
FWD/REV F.B XXXXmA Circuit diagram: Circuit Dana TE 32000FF group 2.0
2/4 FEEDBACK XXXXmA Connection: digital out from D793/B1 and D793/C1 to Y6300
1/3 FEEDBACK XXXXmA
013408

transmission
ANALOGUE OUTPUTS, 2/4 FEEDBACK (transmission

page
–

DIAG TRANSM. 9(X) Circuit diagram: Circuit Dana TE 32000FF group 2.0
ANALOG OUTPUTS
FWD/REV F.B XXXXmA Connection: digital out from D793/F1 and D793/G1 to Y6069
2/4 FEEDBACK XXXXmA
1/3 FEEDBACK XXXXmA Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
013408
transmission
ANALOGUE OUTPUTS, 1/3 FEEDBACK (transmission

page
–

DIAG TRANSM. 9(X)
ANALOG OUTPUTS
FWD/REV F.B XXXXmA Connection: digital out from D793/ D1 and D793/ E1 to Y6067
2/4 FEEDBACK XXXXmA
1/3 FEEDBACK XXXXmA Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
013408
transmission


PRESENT SENSOR INPUT, PRESS FEEDBACK
page
–

Description: Signal from sensor oil pressure in transmission. The
DIAG TRANSM. 10(X) transmission uses a pressure-sensitive make-contact and two resis-
PRESENT SENSOR INPUT tors in the cable harness to generate different voltage levels.
PRESS FEEDBACK XXXXmV
TRANSM.TEMP XXXXmV Circuit diagram: Circuit Dana TE 32000 group 2.0
006870
COOLER TEMP XXXXmV Connection: signal from B6067 to D793/A2
Function: 2.6.2 Sensor oil pressure
Signal value:
0-1000 mV Short-circuiting to ground.
1500-2500 mV Oil pressure is correct.
2500-4000 mV Oil pressure is low.
4500-8000 mV Open circuit.
Over 8000 mV Short-circuiting to voltage
PRESENT SENSOR INPUT, TRANS.TEMP (transmission

page
–
alternative Dana)
Description: Signal from sensor transmission oil temperature.
DIAG TRANSM. 10(X)
PRESENT SENSOR INPUT
PRESS FEEDBACK XXXXmV Connection: signal from B758/766 to D793/H3
TRANSM.TEMP XXXXmV
006870
COOLER TEMP XXXXmV

Signal value: XXXX mV = signal voltage in mV (0-5000mV).
PRESENT SENSOR INPUT, COOLER TEMP (transmission

page
–
alternative Dana)
Description: Signal from oil temperature sensor in radiator, transmis-
DIAG TRANSM. 10(X) sion. The transmission uses a temperature-sensitive NO switch and
PRESENT SENSOR INPUT two resistors in the cable harness to generate different voltage levels.
PRESS FEEDBACK XXXXmV
TRANSM.TEMP XXXXmV Circuit diagram: Circuit Dana TE 32000 group 2.0
006870
COOLER TEMP XXXXmV Connection: signal from S221 to D793/J3

Function: 2.7.4 Sensor oil temperature oil cooler
Signal value:
0 mV Transmission oil has operating temperature.
2500 mV Transmission oil temperature is low.

2/4 PRESSx10 (transmission alternative Dana full flow)

page
–
Description: Signal from oil pressure sensor in transmission.

2/4 PRESSx10 XXXXBar
1/3 PRESSx10 XXXXBar Connection: signal from B6069 to D793/S1
TRANSM.TEMP XXXXmV
CONV OUT TEMP XXXXmV Function: 2.6.2 Sensor oil pressure
013410
Signal value:
0-5 bar Short-circuiting to ground.
8-15 bar Oil pressure is correct.
15-25 bar Oil pressure is high.
Over 25 bar Open circuit or short circuit to voltage.
1/3 PRESSx10 (transmission alternative Dana full flow)

page
–
Description: Signal from oil pressure sensor in transmission.

DIAG TRANSM. 10(X)
1/3 PRESSx10 XXXXBar Connection: signal from B6067 to D793/A2
TRANSM.TEMP XXXXmV
CONV OUT TEMP XXXXmV Function: 2.6.2 Sensor oil pressure
013410
Signal value:
0-5 bar Short-circuiting to ground.
8-15 bar Oil pressure is correct.
15-25 bar Oil pressure is high.
Over 25 bar Open circuit or short circuit to voltage.
TRANSM.TEMP (transmission alternative Dana full flow)

page
–
Description: Signal from sensor transmission oil temperature.

1/3 PRESSx10 XXXXBar Connection: signal from B7660 to D793/H3
TRANSM.TEMP XXXXmV
CONV OUT TEMP XXXXmV Function: 2.7.2 Sensor engine rpm and oil temperature transmission
013410
Signal value: XXXX mV = signal voltage in mV (0-5000mV).
CONV TEMP OUT (transmission alternative Dana full flow)

page
–
Description: Signal from oil temperature sensor in radiator, transmis-

DIAG TRANSM. 10(X) sion. The transmission uses a temperature-sensitive NO switch and
2/4 PRESSx10 XXXXBar two resistors in the cable harness to generate different voltage levels.
TRANSM.TEMP XXXXmV Circuit diagram: Circuit Dana TE 32000FF group 2.0
CONV OUT TEMP XXXXmV
013410
Connection: signal from S2210 to D793/J3

Function: 2.7.4 Sensor oil temperature oil cooler
Signal value:
0 mV Transmission oil has operating temperature.
2500 mV Transmission oil temperature is low.


AXLE RATIO (transmission alternative Dana)
page
–
Description: Drive axle gear ratio.

DIAG TRANSM. 11(X)
Circuit diagram: -
PRESENT VALUE
AXLE RATIO XXXXX Connection: -
RADIUS XXXX
006871
SPEED LIMIT XXXX
Signal value: XXXXX = drive axle’s total gear ratio x 1024
RADIUS (transmission alternative Dana)

page
–
Description: Drive wheels’ radius

DIAG TRANSM. 11(X)
Circuit diagram: -
PRESENT VALUE
RADIUS XXXX
006871
SPEED LIMIT XXXX

Signal value: XXXX = Drive wheels’ radius in mm.
SPEED LIMIT (transmission alternative Dana)

page
–
Description: Speed limitation.

DIAG TRANSM. 11(X)
Circuit diagram: -
PRESENT VALUE
RADIUS XXXX
006871
SPEED LIMIT XXXX

Signal value: XXX = Speed limitation in km/h.
AXLE RATIOx1024 (transmission alternative Dana full

page
–
flow)
Description: Drive axle gear ratio.
DIAG TRANSM. 11(X) Circuit diagram: -
PRESENT VALUE
AXLE RATIOx1024 XXXXX Connection: -
RADIUS XXXX Function: 2.8 Control system, transmission
SPEED LIMIT XXXX
013431
Signal value: XXXXX = drive axle’s total gear ratio
RADIUS (transmission alternative Dana full flow)

page
–
Description: Drive wheels’ radius

PRESENT VALUE
SPEED LIMIT XXXX
013431
Signal value: XXXX = Drive wheels’ radius in mm.
SPEED LIMIT (transmission alternative Dana full flow)

page
–
Description: Speed limitation.

PRESENT VALUE
SPEED LIMIT XXXX
013431
Signal value: XXX = Speed limitation in km/h.


NOT USED
page
–
This menu is not used.

DIAG TRANSM. 12(X)
NOT USED
006872
ACT ERROR AREA
page
–
Description: Indicates malfunction area active error, first part of the er-
DIAG TRANSM. 13(15) ror code. In case of several error codes, the most serious error code
ACT ERROR AREA XXX is shown.
TYPE XXX
NUMBER OF OCCU. XXXXX Circuit diagram: -
000171
TIME AGO XXXXX Connection: -

Signal value: XXX = First part of error code; see section D Error codes.
TYPE
page
–
Description: Indicates type of active error.

DIAG TRANSM. 13(15)
Circuit diagram: -
ACT ERROR AREA XXX
TYPE XXX Connection: -
NUMBER OF OCCU. XXXXX
000171
TIME AGO XXXXX

Signal value: XXX = Second part of error code.
NUMBER OF OCCU.
page
–
Description: Number of times active errors have occurred.

DIAG TRANSM. 13(15)
Circuit diagram: -
ACT ERROR AREA XXX
000171
TIME AGO XXXXX

Signal value: XXXXX = Number of times active errors have occurred.
TIME AGO
page
–
Description: When latest active error occurred.

DIAG TRANSM. 13(15)
Circuit diagram: -
ACT ERROR AREA XXX
000171
TIME AGO XXXXX

Signal value: XXXXX = Operating time in hours since latest error.


CONVERTER STATUS (Nm), TORQUE IMPELLER
page
–
Description: Torque transmitted by from engine to impeller in torque

DIAG TRANSM. 14(X) converter. The torque absorbed by the transmission.
CONVERTER STATUS (Nm)
TORQUE IMPELLER XXXX Circuit diagram: -
TORQUE TURBINE XXXX Connection: -
006873
Signal value: XXXX = Torque in Nm.
CONVERTER STATUS (Nm), TORQUE TURBINE

page
–
Description: Current torque transmitted by torque converter to trans-

DIAG TRANSM. 14(X) mission.
CONVERTER STATUS (Nm)
TORQUE IMPELLER XXXX Circuit diagram: -
TORQUE TURBINE XXXX Connection: -
006873

Signal value: XXXX = Torque in Nm.

8 Control system – 8.4.8 BOOM 101
8.4.8 BOOM
BOOM, description
page
–
This group covers the boom functions.

DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
009275
OP EXTRA RMI

PRESENT INPUT SIGNALS, BOOM UP/DOWN
page
–
Description: Signal from control lever (boom up/down).

DIAG BOOM 1(8)
Circuit diagram: Circuit Joystick group 7.1
PRESENT INPUT SIGNALS
BOOM UP/DOWN XX.XXV Connection: signal from S815/8 to analogue in D790-1/K7:3
BOOM IN/OUT XX.XXV
Function: 7.1.1 Control lever
000175
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.
PRESENT INPUT SIGNALS, BOOM IN/OUT

page
–
Description: Signal from control lever (boom in/out).

DIAG BOOM 1(8)
Circuit diagram: Circuit Joystick group 7.1
BOOM UP/DOWN XX.XXV Connection: signal from S815/4 to analogue in D790-1/K7:4
BOOM IN/OUT XX.XXV
Function: 7.1.1 Control lever
000175
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

BLOCK VALVES, UP/DOWN
page
–
Description: Voltage feed to solenoid valve blocking, lower.

DIAG BOOM 2(8)
Circuit diagram: Circuit Boom up/down group 7.2
BLOCK VALVES
UP/DOWN LE XY RI XY Connection:
IN XY
LE: digital out from D797-F/K1:30 to H6002/1
012097
RELIEVE PRESS. IN XY
RI: digital out from D797-F/K1:31 to H6001/1
Function: 7.2.7 Valve block lift cylinder
Signal value:


ing.

102 8 Control system – 8.4.8.2 BOOM, menu 2
BLOCK VALVES, IN/OUT

page
–
Description: Voltage feed to solenoid valve blocking, boom in.

DIAG BOOM 2(8)
Circuit diagram: Circuit Boom in/out group 7.3
BLOCK VALVES
UP/DOWN LE XY RI XY Connection: digital out from D797-R/K1:5 to B6050/1
IN XY
Function: 7.3.7 Valve block extension cylinder
012097
Signal value:


ing.
BLOCK VALVES, RELIEVE PRESS. IN

page
–
Description: Voltage feed to solenoid valve pump unloading.

DIAG BOOM 2(8)
BLOCK VALVES
UP/DOWN LE XY RI XY Connection: digital out from D797-R/K1:40 to B6062/1
IN XY
Function: 7.3.9 Valve block pump unloading.
012097
Signal value:


ing.

8 Control system – 8.4.8.3 BOOM, menu 3 103

BOOM HIGH SPEED, UP
page
–
Description: Voltage feed to solenoid valve, regeneration boom up.

DIAG BOOM 3(8)
Circuit diagram: Circuit Boom up/down group 7.2
BOOM HIGH SPEED
UP LE XY RI XY Connection:
OUT XY
LE: digital out from D797-F/K1:33 to H6052/1
000177
RE: digital out from D797-F/K1:32 to H6051/1
Function: 7.2.7 Valve block lift cylinder
Signal value:


ing.
BOOM HIGH SPEED, OUT

page
–
Description: Voltage feed to solenoid valve, regeneration, extension.

DIAG BOOM 3(8)
BOOM HIGH SPEED
UP LE XY RI XY Connection: digital out from D797-R/K1:4 to B6046/1
OUT XY
Function: 7.3.7 Valve block extension cylinder
000177
Signal value:


ing.


OUTPUT BOOM UP, REFERENCE
page
–
Description: Status for control current to control valve lift, lower and ex-
DIAG BOOM 4(8) tension (solenoid valve lift).
OUTPUT BOOM UP
REFERENCE XY Circuit diagram: Circuit Boom up/down group 7.2
REQUIRED VALUE XXX Connection: digital out from D797-F/K1:2 to Y6005/1
000178
FEEDBACK XXX
Function: 7.2.5 Control valve lift, lower and extension
Signal value:


ing.
OUTPUT BOOM UP, REQUIRED VALUE

page
–
Description: Reference value for control current to control valve lift,

DIAG BOOM 4(8) lower and extension (solenoid valve lift).
OUTPUT BOOM UP
REQUIRED VALUE XXX Connection: output signal reference value out from D797-F/K1:16 to
000178
FEEDBACK XXX Y6005/2

Signal value: XXX = Current value: in mA for control of solenoid valve.
OUTPUT BOOM UP, FEEDBACK

page
–
Description: Present control current to control valve lift, lower and ex-
DIAG BOOM 4(8) tension (solenoid valve lift).
OUTPUT BOOM UP
REQUIRED VALUE XXX Connection: output signal actual value out from D797-F/K1:16 to
000178

Signal value: XXX = Measured current value in mA.


OUTPUT BOOM DOWN, REFERENCE
page
–
DIAG BOOM 5(8) tension (solenoid valve lower).
OUTPUT BOOM DOWN
000179
FEEDBACK XXX
Signal value:


ing.
OUTPUT BOOM DOWN, REQUIRED VALUE

page
–

DIAG BOOM 5(8) lower and extension (solenoid valve lower).
OUTPUT BOOM DOWN
000179

OUTPUT BOOM DOWN, FEEDBACK

page
–
DIAG BOOM 5(8) tension (solenoid valve lower).
OUTPUT BOOM DOWN
000179



OUTPUT BOOM IN, REFERENCE
page
–
DIAG BOOM 6(8) tension (solenoid valve extension in).
OUTPUT BOOM IN
REFERENCE XY Circuit diagram: Circuit Boom in/out group 7.3
000180
FEEDBACK XXX
Signal value:


ing.
OUTPUT BOOM IN, REQUIRED VALUE

page
–

DIAG BOOM 6(8) lower and extension (solenoid valve extension in).
OUTPUT BOOM IN
000180

OUTPUT BOOM IN, FEEDBACK

page
–
Description: Present value for control current to control valve lift, lower
DIAG BOOM 6(8) and extension (solenoid valve extension in).
OUTPUT BOOM IN
000180



OUTPUT BOOM OUT, REFERENCE
page
–
DIAG BOOM 7(8) tension (solenoid valve extension out).
OUTPUT BOOM OUT
000181
FEEDBACK XXX
Signal value:


ing.
OUTPUT BOOM OUT, REQUIRED VALUE

page
–

DIAG BOOM 7(8) lower and extension (solenoid valve extension out).
OUTPUT BOOM OUT
000181

OUTPUT BOOM OUT, FEEDBACK

page
–
DIAG BOOM 7(8) tension (solenoid valve extension out).
OUTPUT BOOM OUT
000181



PRESENT INPUT SIGNAL BOOM LOW SPEED, UP/DOWN
page
–
Description: Signal from sensor boom angle, to activate damping dur-

DIAG BOOM 8(8) ing lifting and lowering.
BOOM LOW SPEED Circuit diagram: Circuit OP + Scale group 8.2
UP/DOWN X Connection: signal in from B771 to analogue in D797-R/K1:21
000182
IN/OUT X/X
Function: 7.2.11 Sensor, boom angle (position sensor)
Signal value:
0 No signal.
PRESENT INPUT SIGNAL BOOM LOW SPEED, IN/OUT

page
–
Description: Signal from sensor boom length to activate damping dur-

DIAG BOOM 8(8) ing extensions.
BOOM LOW SPEED Circuit diagram: Circuit OP + Scale group 8.2 (Mechanical overload
UP/DOWN X system with analogue position sensor or Electrical overload system),
000182
IN/OUT X/X Circuit Boom in/out group 7.3 (Mechanical overload system)
Connection:
Mechanical overload system with analogue position sensor or
Electrical overload system:
Analogue signal in from B777/3 to analogue in D797-R/K1:22
Mechanical overload system:
Boom in: digital in from B769-3/C to digital in D797-R/K1:26
Boom out: digital in from B769-4/C to analogue in D797-R/K1:23
(software-generated signal from overload system)
Function: 7.3.11 Sensor, boom length
Signal value:
0 No signal.

8 Control system – 8.4.9 ATTACH 109
8.4.9 ATTACH
ATTACH, description
page
–
This group covers attachment functions.

DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
009276
OP EXTRA RMI

PRESENT INPUT SIGNALS, ROT CW/CCW
page
–
Description: Signals from control lever for rotating the attachment

DIAG ATTACHMENT 1(21) Circuit diagram: Circuit Joystick group 7.1
ROT CW/CCW XX.XXV Connection: signal from S815/11 to analogue in D790-1/K7:5
TILT IN/OUT XX.XXV Function: 7.6 Rotation
000184
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in control lever zero posi-
tion.
PRESENT INPUT SIGNALS, TILT IN/OUT

page
–
DIAG ATTACHMENT 1(21)

PRESENT INPUT SIGNALS Description: Signals from control lever for tilting the attachment
ROT CW/CCW XX.XXV Circuit diagram: Circuit Joystick group 7.1
TILT IN/OUT XX.XXV
000184
Connection: signal from S815/1 to analogue in D790-1/K7:6

Function: 7.7 Tilt
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in control lever centre po-
sition.

PRESENT INPUT SIGNALS, SIDE SHIFT
page
–
Description: Signals from control lever for side shift of attachment. If

DIAG ATTACHMENT 2(21) the trigger button is depressed at the same time as side shift then
PRESENT INPUT SIGNALS spreading is activated. Text in brackets describes spreading.
SIDE SHIFT LE X RI X
PISTOL X Circuit diagram: Circuit Joystick group 7.1
000185
30/35 STOP X Connection:

LE: from S815/14 to digital in D790-1/K7:14 (spreading in)
RI: from S815/16 to digital in D790-1/K7:13 (spreading out)
Function: 7.4 Side shift
Signal value:
0 No signal.

110 8 Control system – 8.4.9.3 ATTACH, menu 3
PRESENT INPUT SIGNALS, PISTOL

page
–
Description: Signals from control lever for pistol trigger.

SIDE SHIFT LE X RI X Connection: from S815/19 to digital in D790-1/K7:16
PISTOL X Function: 7.5 Spreading, 7.10.2 Weight Indicator, 7.10.4 Synchro-
000185
30/35 STOP X
nised lift
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, 30/35 STOP

page
–

PRESENT INPUT SIGNALS Description: Signal from switch for stop at 30’/35’.
SIDE SHIFT LE X RI X Circuit diagram: Circuit Spreading Sensor group 7.5
PISTOL X
000185
30/35 STOP X Connection: from S1004/1 to digital in D790-1/K8:10

Function: 7.5 Spreading
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, LOCK TW
page
–
Description: Signal from switch lock twistlock.

DIAG ATTACHMENT 3(21) Circuit diagram: Circuit Twistlock group 7.9
LOCK TW X Connection: from S1003/7 and S1007/2 to digital in D790-1/K8:12
UNLOCK TW X Function: 7.9.1 Twistlocks
000186
BY-PASS HEIGHT X
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, UNLOCK TW

page
–
Description: Signal from control lever to unlock twistlock.

LOCK TW X Connection: from S815/20 to digital in D790-1/K7:15
UNLOCK TW X Function: 7.9.1 Twistlocks
000186
BY-PASS HEIGHT X
Signal value:
0 No signal.

8 Control system – 8.4.9.4 ATTACH, menu 4 111
PRESENT INPUT SIGNALS, BYPASS HEIGHT

page
–

PRESENT INPUT SIGNALS Description: Signal from switch bypass of load centre limitation and
LOCK TW X height limitation if the machine is equipped with these options.
UNLOCK TW X
Circuit diagram: Circuit Bypass group 8.2
000186
BY-PASS HEIGHT X
Connection: from S1014/S1015/1 to digital in D790-1/K8:14
Function: 8.2.2 Bypass
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, TILT LOCKING
page
–
DIAG ATTACHMENT 4(X)

PRESENT INPUT SIGNALS Description: Signal from control lever for tilt locking.
TILT LOCKING X Circuit diagram: Circuit Joystick group 7.1
LEVELLING LOCKING X
006874
AUTO 20'-40' X Connection: from S815/18 to digital in D790-1/K8:2

Function: 7.7 Tilt
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, LEVELLING LOCKING

page
–

PRESENT INPUT SIGNALS Description: Signal from control lever for levelling lock.
TILT LOCKING X Circuit diagram: Circuit Joystick group 7.1
LEVELLING LOCKING X
006874
AUTO 20'-40' X Connection: from S815/17 to digital in D790-1/K8:1

Function: 7.8 Levelling
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, AUTO 20'-40'

page
–

PRESENT INPUT SIGNALS Description: Signal from switch automatic spreading 20'-40'.
TILT LOCKING X Circuit diagram: Circuit Extra equipment group 9.1
LEVELLING LOCKING X
006874
AUTO 20'-40' X Connection: from S199/-2 to digital in D790-1/K8:11
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, LOW SPEED 20/40
page
–
Description: Signal from position sensor spreading for end position

DIAG ATTACHMENT 5(21) damping 20’/40’. On machines with 30’ stop the sensor also produces
PRESENT INPUT SIGNALS a signal to control the stopping point for the 30’ position.
LOW SPEED 20/40 X
30/35 STOP X Circuit diagram: Circuit Spreading Sensor group 7.5
000188
EXTENSION 60CM X Connection: from inductive sensor B769/C to digital in D791-1/K1:12

Function: 7.5.10 Position sensor spreading
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, 30/35 STOP

page
–

PRESENT INPUT SIGNALS Description: Signal from position sensor spreading for stop at 30’/35’.
LOW SPEED 20/40 X The sensor produces a signal for damping at the 30’ position and for
30/35 STOP X stop at the 20’ and 40’ position.
000188
EXTENSION 60CM X
Circuit diagram: Circuit Spreading Sensor group 7.5
Connection: from inductive sensor B777-3/C to digital in D791-1/K1:20
Function: 7.5.10 Position sensor spreading
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, EXTENSION 60CM (model year

page
–
-2008)

PRESENT INPUT SIGNALS Description: Signal from position sensor extension 60 cm, for fixed
LOW SPEED 20/40 X scale.
30/35 STOP X
000188
EXTENSION 60CM X Circuit diagram: Circuit OP + Scale group 8.2
Connection: from inductive sensor B7224/C to digital in D791-1/K1:21
Function: 7.10.2 Weight indicator
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, ALIGNMENT, FRONT
page
–
Description: Signals from sensors alignment right front and left front.
Circuit diagram: Circuit Twistlock group 7.9
ALIGNMENT LE RI Connection:
FRONT X X
LE: signal from B7202L/C to analogue in (used as digital)
000202
REAR X X
D791-1/K1:13
RI: signal from B7202R/C to digital in D791-1/K1:40
Function: 7.9.1.8 Alignment sensor
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, ALIGNMENT, REAR

page
–
Description: Signals from sensors alignment right rear and left rear.
ALIGNMENT LE RI Connection:
FRONT X X
000202
REAR X X
D791-1/K1:27
Function: 7.9.1.8 Alignment sensor
Signal value:
0 No signal.


PRESENT INPUT SIGNAL, LOCKED TW
page
–
Description: Signals from sensors locked twistlock right and left.

LE RI Connection:
LOCKED TW X X
001633
UNLOCKED TW X X
D791-1/K1:23
RI: signal from B7205R/C to analogue in (used as digital)
D791-1/K1:24
Function: 7.9.1.9 Sensor twistlock
Signal value:
0 No signal.
PRESENT OUTPUT SIGNAL, UNLOCKED TW

page
–
Description: Signals from sensors open twistlock right and left.

LE RI Connection:
LOCKED TW X X
001633
UNLOCKED TW X X
D791-1/K1:22
RI: signal from B7204R/C to analogue in (used as digital)
D791-1/K1:41
Function: 7.9.1.9 Sensor twistlock
Signal value:
1 Output signal active.
0 No signal.


PRESENT OUTPUT SIGNAL, SIDE SHIFT LEFT
page
–
Description: Voltage feed to control valve attachment, side shift left.

DIAG ATTACHMENT 8(21) Circuit diagram: Circuit Spreading Valves group 7.5
SIDE SHIFT LEFT XY Connection: digital out from D791-1/K1:31 to Y6020/1
SIDE SHIFT RIGHT XY Function: 7.4.3 Control valve attachment
000189
Signal value:


ing.
PRESENT OUTPUT SIGNAL, SIDE SHIFT RIGHT

page
–
Description: Voltage feed to control valve attachment, side shift right.

DIAG ATTACHMENT 8(21) Circuit diagram: Circuit Spreading Valves group 7.5
SIDE SHIFT LEFT XY Connection: digital out from D791-1/K1:30 to Y6021/1
SIDE SHIFT RIGHT XY Function: 7.4.3 Control valve attachment
000189
Signal value:


ing.


PRESENT OUTPUT SIGNAL, LOCK TW
page
–
Description: Voltage feed to attachment control valve, lock twistlock.

LOCK TW XY Connection: digital out from D791-1/K1:32 to Y6040/1
UNLOCK TW XY
000190
Function: 7.9.1.3 Attachment control valve
Signal value:


ing.
PRESENT OUTPUT SIGNAL, UNLOCK TW

page
–
Description: Voltage feed to control valve attachment, open twistlock.

LOCK TW XY Connection: digital out from D791-1/K1:33 to Y6039/1
UNLOCK TW XY
000190
Function: 7.9.1.3 Attachment control valve

Signal value:


ing.


PRESENT OUTPUT SIGNAL, IND. LOCKED TW
page
–
Description: Voltage feed indicator light locked twistlock.

IND. LOCKED TW XY Connection: digital out from D791-1/K1:39 to H563/1
IND. UNLOCKED TW XY
000191
IND. ALIGNMENT XY
Signal value:


ing.
PRESENT OUTPUT SIGNAL, IND. UNLOCKED TW

page
–
Description: Voltage feed indicator light open twistlock.

IND. UNLOCKED TW XY
000191

IND. ALIGNMENT XY
Signal value:


ing.

PRESENT OUTPUT SIGNAL, ALIGNMENT

page
–
Description: Voltage feed indicator light alignment.

IND. UNLOCKED TW XY
000191
IND. ALIGNMENT XY
Signal value:


ing.

OUTPUT ROTATION C.W., REFERENCE
page
–
Description: Status control current to control valve attachment for ro-

DIAG ATTACHMENT 11(21) tation clockwise.
OUTPUT ROTATION C.W.
REFERENCE XY Circuit diagram: Circuit Rotation, group 7.6
RQUIRED VALUE XXX Connection: digital out from D791-1/K1:2 to solenoid valve Y6008/1
000192
FEEDBACK XXX
Function: 7.6.3 Control valve attachment
Signal value:


ing.

OUTPUT ROTATION C.W., REQUIRED VALUE

page
–
Description: Reference value for control current to control valve at-

DIAG ATTACHMENT 11(21) tachment for rotation clockwise.
RQUIRED VALUE XXX Connection: output signal reference value out from D791-1/K1:16 to
000192
OUTPUT ROTATION C.W., FEEDBACK

page
–
Description: Present control current to control valve attachment for ro-

RQUIRED VALUE XXX Connection: output signal, actual value out from D791-1/K1:16 to
000192


OUTPUT ROTATION C.C.W., REFERENCE
page
–
Description: Status control current to control valve attachment for ro-

DIAG ATTACHMENT 12(21) tation anticlockwise.
OUTPUT ROTATION C.C.W.
REQUIRED VALUE XXX Connection: digital out from D791-1/K1:3 to solenoid valve Y6009/1
000193
FEEDBACK XXX
Signal value:


ing.
OUTPUT ROTATION C.C.W., REQUIRED VALUE

page
–

DIAG ATTACHMENT 12(21) tachment for rotation anticlockwise.
REQUIRED VALUE XXX Connection: output signal reference value out from D791-1/K1:17 to
000193


OUTPUT ROTATION C.C.W., FEEDBACK

page
–
Description: Present control current to control valve attachment for ro-

REQUIRED VALUE XXX Connection: output signal, actual value out from D791-1/K1:17 to
000193

OUTPUT SPREADER OUT, REFERENCE
page
–
Description: Status control current to control valve attachment for

DIAG ATTACHMENT 13(21) spreader out.
OUTPUT SPREADER OUT
REFERENCE XY Circuit diagram: Circuit Spreading Valves group 7.5
REQUIRED VALUE XXX Connection: digital out from D791-1/K1:4 to Y6018/1
000194
FEEDBACK XXX
Signal value:


ing.
OUTPUT SPREADER OUT, REQUIRED VALUE

page
–

DIAG ATTACHMENT 13(21) tachment for output signal, spreading out.
OUTPUT SPREADER OUT
REQUIRED VALUE XXX Connection: output signal reference value out from D791-1/K1:18 to
000194

OUTPUT SPREADER OUT, FEEDBACK

page
–
Description: Present control current to control valve attachment for

DIAG ATTACHMENT 13(21) spreader out.
OUTPUT SPREADER OUT
REQUIRED VALUE XXX Connection: output signal, actual value out from D791-1/K1:18 to
000194



OUTPUT SPREADER IN, REFERENCE
page
–
Description: Status control current to control valve attachment for

DIAG ATTACHMENT 14(21) spreader in.
OUTPUT SPREADER IN Circuit diagram: Circuit Spreading Valves group 7.5
REFERENCE XY
RQUIRED VALUE XXX Connection: digital out from D791-1/K1:5 to Y6019/1
000195
FEEDBACK XXX
Signal value:


ing.
OUTPUT SPREADER IN, REQUIRED VALUE

page
–

DIAG ATTACHMENT 14(21) tachment for spreading in.
REFERENCE XY
RQUIRED VALUE XXX Connection: output signal, reference value out from D791-1/K1:19 to
000195

OUTPUT SPREADER IN, FEEDBACK

page
–
Description: Present control current to control valve attachment for

DIAG ATTACHMENT 14(21) spreader in.
REFERENCE XY
RQUIRED VALUE XXX Connection: output signal, actual value out from D791-1/K1:19 to
000195



PRESENT OUTPUT SIGNAL, TILT LOCKING 1
page
–

PRESENT OUTPUT SIGNAL Description: Voltage feed to lock valve tilt.
TILT LOCKING 1 XY Circuit diagram: Circuit Tilt locking group 7.7
TILT LOCKING 2 XY
006875
BUZZER AUTO 20-40 XY Connection: digital out from D791-1/K1:7 to Y6012-1/1
Function: 7.7.4 Lock valve tilt
Signal value:


ing.
PRESENT OUTPUT SIGNAL, TILT LOCKING 2

page
–

PRESENT OUTPUT SIGNAL Description: Voltage feed to lock valve tilt.
TILT LOCKING 1 XY Circuit diagram: Circuit Tilt locking group 7.7
TILT LOCKING 2 XY
006875
BUZZER AUTO 20-40 XY Connection: digital out from D791-1/K1:9 to Y6012-2/1

Function: 7.7.4 Lock valve tilt
Signal value:


ing.

PRESENT OUTPUT SIGNAL, BUZZER AUTO 20-40

page
–

PRESENT OUTPUT SIGNAL Description: Voltage feed to buzzer automatic spreading 20’-40’.
TILT LOCKING 1 XY Circuit diagram: Circuit Spreading Auto group 7.5
TILT LOCKING 2 XY
006875
BUZZER AUTO 20-40 XY Connection: digital out from D791-1/K1:28 to H9003/1
Signal value:


ing.

OUTPUT TILT OUT, REFERENCE
page
–

OUTPUT TILT OUT Description: Status control current to control valve attachment for tilt
REFERENCE XY out.
REQUIRED VALUE XXX
000197
FEEDBACK XXX Circuit diagram: Circuit Tilt + Levelling group 7.7

Connection:
Top lift attachment: digital out from D791-2/K1:4 to Y6010/1
Combi attachment: digital out from D791-4/K1:2 to Y6010
Signal value:


ing.

OUTPUT TILT OUT, REQUIRED VALUE

page
–

OUTPUT TILT OUT Description: Reference value for control current to control valve at-
REFERENCE XY tachment for tilt out.
REQUIRED VALUE XXX
000197
Connection:
Top lift attachment: output signal reference value out from D791-
2/K1:18 to Y6010/2
Combi attachment: output signal reference value out from D791-
4/K1:16 to Y6010/2
OUTPUT TILT OUT, FEEDBACK

page
–

OUTPUT TILT OUT Description: Present control current to control valve attachment for tilt
REFERENCE XY out.
REQUIRED VALUE XXX
000197

Connection:
Top lift attachment: output signal actual value out from D791-2/
K1:18 to Y6010/2
Combi attachment: output signal actual value out from D791-4/
K1:16 to Y6010/2


OUTPUT TILT IN, REFERENCE
page
–

OUTPUT TILT IN Description: Status control current to control valve attachment for tilt
REFERENCE XY in.
REQUIRED VALUE XXX
000198
Connection:
Combi attachment: digital out from D791-4/K1:3 to Y6011/1
Signal value:


ing.
OUTPUT TILT IN, REQUIRED VALUE

page
–

OUTPUT TILT IN Description: Reference value for control current to control valve at-
REFERENCE XY tachment for tilt in.
REQUIRED VALUE XXX
000198

Connection:
2/K1:19 to Y6011/2
4/K1:17 to Y6011/2

OUTPUT TILT IN, FEEDBACK

page
–

OUTPUT TILT IN Description: Present control current to control valve attachment for tilt
REFERENCE XY in.
REQUIRED VALUE XXX
000198
Connection:
K1:19 to Y6011/2
K1:17 to Y6011/2

PRESENT OUTPUT SIGNAL, LOCK LEVELLING 1
page
–

PRESENT OUTPUT SIGNAL Description: Voltage feed to lock valve levelling.
LOCK LEVELLING 1 XY Circuit diagram: Circuit Tilt + Levelling group 7.7
LOCK LEVELLING 2 XY
000199
Connection:
Top lift attachment: digital out from D791-2/K1:30 to Y6034-1/1
Combi attachment: digital out from D791-3/K1:15 to Y6034-1/1
and Y6034-2/1
Function: 7.8.6 Valve block, levelling cylinders
Signal value:


ing.

PRESENT OUTPUT SIGNAL, LOCK LEVELLING 2

page
–

PRESENT OUTPUT SIGNAL Description: Voltage feed to lock valve levelling.
LOCK LEVELLING 1 XY Connection: Circuit Tilt + Levelling group 7.7
LOCK LEVELLING 2 XY
000199
Top lift attachment: digital out from D791-2/K1:31 to Y6034-2/1
Combi attachment: digital out from D791-3/K1:15 to Y6034-1/1
and Y6034-2/1
Function: 7.8.6 Valve block, levelling cylinders
Signal value:


ing.

OUTPUT LEVELLING RI, REFERENCE
page
–

OUTPUT LEVELLING RI Description: Status control current to control valve attachment for lev-
REFERENCE XY elling right.
RQUIRED VALUE XXX
000200

Connection:
Signal value:


ing.

OUTPUT LEVELLING RI, REQUIRED VALUE

page
–

OUTPUT LEVELLING RI Description: Reference value for control current to control valve at-
REFERENCE XY tachment for levelling right.
RQUIRED VALUE XXX
000200
Connection:
2/K1:16 to Y6035/2
3/K1:16 to Y6035/2
OUTPUT LEVELLING RI, FEEDBACK

page
–

OUTPUT LEVELLING RI Description: Present control current to control valve attachment for
REFERENCE XY levelling right.
RQUIRED VALUE XXX
000200

Connection:
K1:16 to Y6035/2
K1:16 to Y6035/2


OUTPUT LEVELLING LE, REFERENCE
page
–

OUTPUT LEVELLING LE Description: Status control current to control valve attachment for lev-
REFERENCE XY elling left.
REQUIRED VALUE XXX
006876
Connection:
Signal value:


ing.
OUTPUT LEVELLING LE, REQUIRED VALUE

page
–

OUTPUT LEVELLING LE Description: Reference value for control current to control valve at-
REFERENCE XY tachment for levelling left.
REQUIRED VALUE XXX
006876

Connection:
2/K1:17 to Y6036/2
3/K1:17 to Y6036/2

OUTPUT LEVELLING LE, FEEDBACK

page
–

OUTPUT LEVELLING LE Description: Present control current to control valve attachment for
REFERENCE XY levelling left.
REQUIRED VALUE XXX
006876
Connection:
K1:17 to Y6036/2
K1:17 to Y6036/2

ROTATION STOP, SWITCH
page
–

PRESENT INPUT SIGNALS Description: Signal from rotation stop switch.
ROTATION STOP Circuit diagram: Circuit Bypass group 8.2
SWITCH X
006877
SENSOR STOP X Connection: signal from S1014/1015/3 to digital in D790-1/K8:14

Function: 7.6 Rotation
Signal value:
0 No signal.
ROTATION STOP, SENSOR STOP

page
–

PRESENT INPUT SIGNALS Description: Signal from sensor rotation stop, with rotation 25 °.
ROTATION STOP Circuit diagram: Circuit Rotation, group 7.6
SWITCH X
006877
SENSOR STOP X Connection: signal from B7225/C to digital in D791-1/K1:11

Function: 7.6.10 Sensor, rotation stop
Signal value:
0 No signal.


PRESENT INPUT SIGNAL, LENGTH TO CONTAINER
page
–

PRESENT INPUT SIGNAL Description: Current distance from attachment to container.
LENGTH TO Circuit diagram: Circuit diagram sensor ultrasonic
CONTAINER (cm) XXXX
006878
DAMP DOWN X Connection: signal from B769/4 to analogue in D791-1/K1:21
Function: 7.2 lifting/lowering
Signal value: XXXX = distance to container in cm.
PRESENT INPUT SIGNAL, DAMP DOWN

page
–

PRESENT INPUT SIGNAL Description: Status damping lower boom.
LENGTH TO Circuit diagram:
CONTAINER (cm) XXXX
006878
DAMP DOWN X Connection: -

Function: 7.2 Lifting/lowering
Signal value:
1 Damping active.
0 No damping.

132 8 Control system – 8.4.10 OP
8.4.10 OP
OP, description
page
–
This group covers the overload system functions.

DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
009277
OP EXTRA RMI
8.4.10.1 OP, menu 1

PRESENT INPUT SIGNAL, STEERING AXLE (model year -
page
–
2008)
Description: Signal from sensor steering axle load right and left (me-
DIAG OP 1(X) chanical overload system). It is sufficient that a sensor produces a sig-
PRESENT INPUT SIGNAL nal to activate an overload warning.
STEERING AXLE X X
BOOM ANGLE X Circuit diagram: Circuit OP + Scale group 8.2
008203
EXTENSION X Connection: signal from B7221R/C to digital in D797-R/K1:12 and

B7221L/C digital I D797-R/K1:11
Function: 8.2.1.1 Sensor, steering axle load
Signal value:
11 Input signal active left and right.
10 No signal left, input signal active right.
01 Input signal active left, no signal right.
00 No signal right and left.
PRESENT INPUT SIGNAL, BOOM ANGLE (model year -

page
–
2008)
DIAG OP 1(X)
PRESENT INPUT SIGNAL Description: Status for boom angle to overload system indicates when
STEERING AXLE X X the boom angle is over 35 °.
BOOM ANGLE X
008203
EXTENSION X
Connection: signal from B771/3 to analogue in D797-R/K1:21
Function: 8.2.1.2 Sensor, boom angle
Signal value:
1 Input signal active. Boom angle over 35 °.
0 No signal. Boom angle under 35 °.

8 Control system – 8.4.10.2 OP, menu 2 133
PRESENT INPUT SIGNAL, EXTENSION (model year -2008)

page
–
DIAG OP 1(X)
PRESENT INPUT SIGNAL Description: Signal from sensor boom length (position sensor boom
STEERING AXLE X X length 1.5 m). On machines with mechanical overload system with an-
BOOM ANGLE X alogue position sensors or electrical overload system the menu is
008203
EXTENSION X used to show the status for boom extension to the overload system.
Connection: signal from B777/C to analogue in (used as digital) D797-
R/K1:22
Function: 8.2.1.3 Sensor, boom length
Signal value:
1 Input signal active. Boom extension over 1.5 m.
0 No signal. Boom extension under 1.5 m.
8.4.10.2 OP, menu 2

PRESENT INPUT SIGNAL, BYPASS
page
–
Description: Signal from bypass switch.

DIAG OP 2(5)
Circuit diagram: Circuit Bypass group 8.2
BY-PASS X
Function: 7.1.3 Bypass switch
000206
Signal value:
1 Input signal active. Signal is only active for max. 60 seconds.
0 No signal.

134 8 Control system – 8.4.10.3 OP, menu 3
8.4.10.3 OP, menu 3

PRESENT INPUT SIGNAL LIFT CYL LE RI, C-
page
–
DIAG OP 3(5)
PRESENT INPUT SIGNAL Description: Signal from hydraulic pressure sensor, lift cylinder (C- rod
LIFT CYL LE RI side). See also PRESSURE LIFTING CYL, C- page 71 (for pressure
C- X.XXV X.XXV information).
C+ X.XXV X.XXV
Connection:
LE: signal from B768-L2/3 to analogue in D797-F/K1:22
RI: signal from B768-R2/3 to analogue in D797-F/K1:24

1 Signal value: X.XXV = 0.50-4.50 V = Hydraulic oil pressure, 0.50 V
corresponds to 0 MPa, 4.50 V corresponds to 25 MPa.
2
000207
1. Pressure C-
2.Pressure C+
PRESENT INPUT SIGNAL LIFT CYL LE RI, C+

page
–
DIAG OP 3(5)
PRESENT INPUT SIGNAL Description: Signal from hydraulic pressure sensor, lift cylinder (C+
LIFT CYL LE RI piston side). See also PRESSURE LIFTING CYL, C+ page 72 for
C- X.XXV X.XXV pressure.
C+ X.XXV X.XXV
Connection:
LE: signal from B768-L1 to analogue in D797-F/K1:21
RI: signal from B768-R1 to analogue in D797-F/K1:23

Signal value: X.XXV = 0.50-4.50 V = Hydraulic oil pressure, 0.50 V
1
corresponds to 0 MPa, 4.50 V corresponds to 25 MPa.
2
000207
1. Pressure C-
2.Pressure C+

8 Control system – 8.4.10.4 OP, menu 4 135
8.4.10.4 OP, menu 4

PRESENT INPUT SIGNAL, BOOM ANGLE
page
–
(Standard model year 2009-)

DIAG OP 4(5)
PRESENT INPUT SIGNAL Description: Signal from sensor boom angle.
BOOM ANGLE X.XXV Circuit diagram: Circuit OP + Scale group 8.2
BOOM EXTENSION X.XXV
000208
Function: 7.2.11 Sensor, boom angle
PRESENT INPUT SIGNAL, BOOM EXTENSION

page
–
(Standard model year 2009-)

DIAG OP 4(5)
PRESENT INPUT SIGNAL Description: Signal from sensor boom length (analogue sensor).
BOOM ANGLE X.XXV Circuit diagram: Circuit OP + Scale group 8.2
BOOM EXTENSION X.XXV
000208

Function: 7.3.11 Sensor, boom length
8.4.10.5 OP, menu 5

ALLOWED LOAD
page
–
Description: Permitted load at the current load centre.

DIAG OP 5(X)
Circuit diagram: -
ALLOWED LOAD XXXXXkg
PRESENT LOAD XXXXXkg Connection: -
LOAD STR.AXLE XXXXXkg
006879
LOAD-CENTER XX.XXm
Signal value: XXXXkg = Weight in kg.
PRESENT LOAD
page
–
Description: Calculated load.

DIAG OP 5(X)
Circuit diagram: -
006879
LOAD-CENTER XX.XXm
LOAD STR.AXLE
page
–
Description: Estimated load on the steering axle.

DIAG OP 5(X)
Circuit diagram: -
006879
LOAD-CENTER XX.XXm

136 8 Control system – 8.4.10.6 OP, menu 6
LOAD-CENTRE
page
–
Description: Horizontal distance between centre drive axle and load

DIAG OP 5(X) centre.
PRESENT LOAD XXXXXkg Circuit diagram: -
LOAD STR.AXLE XXXXXkg Connection: -
006879
LOAD-CENTER XX.XXm
Function: 8.2.1 Overload system, 8.2.3 Load centre limitation
Signal value: XX.XXm = distance in metres
8.4.10.6 OP, menu 6

BOOM ANGLE
page
–
Description: Current boom angle.

DIAG OP 6(X)
Circuit diagram: -
BOOM ANGLE XXX
EXTENSION XXX Connection: -
BOOM HEIGHT XXX
006880
BOOM HEIGHT-NOSE XXX

Signal value: XXX = boom angle in °.
BOOM EXTENSION
page
–
Description: Current boom extension.

DIAG OP 6(X)
Circuit diagram: -
BOOM ANGLE XXX
EXTENSION XXX Connection: -
BOOM HEIGHT XXX
006880

Signal value: XXX = boom extension in cm.
BOOM HEIGHT
page
–
Description: Status for boom height at the top edge of the boom, the
DIAG OP 6(X) machine’s total height.
BOOM ANGLE XXX
EXTENSION XXX Circuit diagram: -
BOOM HEIGHT XXX Connection: -
006880

Function: 8.2.4 Height limitation
Signal value: XXX = height above ground in cm.
BOOM HEIGHT-NOSE
page
–
Description: Status for current height of the attachment’s fixing point in

DIAG OP 6(X) the boom, suspension. The height is used to calculate the load’s cen-
BOOM ANGLE XXX tre of gravity as a part of the overload system.
EXTENSION XXX
BOOM HEIGHT XXX Circuit diagram: -
006880
BOOM HEIGHT-NOSE XXX Connection: -

Signal value: XXX = height above ground in cm.

8 Control system – 8.4.11 EXTRA 137
8.4.11 EXTRA
EXTRA, description
page
–
DIAGNOSIS
CAN/POWER LIGHTS CAB This menu consists of optional functions:
CLIMATE HYD ENGINE
• Bottom lift-attachment, COMBI
TRANSM BOOM ATTACH
009278
OP EXTRA RMI • Sliding cab, SLIDING-CAB
• Support jacks, SUPPORT-JACKS
• Lever steering or mini-wheel, EL-STEERING
Confirm selection in main menu with function key for Enter.
8.4.11.1 COMBI
COMBI, menu 1
page
–
This menu handles the function of the bottom lift-attachment.

DIAGNOSIS EXTRA
COMBI SLIDING-CAB Confirm selection with function key for Enter.
SUPPORT-JACKS
EL-STEERING
000211
SWITCHES, FRONT LEG UP/DOWN

Description: Signal from switch lowering front jacks (bottom lift).
DIAG COMBI 1(17)
Circuit diagram: Circuit Combi Att group 7.9
SWITCHES
FRONT LEG UP/DOWN X/Y Connection:
REAR LEG UP/DOWN X/Y
Up: signal from S1006/1 to digital in D790-1/K9:3
CLAMP IN/OUT X/Y
Down: signal from S1006/7 to digital in D790-1/K9:4
Function: 7.9.2 Lifting jacks
Signal value:
1/0 Input signal active, jack up

1
0/1 Input signal active, jack down
0/0 No signal.
2
3
000212
1. Knee
2.Jack
3.Clamping plate

138 8 Control system – 8.4.11.1 COMBI
SWITCHES, REAR LEG UP/DOWN

Description: Signal from switch lowering rear jacks (bottom lift).
DIAG COMBI 1(17)
SWITCHES
Up: signal from S1007/1 to digital in D790-1/K9:5
CLAMP IN/OUT X/Y
Down: signal from S1007/7 to digital in D790-1/K9:10
Signal value:

1
0/1 Input signal active, jack down
0/0 No signal.
2
3
000212
1. Knee
2.Jack
3.Clamping plate
SWITCHES, CLAMP IN/OUT

Description: Signal from switch clamp/release jacks (bottom lift).
DIAG COMBI 1(17)
SWITCHES
Together: signal from S1008/1 to analogue in (used as digital)
CLAMP IN/OUT X/Y
D790-1/K9:8
Apart: signal from S1008/7 to analogue in (used as digital) D790-
1/K9:9
Signal value:
1
2 0/1 Input signal active, jack down
0/0 No signal.
3
000212
1. Knee
2.Jack
3.Clamping plate

8 Control system – 8.4.11.1 COMBI 139
COMBI, menu 2
page
–
PRESENT INPUT SIGNAL CLAMPING SENSORS, FRONT

LEGS
Description: Signal from sensor clamping position front (jack against
DIAG COMBI 2(17) load).
CLAMPING SENSORS Circuit diagram: Circuit Combi Att group 7.9
FRONT LEGS LE X RI X Connection:
REAR LEGS LE X RI X
LE: signal from B7215L/C to digital in D791-3/K1:36
Function: 7.9.2.15 Sensor clamping position
Signal value:
0 No signal.
1
000214
1. Sensor clamping position
PRESENT INPUT SIGNAL CLAMPING SENSORS, REAR

LEGS
Description: Signal from sensor clamping position rear (jack against
DIAG COMBI 2(17) load).
CLAMPING SENSORS Circuit diagram: Circuit Combi Att group 7.9
FRONT LEGS LE X RI X Connection:
REAR LEGS LE X RI X
Function: 7.9.2.15 Sensor clamping position
Signal value:
0 No signal.
1
000214
1. Sensor clamping position

COMBI, menu 3
page
–
PRESENT INPUT SIGNAL ALIGNMENT SENSORS, FRONT

LEGS
Description: Signal from sensor alignment front (load secured).
DIAG COMBI 3(17) Circuit diagram: Circuit Combi Att group 7.9
ALIGNMENT SENSORS Connection:
FRONT LEGS LE X RI X LE: signal from B7213L/C to digital in D791-3/K1:13
REAR LEGS LE X RI X
Function: 7.9.2.14 Sensor, alignment
Signal value:
0 No signal.
1
000216
1. Alignment sensor
PRESENT INPUT SIGNAL ALIGNMENT SENSORS, REAR

LEGS
Description: Signal from sensor alignment rear (load secured).
DIAG COMBI 3(17) Circuit diagram: Circuit Combi Att group 7.9
ALIGNMENT SENSORS Connection:
FRONT LEGS LE X RI X LE: signal from B7214L/C to digital in D791-3/K1:20
REAR LEGS LE X RI X
Function: 7.9.2.14 Sensor, alignment
Signal value:
0 No signal.
1
000216
1. Alignment sensor

COMBI, menu 4
page
–
PRESENT INPUT SIGNAL END POS SENSORS FRONT,

KNEE
Description: Signal from sensor knee front.
DIAG COMBI 4(17)
END POS SENSORS FRONT Connection:
KNEE LE X RI X
000217
LEG LE X RI X
Function: 7.9.2.10 Sensor knee
Signal value:
1 Input signal active. In motion.
0 No signal.
PRESENT INPUT SIGNAL END POS SENSORS FRONT,

LEG
Description: Signal from sensor lifting jacks front.
DIAG COMBI 4(17)
END POS SENSORS FRONT Connection:
KNEE LE X RI X
000217
LEG LE X RI X
Function: 7.9.2.13 Sensor, lifting jacks
Signal value:
0 No signal.
COMBI, menu 5
page
–
PRESENT INPUT SIGNAL END POS SENSORS REAR,

KNEE
Description: Signal from sensor knee rear.
DIAG COMBI 5(17)
END POS SENSORS REAR Connection:
KNEE LE X RI X
000218
LEG LE X RI X
Function: 7.9.2.10 Sensor knee
Signal value:
0 No signal.

PRESENT INPUT SIGNAL END POS SENSORS REAR, LEG

Description: Signal from sensor lifting jacks rear
DIAG COMBI 5(17)
END POS SENSORS REAR Connection:
KNEE LE X RI X
000218
LEG LE X RI X
Function: 7.9.2.13 Sensor, lifting jacks
Signal value:
0 No signal.
COMBI, menu 6
page
–
PRESENT INPUT SIGNAL LEGS IN DRIVE, POSITION

Description: Signal from sensor operating position.
DIAG COMBI 6(17)
LEGS IN DRIVE Connection:
POSITION LE X RI X
000219

Function: 7.9.2.9 Sensor operating position
Signal value:
0 No signal.

COMBI, menu 7
page
–
INDICATION LAMPS ALIGNMENT, FRONT

Description: Voltage feed to indicator light alignment front.
DIAG COMBI 7(17)
INDICATION LAMPS
ALIGNMENT Connection:
FRONT LE XY RI XY
LE: digital out from D791-3/K1:29 to H566L/1
000220
REAR LE XY RI XY
RI: digital out from D791-3/K1:10 to H566R/1
Signal value:


ing.
INDICATION LAMPS ALIGNMENT, REAR

Description: Status for voltage feed to indicator light alignment rear.
DIAG COMBI 7(17)
INDICATION LAMPS
ALIGNMENT Connection:
FRONT LE XY RI XY
LE: digital out from D791-3/K1:39 to H567L/1
000220
REAR LE XY RI XY
RI: digital out from D791-3/K1:25 to H567R/1
Signal value:


ing.

COMBI, menu 8
page
–
INDICATION LAMPS CLAMP, FRONT

Description: Status for voltage feed to indicator light clamping position
DIAG COMBI 8(17) front.
INDICATION LAMPS
CLAMP Circuit diagram: Circuit Combi Att group 7.9
FRONT XY Connection: digital out from D791-4/K1:29 to H578/1
000221
REAR XY
Signal value:


ing.
INDICATION LAMPS CLAMP, REAR

Description: Status for voltage feed to indicator light clamping position
DIAG COMBI 8(17) rear.
INDICATION LAMPS
FRONT XY Connection: digital out from D791-4/K1:39 to H579/1
000221
REAR XY
Signal value:


ing.

COMBI, menu 9
page
–
INDICATION LAMPS, FRONT LEGS UP

Description: Status for voltage feed to indicator light front jacks raised.
DIAG COMBI 9(17)
INDICATION LAMPS
Connection: digital out from D791-4/K1:10 to H580/1
FRONT LEGS UP XY
000222
FRONT LEGS DOWN XY
Signal value:


ing.
INDICATION LAMPS, FRONT LEGS DOWN

Description: Status for voltage feed to indicator light front jacks low-
DIAG COMBI 9(17) ered.
INDICATION LAMPS
FRONT LEGS UP XY Connection: digital out from D791-4/K1:25 to H581/1
000222
FRONT LEGS DOWN XY

Signal value:


ing.

COMBI, menu 10
page
–
PRESENT OUTPUT SIGNAL FRONT LEGS DOWN, KNEE

Description: Status for voltage feed to control valve lifting jacks, sole-
DIAG COMBI 10(17) noid valve front knee out.
FRONT LEGS DOWN Circuit diagram: Circuit Combi Att group 7.9
KNEE LE XY RI XY Connection:
000223
LEGS LE XY RI XY
LE: digital out from D791-3/K1:5 to Y6056L/1
RI: digital out from D791-4/K1:5 to Y6056R/1
Function: 7.9.2.3 Control valve lifting jacks
Signal value:


ing.
PRESENT OUTPUT SIGNAL FRONT LEGS DOWN, LEGS

DIAG COMBI 10(17) noid valve front jacks down.
FRONT LEGS DOWN Circuit diagram: Circuit Combi Att group 7.9
000223
LEGS LE XY RI XY
Signal value:


ing.

COMBI, menu 11
page
–
PRESENT OUTPUT SIGNAL FRONT LEGS UP, KNEE

DIAG COMBI 11(17) noid valve front knee in.
FRONT LEGS UP Circuit diagram: Circuit Combi Att group 7.9
000224
LEGS LE XY RI XY
Signal value:


ing.
PRESENT OUTPUT SIGNAL FRONT LEGS UP, LEGS

DIAG COMBI 11(17) noid valve front jacks up.
FRONT LEGS UP Circuit diagram: Circuit Combi Att group 7.9
000224
LEGS LE XY RI XY
Signal value:


ing.

COMBI, menu 12
page
–
PRESENT OUTPUT SIGNAL REAR LEGS DOWN, KNEE

DIAG COMBI 12(17) noid valve rear knee out.
REAR LEGS DOWN Circuit diagram: Circuit Combi Att group 7.9
000225
LEGS LE XY RI XY
Function: 7.9.2.3 Solenoid valve lifting jacks
Signal value:


ing.
PRESENT OUTPUT SIGNAL REAR LEGS DOWN, LEGS

DIAG COMBI 12(17) noid valve rear jacks down.
REAR LEGS DOWN Circuit diagram: Circuit Combi Att group 7.9
000225
LEGS LE XY RI XY
Signal value:


ing.

COMBI, menu 13
page
–
PRESENT OUTPUT SIGNAL REAR LEGS UP, KNEE

DIAG COMBI 13(17) noid valve rear knee in.
REAR LEGS UP Circuit diagram: Circuit Combi Att group 7.9
000226
LEGS LE XY RI XY
Signal value:


ing.
PRESENT OUTPUT SIGNAL REAR LEGS UP, LEGS

DIAG COMBI 13(17) noid valve rear jacks up.
REAR LEGS UP Circuit diagram: Circuit Combi Att group 7.9
000226
LEGS LE XY RI XY
Signal value:


ing.

COMBI, menu 14
page
–
SEQUENCE MODE, FRONT

Description: Current sequence mode for lowering the front jacks.
DIAG COMBI 14(17)
SEQUENCE MODE
LE RI Connection: -
FRONT X X
000227
REAR X X
Signal value:
0 Sequence error
1 Jack up (0), knee in (0).
2 Jack up (0), knee moving (1).
3 Jack up (0), knee out (0).
4 Jack moving (1), knee out (0).
5 Jack down (0), knee out (0). No signal.
SEQUENCE MODE, REAR

Description: Current sequence mode for lowering the rear jacks.
DIAG COMBI 14(17)
SEQUENCE MODE
LE RI Connection: -
FRONT X X
000227
REAR X X
Signal value:
0 Sequence error
1 Jack up (0), knee in (0).
2 Jack up (0), knee moving (1).
3 Jack up (0), knee out (0).
4 Jack moving (1), knee out (0).
5 Jack down (0), knee out (0). No signal.

COMBI, menu 15
page
–
PRESENT OUTPUT SIGNAL CLAMP, OUT

DIAG COMBI 15(X) noid valve clamp release.
IN LE XY RI XY Connection:
006881
OUT LE XY RI XY
Signal value:


ing.
PRESENT OUTPUT SIGNAL CLAMP, IN

DIAG COMBI 15(X) noid valve clamp.
IN LE XY RI XY Connection:
006881
OUT LE XY RI XY
Signal value:


ing.

COMBI, menu 16
page
–
PRESENT OUTPUT SIGNAL DRIVE POSITION

DIAG COMBI 16(17)
Description: Status for voltage feed to solenoid valve operating posi-
DRIVE POSITION tion.
000229
LE XY RI XY
Connection:
LE: digital out from D791-3/K1:42 to Y6053L
RI: digital out from D797-4/K1:42 to Y6053R
Function: 7.9.2.5 Valve block operating position
Signal value:


ing.

COMBI, menu 17
page
–
FORCE CONTROL (+/-), VALVE

DIAG COMBI 17(17)
Description: Forced operation of the solenoid valves that control the
FORCE CONTROL (+/-)
lifting jacks. Select solenoid valve with the +/- keys and activate the
"VALVE" valve with the Enter key.
000230
0: no valve selected
1: Y6056L (knee out left front)
2: Y6057L (knee in left front)
3: Y6013L (jack down left front)
4: Y6060L (jack up left front)
5: Y6056R (knee out right front)
6: Y6057R (knee in right front)
7: Y6013R (jack down right front)
8: Y6060R (jack up right front)
9: Y6058L (knee out left rear)
10: Y6059L (knee in left rear)
11: Y6014K (jack down left rear)
12: Y6061L (jack up left rear)
13: Y6058R (knee out right rear)
14: Y6059R (knee in right rear)
15: Y6014R (jack down right rear)
16: Y6061R (jack up right rear)
17: Y6054L (clamp left)
18: Y6055L (clamp release left)
19: Y6054R (clamp right)
20: Y6055R (clamp release right)
Connection: -
Signal value: -

154 8 Control system – 8.4.11.2 SLIDING-CAB
8.4.11.2 SLIDING-CAB
SLIDING-CAB, menu 1
page
–
This group handles functions for hydraulic sliding cab and hydraulic
DIAGNOSIS EXTRA vertically adjustable cab. The menu texts are created for hydraulic slid-
COMBI SLIDING-CAB ing cab.
SUPPORT-JACKS
EL-STEERING Confirm selection with function key for Enter.
000231
SWITCHES, FORWARD
Description: Signal from switch hydraulic sliding cab (forward) or
DIAG SLID-CAB 1(4) switch hydraulic vertically adjustable cab (up).
SWITCHES
FORWARD X Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10
REVERSE X Connection: from S177/1 to digital in D790-1/K8:7
000215
OPENED DOORS X
Function: 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab
Signal value:
0 No signal.
SWITCHES, REVERSE
Description: Signal from switch hydraulic sliding cab (backward) or
DIAG SLID-CAB 1(4) switch hydraulic vertically adjustable cab (down).
SWITCHES
FORWARD X Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10
REVERSE X Connection: from S177/7 to digital in D790-1/K8:6
000215
OPENED DOORS X
Function: 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab
Signal value:
0 No signal.
SWITCHES, OPENED DOORS

Description: Signal from door contacts, provided that the doors are
DIAG SLID-CAB 1(4) closed.
SWITCHES
FORWARD X Circuit diagram: Circuit Lighting group 9.6
REVERSE X Connection: from S266-LE/2 or S266-RI/2 to digital in D790-1/K11:3
000215
OPENED DOORS X
Signal value:
1 Input signal active. Door open.
0 No signal. Doors closed.

8 Control system – 8.4.11.2 SLIDING-CAB 155
SLIDING-CAB, menu 2
page
–
PRESENT INPUT SIGNAL, LOW SPEED

Description: Signal from sensor damping end position, sliding cab or
DIAG SLID-CAB 2(4) vertically adjustable cab.
LOW SPEED X Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10
CAB DOWN (LIFT) X Connection: from B769-2/3 to digital in D790-1/K10:6
000232
Function: 9.10.4.8 Sensor damping end position, 9.10.5.9 Sensor
damping end position
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, CAB SPEED (LIFT)

Description: Signal from sensor lowered cab (vertically adjustable
DIAG SLID-CAB 2(4) cab).
LOW SPEED X Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10
CAB DOWN (LIFT) X Connection: from B777-2/3 to analogue in (used as digital) D797-O/
000232
K1:21
Function: 9.10.5.8 Sensor lowered cab
Signal value:
0 No signal.
SLIDING-CAB, menu 3
page
–
OUTPUT FORWARD, REFERENCE

Description: Status for control current to control valve option, solenoid
DIAG SLID-CAB 3(4) valve sliding cab forward.
OUTPUT FORWARD
REFERENCE XY Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10
REQUIRED VALUE XXX Connection: digital out from D797-O/K1:2 to B6016/1
000233
FEEDBACK XXX
Function: 9.10.4.4 Control valve option frame
Signal value:


ing.

OUTPUT FORWARD, REQUIRED VALUE

Description: Reference value for control current to control valve op-
DIAG SLID-CAB 3(4) tion, solenoid valve sliding cab forward.
OUTPUT FORWARD
REQUIRED VALUE XXX Connection: output signal reference value out from D797-O/K1:16 to
000233
OUTPUT FORWARD, FEEDBACK

Description: Present control current to control valve option, solenoid
DIAG SLID-CAB 3(4) valve sliding cab forward.
OUTPUT FORWARD
REQUIRED VALUE XXX Connection: output signal actual value out from D797-O/K1:16 to
000233

Signal value: XXX = Measured value in mA.
SLIDING-CAB, menu 4
page
–
OUTPUT REVERSE, REFERENCE

Description: Status for control current to control valve option, solenoid
DIAG SLID-CAB 4(4) valve sliding cab backward.
OUTPUT REVERSE
REQUIRED VALUE XXX Connection: digital out from D797-O/K1:3 to B6017/1
000234
FEEDBACK XXX
Signal value:


ing.

OUTPUT REVERSE, REQUIRED VALUE

Description: Reference value for control current to control valve op-
DIAG SLID-CAB 4(4) tion, solenoid valve sliding cab backward.
OUTPUT REVERSE
REQUIRED VALUE XXX Connection: output signal reference value out from D797-O/K1:17 to
000234
OUTPUT REVERSE, FEEDBACK

Description: Present control current to control valve option, solenoid
DIAG SLID-CAB 4(4) valve sliding cab backward.
OUTPUT REVERSE
REQUIRED VALUE XXX Connection: output signal actual value out from D797-O/K1:17 to
000234

Signal value: XXX = Measured value in mA.

158 8 Control system – 8.4.11.3 SUPPORT-JACKS
8.4.11.3 SUPPORT-JACKS
SUPPORT-JACKS, menu 1
page
–
This group covers the support jacks functions.

DIAGNOSIS EXTRA
SUPPORT-JACKS
EL-STEERING
000235
SWITCHES, UP
Description: Signal from switch support jacks (up).
DIAG S-JACKS 1(4) Circuit diagram: Circuit Hyd support jacks group 7.10
SWITCHES
UP X Connection: from S1013/1 to digital in D790-1/K8:9
DOWN X Function: 7.10.1 Support jacks
000213
Signal value:
0 No signal.
SWITCHES, DOWN
Description: Signal from switch support jacks (down).
DIAG S-JACKS 1(4) Circuit diagram: Circuit Hyd support jacks group 7.10
SWITCHES
UP X Connection: from S1013/7 to digital in D790-1/K8:8
DOWN X Function: 7.10.1 Support jacks
000213
Signal value:
0 No signal.
page
–
PRESENT INPUT SIGNALS, UP

Description: Signal from sensor support jacks up.
DIAG S-JACKS 2(4)
Circuit diagram: Circuit Hyd support jacks group 7.10
Connection:
UP LE X RI X
LE: from B7222L/A, to digital in D797-O/K1:13
000236
DOWN LE X RI X
RI: from B7222R/A, to digital in D797-O/K1:27
Function: 7.10.1.5 Sensor support jacks up
Signal value:
0 No signal.

8 Control system – 8.4.11.3 SUPPORT-JACKS 159
PRESENT INPUT SIGNALS, DOWN

Description: Signal from sensor support jacks down.
DIAG S-JACKS 2(4)
Connection:
UP LE X RI X
• LE: from B7223L/A, to digital in D797-O/K1:20
000236
DOWN LE X RI X
• RI: from B7223R/A, to digital in D797-O/K1:41
Function: 7.10.1.6 Sensor support jacks down
Signal value:
0 No signal.
page
–
OUTPUT VALVE S-J UP

Description: Voltage feed to control valve option frame, solenoid valve
DIAG S-JACKS 3(4) support jacks up.
OUTPUT VALVE
S-J UP XY Circuit diagram: Circuit Hyd support jacks group 7.10
S-J DOWN XY Connection: digital out from D797-O/K1:30 to B6063/1
000237

Signal value:


ing.

160 8 Control system – 8.4.11.3 SUPPORT-JACKS
OUTPUT VALVE S-J DOWN

Description: Voltage feed to control valve option frame, solenoid valve
DIAG S-JACKS 3(4) support jacks down.
OUTPUT VALVE
S-J UP XY Circuit diagram: Circuit Hyd support jacks group 7.10
S-J DOWN XY Connection: digital out from D797-O/K1:31 to B6064/1
000237
Signal value:


ing.
page
–
INDICATION LAMP, DOWN

Description: The status of voltage feed to indicator light support jacks
DIAG S-JACKS 4(4) down.
INDICATOR LAMP
DOWN XY Connection: digital out from D790-1/K7:11 to H574/1
000238
Function: 7.10.1 Support jacks

Signal value:


ing.

8 Control system – 8.4.11.4 EL-STEERING 161
8.4.11.4 EL-STEERING
EL-STEERING, menu 1
page
–
This group handles functions for lever steering/mini-wheel steering.

DIAGNOSIS EXTRA
SUPPORT-JACKS
EL-STEERING
000239
PRESENT INPUT SIGNAL, SIGNAL 1
Description: Signal from mini-wheel (signal 1) or steering lever.
DIAG STEERING 1(5)
Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit
SIGNAL 1 X.XXV Steering lever/mini wheel and Combi att. group 5.2
SIGNAL 2 X.XXV Connection:
001972
Top lift attachment: signal from R825/H1 to digital in D790-1/K9:8

Combi attachment: signal from R825/H1 to digital in D790-3/
K1:21
Function: 5.2 Power assisted system
PRESENT INPUT SIGNAL, SIGNAL 2

Description: Signal from mini-wheel (signal 2). (Only applies to mini-
DIAG STEERING 1(5) wheel)
SIGNAL 1 X.XXV Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit
SIGNAL 2 X.XXV Steering lever/mini wheel and Combi att. group 5.2
001972
Connection:
Top lift attachment: signal from R825/H2 to digital in D790-1/K9:9
Combi attachment: signal from R825/H2 to digital in D790-3/
K1:22
EL-STEERING, menu 2
page
–
SWITCHES, ON/OFF
Description: Signal from switch mini-wheel/steering lever.
DIAG STEERING 2(5)
SWITCHES
ON/OFF X Steering lever/mini wheel and Combi att. group 5.2
FORWARD X Connection:
000240
REVERSE X
Top lift attachment: signal from S113/1 to digital in D790-1/K9:5
Combi attachment: signal from S113/1 to digital in D790-3/K1:27
Signal value:
0 No signal.

162 8 Control system – 8.4.11.4 EL-STEERING
SWITCHES, FORWARD
Description: Signal from mini-wheel or steering lever (travel direction
DIAG STEERING 2(5) selector forward).
SWITCHES
ON/OFF X Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit
FORWARD X Steering lever/mini wheel and Combi att. group 5.2
000240
REVERSE X Connection:
Top lift attachment: signal from S160-2/1 to digital in D790-1/K9:4
Combi attachment: signal from S160-2/1 to digital in D790-3/
K1:20
Signal value:
0 No signal.
SWITCHES, REVERSE
Description: Signal from mini-wheel or steering lever (travel direction
DIAG STEERING 2(5) selector reverse).
SWITCHES
ON/OFF X Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit
FORWARD X Steering lever/mini wheel and Combi att. group 5.2
000240
REVERSE X Connection:
Top lift attachment: signal from S160-2/7 to digital in D790-1/K9:3
K1:13
Signal value:
0 No signal.

EL-STEERING, menu 3
page
–
PRESENT INPUT SIGNAL, HORN

Description: Signal from mini-wheel or steering lever (audible signal).
DIAG S-JACKS 3(X)
HORN X Steering lever/mini wheel and Combi att. group 5.2
STEER.WHEEL CUT OFF X Connection:
006882
Top lift attachment: signal from S149-2/1 to digital in D790-1/
K9:10
K1:41
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, STEER.WHEEL CUT OFF

Description: Signal from sensor steering angle.
DIAG S-JACKS 3(X)
HORN X Steering lever/mini wheel and Combi att. group 5.2
STEER.WHEEL CUT OFF X Connection: from B720/2 to digital in D790-2/K8:2
006882
Function: 5.2.12 Sensor steering angle

Signal value:
0 No signal.

164 8 Control system – 8.4.11.4 EL-STEERING
EL-STEERING, menu 4
page
–
OUTPUT STEERING LEFT, REFERENCE

Description: Status for control current to control valve option frame,
DIAG STEERING 4(5) solenoid valve steering left.
OUTPUT STEERING LEFT
REFERENCE XY Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit
REQUIRED VALUE XXX Steering lever/mini wheel and Combi att. group 5.2
000242
FEEDBACK XXX Connection: output signal reference value out from D797-O/K1:4 to
Y636L/1
Function: 5.2.10 Control valve option frame
Signal value:


ing.
OUTPUT STEERING LEFT, REQUIRED VALUE

Description: Reference value for control current to control valve option
DIAG STEERING 4(5) frame, solenoid valve steering left.
000242
Y636L/2
OUTPUT STEERING LEFT, FEEDBACK

Description: Present control current to control valve option frame, so-
DIAG STEERING 4(5) lenoid valve steering left.
000242
FEEDBACK XXX Connection: output signal, reference value out from D797-0/K1:18 to
Y636L/2

EL-STEERING, menu 5
page
–
OUTPUT STEERING RIGHT, REFERENCE

Description: Status for control current to control valve option frame,
DIAG STEERING 5(5) solenoid valve steering left.
OUTPUT STEERING RIGHT
000243
Y636R/1
Signal value:


ing.
OUTPUT STEERING RIGHT, REQUIRED VALUE

Description: Reference value for control current to control valve option
DIAG STEERING 5(5) frame, solenoid valve steering left.
000243
Y636R/2
OUTPUT STEERING RIGHT, FEEDBACK

Description: Present control current to control valve option frame, so-
DIAG STEERING 5(5) lenoid valve steering left.
000243
Y636R/2

166 8 Control system – 8.4.13 RMI
8.4.13 RMI
RMI, description
page
–
DIAGNOSIS
CAN/POWER LIGHTS CAB This group covers RMI (Remote Machine Interface) function.
CLIMATE HYD ENGINE
Confirm selection with function key for Enter.
TRANSM BOOM ATTACH
007442
OP EXTRA RMI
8.4.13.1 RMI, menu 1

MIU SW VER
page
–
DIAG RMI 1(3)

MIU SW VER XXXX.XXXX Description: Software version in RMI interface.
MIU TIME XXXX.XX.XX Circuit diagram: -
007439
Connection: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: xxxx.xxxx = software number.
MIU TIME
page
–
DIAG RMI 1(3)

MIU SW VER XXXX.XXXX Description: Date setting in RMI interface.
MIU TIME XXXX.XX.XX Circuit diagram: -
007439
Connection: -
Signal value: xxxx.xx.xx = Date in format YYYY.MM.DD.
8.4.13.2 RMI, menu 2

SIGNAL QUALITY, GSM
page
–
DIAG RMI 2(3)

SIGNAL QUALITY Description: Signal strength of GSM signal through receiver in the RMI
GSM XXX GPRS XXX interface.
WLAN XXX RADIO XXX
Circuit diagram: Circuit RMI group 8.2
007440
SMS XXX:UNS.DATA XXX

Connection: -
Signal value: XXX = 0-100 = Signal strength, 0-100%.

8 Control system – 8.4.13.2 RMI, menu 2 167
SIGNAL QUALITY, GPRS

page
–
DIAG RMI 2(3)

SIGNAL QUALITY Description: Signal strength of GPRS signal through receiver in the
GSM XXX GPRS XXX RMI interface.
WLAN XXX RADIO XXX
007440
Connection: -
SIGNAL QUALITY, WLAN

page
–
Description: Signal strength of WLAN signal through receiver in the

RMI interface.
Connection: -
SIGNAL QUALITY, RADIO

page
–
DIAG RMI 2(3)

SIGNAL QUALITY Description: Signal strength of RADIO signal through receiver in the
GSM XXX GPRS XXX RMI interface.
WLAN XXX RADIO XXX
007440

Connection: -
SIGNAL QUALITY, SMS

page
–
DIAG RMI 2(3)

SIGNAL QUALITY Description: Signal strength of SMS signal through receiver in the RMI
WLAN XXX RADIO XXX
007440

Connection: -

168 8 Control system – 8.4.13.3 RMI, menu 3
SIGNAL QUALITY, UNS.DATA

page
–
DIAG RMI 2(3)

SIGNAL QUALITY Description: Amount of unsent data in line in transmitter part in the RMI
WLAN XXX RADIO XXX
007440
Connection: -
Signal value: XXX = 0-100 = Data amount in percent of transmitter
buffer, 0-100%.
8.4.13.3 RMI, menu 3

ERROR
page
–
DIAG RMI 3(3)

ERROR XX.XX.XX.XX Description: Internal error code for the RMI interface
ERR.VALID XX.XX.XX.XX Circuit diagram: Circuit RMI group 8.2
ACT.ERR. XX.XX.XX.XX
007441
Connection:-
Signal value: XX.XX.XX.XX = Error code
ERR.VALID
page
–
DIAG RMI 3(3)

007441
Connection:-
ACT.ERR
page
–
DIAG RMI 3(3)

007441
Connection: -

8 Control system – 8.5 Setup 169
8.5 Setup
Setup, general
page
–
Settings are built-in functions to adapt the functions to the unique ma-
chine individual. Settings are performed via menus in the display. Set-
tings are divided into initiation and calibration.
Initiation
Initiation, which involves setting start and stop currents for the steering
and hydraulic functions, is performed before the machine is used in
work. This is done to compensate for mechanical and electrical toler-
ances (variations between different machines).
Calibration
Calibration is performed after the machine has started to be used for
work, after change of control units, and in certain cases, service or
change of components. Calibration is performed so that certain func-
tions shall function properly and show correct values.
8.5.1 Initiation
Initiation, description
page
–
1 2
D ANGER
INIT STEERING 9(10)
START CURRENT The settings influence the functions. Adjustments
STEERING LEFT may impair the function. If uncertain, contact Cargot-
4 STORED VALUE XXXmA
3 ec Service.
000058
PRESENT VALUE XXXmA

Example of initiation menu, start current for lift func-
tion.
NOTE
1.Menu group Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
2.Menu number (in brackets, total number of menus)
In order that hydraulic functions shall work satisfactorily and safely,
3.Values
certain values must be set to operate the machine, this is known as in-
4.Actual variable
itiation.
Initiation consists of several menus grouped according to functions.
Each individual menu sets a specific variable. The menus are similar
in construction and use a common terminology explained here:
PRESENT
Displays the stored value when the menu is opened. Adjust the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Go back with the R-key.
STORED
States the stored value for the current variable.

170 8 Control system – 8.5.1 Initiation
START CURRENT
Specifies the start current to the solenoid valve for the selected func-
tion. The start current is the lowest current that can be actuated. In
practice, this controls how slowly a function can be operated. On func-
tions with analogue control activation (variable), e.g. lift, this is the cur-
rent that is triggered when the lever leaves the zero position. On
certain functions with digital activation (off/on) which are soft-started,
this is the current which is triggered immediately the function is activat-
ed.
END CURRENT
Specifies the max. current to the solenoid valve for the selected func-
tion. The max. current is the highest current that can be triggered. In
practice, it controls how quickly a function can be operated. On func-
tions with analogue control activation (controllable), e.g. lift, this is the
current when the lever is in the end position. On certain functions with
digital activation (off/on) which are soft-started, this is the current
which is triggered after the ramp time when the function is activated.
The interval between START CURRENT and END CURRENT is the
active range for controlling the solenoid valve.
PROC DAMPING
Specifies how much the control current shall be reduced during damp-
ing. The interval is specified as 0-100% of the active range between
START CURRENT and END CURRENT.
Overview initiations
Function Menu
INIT DRIVE-TRAIN, menu 9 page 194
1 Engine, speed limitation (limitation of engine speed )
INIT DRIVE-TRAIN, menu 11 page

1 Engine, automatic shut-down on idling
194
2 Transmission, starting gear INIT DRIVE-TRAIN, menu 1 page 191
2 Transmission, speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 2 page 191
2 Transmission, engine speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 3 page 192
2 Transmission, engine speed limit shifting neutral - gear INIT DRIVE-TRAIN, menu 4 page 192
2 Transmission, engine speed limit kickdown to 1st INIT DRIVE-TRAIN, menu 5 page 193
2 Transmission, speed limit declutch INIT DRIVE-TRAIN, menu 6 page 193

2 Transmission, speed limitation (gear lock-out)
194

2 Transmission, automatic engine speed reduction for shift forward - reverse
195
5.2 Power assisted system (product option joystick control or mini-wheel), lever re- INIT STEERING, menu 1 page 186
sponse

8 Control system – 8.5.1 Initiation 171
Function Menu
5.2 Power assisted system (product option joystick control or mini-wheel), speed INIT STEERING, menu 2 page 187
dependent INIT STEERING, menu 3 page 187
INIT STEERING, menu 4 page 188
5.2 Power assisted system (product option joystick control or mini-wheel), steering INIT STEERING, menu 7 page 189
angle right INIT STEERING, menu 8 page 189
5.2 Power assisted system (product option joystick control or mini-wheel), steering INIT STEERING, menu 9 page 190
angle left INIT STEERING, menu 10 page 190
7.2 Lifting/lowering, boom up INIT BOOM, menu 1 page 173

INIT BOOM, menu 2 page 173
7.2 Lifting/lowering, boom down INIT BOOM, menu 3 page 174

Note: The current value is for unladen machines. When loaded, the current value is INIT BOOM, menu 4 page 174
controlled by the limited lowering speed.
7.2 Lifting/lowering, lift speed during operation INIT BOOM, menu 9 page 176
7.2 Lifting/lowering, damping at container (top lift) INIT ATTACH, menu 15 page 182
7.2 Lifting/lowering, damping at container (bottom lift) INIT ATTACH, menu 16 page 182
7.3 Extension, boom out INIT BOOM, menu 5 page 174

INIT BOOM, menu 6 page 175
7.3 Extension, boom in INIT BOOM, menu 7 page 175

Note: The current value is for unladen machines. When loaded, the current value is INIT BOOM, menu 8 page 175
controlled by the limited lowering speed.
7.5 Spreading out INIT ATTACH, menu 9 page 180

INIT ATTACH, menu 10 page 180
7.5 Spreading in INIT ATTACH, menu 12 page 181

7.6 Rotation, clockwise INIT ATTACH, menu 1 page 177

7.6 Rotation, anticlockwise INIT ATTACH, menu 3 page 178

7.7 Tilt INIT ATTACH, menu 5 page 178

7.8 Levelling INIT ATTACH, menu 7 page 179

8.2.3 Load centre limitation INIT BOOM, menu 10 page 176

172 8 Control system – 8.5.1 Initiation
Function Menu
8.2.4 Height limitation INIT BOOM, menu 11 page 176
9.10.4 Sliding cab, forward INIT SLID-CAB, menu 1 page 183

9.10.5 Vertically adjustable cab, up INIT SLID-CAB, menu 2 page 184
INIT SLID-CAB, menu 3 page 184
9.10.4 Sliding cab, backward INIT SLID-CAB, menu 4 page 184

9.10.5 Vertically adjustable cab, down INIT SLID-CAB, menu 5 page 185
INIT SLID-CAB, menu 6 page 185
Initiate hydraulic function, work instruction

page
–
To select a hydraulic function to initiate, proceed as follows:

All hydraulic functions are initiated the same way.
1 Navigate to the service menu.
2 Press Enter.
000056
3 Enter the code for initiation.

1 23
4 5 NOTE
000060
The code determines which service menu is activated (Diag-

nostic test, Initiation or Calibration).
4 Select group by scrolling with the arrow keys (1 and 2) and con-
INITIATION firm with Enter.
BOOM ATTACHMENT Each initiation consists of a sequence of a number of menus. The

SLIDING-CAB STEERING first menu for the selected initiation opens in the display. Select
000057
TIMES RETURN the desired menus with the arrow keys (1 and 2).
5 Change the current value with the plus and minus keys.
INITIATION BOOM 1(8)
START CURRENT
LIFT NOTE
STORED VALUE XXXmA Current values can only be adjusted within specific limits.
PRESENT VALUE XXXmA 6 Use the function key for Enter to store the desired current value
setting, "STORED".
INITIATION BOOM 2(8)

END CURRENT
LIFT
STORED VALUE XXXmA
000061
PRESENT VALUE XXXmA

8 Control system – 8.5.1.1 BOOM 173
8.5.1.1 BOOM
INIT BOOM
page
–
This function menu group handles initiation of the boom functions lift,
INITIATION lower and extension.
BOOM ATTACHMENT
SLIDING-CAB STEERING
D ANGER
000651
DRIVE-TRAIN
The settings affect the functions lift, lower, and exten-

sion. Adjustment can impair functionality. If in doubt,
contact Cargotec Service.
NOTE
Initiation does not need to be performed in one process but each
INIT BOOM, menu 1

page
–
START CURRENT, LIFT

INIT BOOM 1(11)
Description: Start current for activation of solenoid valve, lift (Y6005).
START CURRENT
LIFT PRESENT VALUE: Indicates the current value for the start current.
STORED VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
005042
PRESENT VALUE XXXmA the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Component: Solenoid valve, lift (Y6005)
Signal value: XXXmA = 0 - 999 mA
INIT BOOM, menu 2

page
–
END CURRENT, LIFT

INIT BOOM 2(11)
Description: Control current at full lever actuation for the activation of
END CURRENT
LIFT the solenoid valve for lift (Y6005).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
005043
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Component: Solenoid valve, lift (Y6005)

174 8 Control system – 8.5.1.1 BOOM
INIT BOOM, menu 3

page
–
START CURRENT, LOWER

INIT BOOM 3(11)
Description: Start current for activation of solenoid valve, lower
START CURRENT
LOWER (Y6004).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
005044
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE indicates stored value for start current.
Component: Solenoid valve, lower (Y6004)
INIT BOOM, menu 4

page
–
END CURRENT, LOWER

INIT BOOM 4(11)
END CURRENT
LOWER the solenoid valve for lower (Y6004).
005045
R-key.
Component: Solenoid valve, lower (Y6004)
INIT BOOM, menu 5

page
–
START CURRENT, BOOM OUT

INIT BOOM 5(11)
Description: Start current for activation of solenoid valve, boom out
START CURRENT
BOOM OUT (Y6006).
005046
with the R-key.
Component: solenoid valve boom out (Y6006)

8 Control system – 8.5.1.1 BOOM 175
INIT BOOM, menu 6

page
–
END CURRENT, BOOM OUT

INIT BOOM 6(11)
END CURRENT
BOOM OUT the solenoid valve for boom out (Y6006).
005047
R-key.
Component: solenoid valve boom out (Y6006)
INIT BOOM, menu 7

page
–
START CURRENT, BOOM IN

INIT BOOM 7(11)
Description: Start current for activation of solenoid valve, boom in
START CURRENT
BOOM IN (Y6007).
005048
with the R-key.
Component: solenoid valve boom in (Y6007)
INIT BOOM, menu 8

page
–
END CURRENT, BOOM IN

INIT BOOM 8(11)
END CURRENT
BOOM IN the solenoid valve for boom in (Y6007).
005049
R-key.
Component: solenoid valve boom in (Y6007)

176 8 Control system – 8.5.1.1 BOOM
INIT BOOM, menu 9

page
–
OUTPUT LIFT AT F/R

INIT BOOM 9(11)
Description: Lift speed with gear engaged, as a percentage of max. lift
OUTPUT LIFT AT F/R
(PROC) speed.
STORED VALUE XXX PRESENT VALUE: Indicates the current value for the lift speed. Ad-
004930
PRESENT VALUE XXX just the value with the plus and minus keys. Save the set value with
with the R-key.
STORED VALUE: indicates stored value for lift speed.
Function: 7.2 Lifting/lowering
Component: -
Signal Value: XXX = lift speed as a percentage of max. value.
INIT BOOM, menu 10

page
–
OPTION LC-LIMIT
INIT BOOM 10(11)
OPTION LC-LIMIT
Description: Limit value for load centre limitation in metres. Distance
STORED VALUE XX.XX
004931
PRESENT VALUE XX.XX from the drive axle’s centre.
NOTE
On machines with vertically adjustable cab, a load centre less
than the cab’s frontmost point cannot be selected.
PRESENT VALUE: Indicates the current value for load centre. Adjust
the value with the plus and minus keys. Save the set value with the En-
R-key.
STORED VALUE indicates stored value for load centre.
Function: 8.2.3 Load centre limitation
Component: -
Signal Value: XX.XX = load centre limitation in metres.
INIT BOOM, menu 11

page
–
OPTION HEIGHT-LIMIT
INIT BOOM 11(11)
OPTION HEIGHT-LIMIT
Description: Limit value for height limitation in metres. Distance to the
STORED VALUE XX.XX
004932
PRESENT VALUE XX.XX boom’s highest point.

PRESENT VALUE: Indicates the current value for height limitation.
Adjust the value with the plus and minus keys. Save the set value with
with the R-key.
STORED VALUE indicates stored value for height limitation.
Function: 8.2.4 Height limitation
Component: -
Signal Value: XX.XX = height limitation in metres.

8 Control system – 8.5.1.2 ATTACHMENT 177
8.5.1.2 ATTACHMENT
INIT ATTACH
page
–
This function handles initiation of the attachment functions rotation,

INITIATION controllable tilt and controllable levelling.
BOOM ATTACHMENT
SLIDING-CAB STEERING
D ANGER
001157
DRIVE-TRAIN
The settings affect the functions rotation, controllable

tilt and controllable levelling. Adjustments can impair
functionality. Contact Cargotec Service in the event of
uncertainty.
NOTE
INIT ATTACH, menu 1

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–
START CURRENT, ROTATION CW

INIT ATTACH 1(14)
Description: Start current for activation of solenoid valve, rotation
START CURRENT
ROTATION CW clockwise (Y6008).
005091
with the R-key.
Component: Solenoid valve rotation clockwise (Y6008)
INIT ATTACH, menu 2

page
–
END CURRENT, ROTATION CW

INIT ATTACH 2(14)
END CURRENT
ROTATION CW the solenoid valve for rotation anticlockwise (Y6009).
005092
R-key.
Component: Solenoid valve anticlockwise (Y6009)

178 8 Control system – 8.5.1.2 ATTACHMENT
INIT ATTACH, menu 3

page
–
START CURRENT, ROTATION CCW

INIT ATTACH 3(14)
Description: Start current for activation of solenoid valve, rotation an-
START CURRENT
ROTATION CCW ticlockwise (Y6009).
005093
with the R-key.
Component: Solenoid valve rotation anticlockwise (Y6009)
INIT ATTACH, menu 4

page
–
END CURRENT, ROTATION CCW

INIT ATTACH 4(14)
END CURRENT
ROTATION CCW the solenoid valve for rotation anticlockwise (Y6009).
005094
R-key.
Component: Solenoid valve anticlockwise (Y6009)
INIT ATTACH, menu 5

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START CURRENT, TILT

INIT ATTACH 5(14)
Description: Start current for activation of solenoid valve for rotation tilt
START CURRENT
TILT in (Y6010) and solenoid valve for tilt out (Y6011).
005095
with the R-key.
Component: Solenoid valve rotation tilt in (Y6010), Solenoid valve tilt
out (Y6011)

INIT ATTACH, menu 6

page
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END CURRENT, TILT

INIT ATTACH 6(14)
Description: Control current at full lever actuation for activation of so-
END CURRENT
TILT lenoid valve for rotation tilt in (Y6010), and solenoid valve for tilt out
STORED VALUE XXXmA (Y6011).
005096
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
R-key.
Component: Solenoid valve rotation tilt in (Y6010), Solenoid valve tilt
out (Y6011)
INIT ATTACH, menu 7

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–
START CURRENT, LEVELLING

INIT ATTACH 7(14)
Description: Start current of activation of solenoid valve for levelling
START CURRENT
LEVELING right (Y6035) and solenoid valve for levelling left (Y6036).
005097
with the R-key.
Component: Solenoid valve for levelling right (Y6035), Solenoid valve
for levelling left (Y6036)
INIT ATTACH, menu 8

page
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END CURRENT, LEVELLING

INIT ATTACH 8(14)
Description: Control current at full lever actuation of activation of sole-
END CURRENT
LEVELING noid valve for levelling right (Y6035) and solenoid valve for levelling
STORED VALUE XXXmA left (Y6036).
005098
R-key.
Component: Solenoid valve for levelling right (Y6035), Solenoid valve
for levelling left (Y6036)

INIT ATTACH, menu 9

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START CURRENT, SPREADER OUT, 20'-40'

INIT ATTACH 9(X)
Description: Start current for activation of solenoid valve for spreading
START CURRENT
SPREADER OUT, 20'-40' out (Y6018).
I [mA] ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
1
2 Function: 7.5.3 Control valve attachment
3 005517
Component: Solenoid valve for spreading out (6018)
t [s]
Signal value: XXXmA = 0 - 999 mA.
1. Max. current (END CURRENT)
2. Damping (PROC DAMPING)
3. Start current (START CURRENT)
INIT ATTACH, menu 10

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END CURRENT, SPREADER OUT 20'-40'

INIT ATTACH 10(X)
END CURRENT
SPREADER OUT, 20'-40' lenoid valve for spreading out (Y6018).
R-key.
1
3
005518
Component: Solenoid valve for spreading out (Y6018)

t [s]

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DAMP (PROC), SPREADING, OUT 20'-40'

INIT ATTACH 11(X)
Description: Control current to solenoid valve for spreading out
DAMP (PROC)
SPREADER OUT, 20'-40' (Y6018) during damping, when damping is approaching 40’.
STORED VALUE XX PRESENT VALUE: Indicates the current value for max. current. Adjust
PRESENT VALUE XX the value with the plus and minus keys. Save the set value with the En-
R-key.
1
STORED VALUE: indicates stored value in percent.
3
005519
Component: Solenoid valve for spreading out (Y6018)

t [s]
Signal value: XXX = 0 - 100%. 100% means no damping i.e. max. cur-
1. Max. current (END CURRENT) rent. 0% means full damping i.e. start current


page
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START CURRENT, SPREADER IN 40'-20'

INIT ATTACH 12(X)
Description: Start current for activation of solenoid valve for spreading
START CURRENT
SPREADER IN, 40'-20' in (Y6019).
R-key.
1
3
005520
Component: Solenoid valve for spreading in (6019)
t [s]
Signal value: XXXmA = 0 - 999 mA.

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END CURRENT, SPREADER IN 40'-20'

INIT ATTACH 13(X)
END CURRENT
SPREADER IN, 40'-20' lenoid valve for spreading in (Y6019).
R-key.
1
3
005521
Component: Solenoid valve for spreading in (Y6019)

t [s]

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DAMP (PROC), SPREADING, IN 40'-20'

INIT ATTACH 14(X)
Description: Control current to solenoid valve for spreading in (Y6019)
DAMP (PROC)
SPREADER IN, 40'-20' during damping, when damping is approaching 20’.
STORED VALUE XX PRESENT VALUE: Indicates the current value for max. current. Adjust
PRESENT VALUE XX the value with the plus and minus keys. Save the set value with the En-
R-key.
1
STORED VALUE: indicates stored value in percent.
3
005522
Component: Solenoid valve for spreading in (Y6019)

t [s]
Signal value: XXX = 0 - 100%. 100% means no damping i.e. max. cur-
1. Max. current (END CURRENT) rent. 0% means full damping i.e. start current


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INIT ATTACH 15(X)

OPT DAMP BOOM DOWN
TOP LIFT (cm) OPT DAMP BOOM DOWN, TOP LIFT (cm)
STORED VALUE XXXX Description: Distance setting for activation of damping of lowering
006756
PRESENT VALUE XXXX speed for top lift, the distance between the attachment and the con-
tainer.
PRESENT VALUE: Indicates the current value for the distance. Adjust
R-key.
STORED VALUE: indicates stored value for the distance.
Function:
Component:
Signal value: XXXX = distance in cm.

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OPT DAMP DOWN, BOTTOM LIFT (cm)

INIT ATTACH 16(X)
Description: Distance setting for activation of damping of lowering
OPT DAMP BOOM DOWN
BOTTOM LIFT (cm) speed for bottom lift, the distance between the attachment and the
STORED VALUE XXXX trailer.
006842
PRESENT VALUE XXXX PRESENT VALUE: Indicates the current value for the distance. Adjust
R-key.
STORED VALUE: indicates stored value for the distance.
Function:
Component:
Signal value: XXXX = distance in cm

8.5.1.3 SLIDING-CAB
INIT SLIDING-CAB
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This function handles the initiation of hydraulic sliding cab or cab hy-
INITIATION draulic cab lift.
BOOM ATTACHMENT The sliding cab is smooth started by means of the control current to
SLIDING-CAB STEERING the solenoid valves being increased from a low start value to a max.
001645
DRIVE-TRAIN level. When the cab reaches an end position the speed is dampened
by means of the control current being reduced.
D ANGER
The settings affect the function of the hydraulic slid-
ing cab, vertically adjustable cab and tiltable cab. Ad-
justments can impair functionality. Contact Cargotec
Service in the event of uncertainty.
NOTE
INIT SLID-CAB, menu 1

page
–
START CURRENT, FORWARD

INIT SLID-CAB 1(6)
Description: Start current to solenoid valve sliding cab forward
START CURRENT
FORWARD (Y6016) at activation of sliding cab. The control current controls the
STORED VALUE XXXmA start speed for sliding cab forward.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
I [mA] Adjust the value with the plus and minus keys. Save the set value with
1 with the R-key.
2 STORED VALUE: indicates stored value for start current.
3 Function: 9.10.4.3 Control valve option frame
001698
t [s] Component: Solenoid valve sliding cab forward (Y6016)

1. Max. current (END CURRENT) Signal value: XXXmA = 0 - 999 mA


page
–
END CURRENT, FORWARD

INIT SLID-CAB 2(6)
Description: Control current to solenoid valve for sliding cab forward
END CURRENT
FORWARD (Y6016) after full ramp time at activation of switch for cab sliding. This
STORED VALUE XXXmA current controls maximum speed cab sliding speed forward.
I [mA] the value with the plus and minus keys. Save the set value with the En-
1 R-key.
2 STORED VALUE indicates stored value for max. current.
3 001787 Function: 9.10.4.3 Control valve option frame

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–
PROC DAMPING, FORWARD

INIT SLID-CAB 3(6)
Description: Percentage damping of control current to solenoid valve
PROC DAMPING
FORWARD for sliding cab forward (Y6016) when the cab is at the end position for
STORED VALUE XXXmA forward.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for damping. Adjust the
I [mA] value with the plus and minus keys. Save the set value with the Enter
key. Go to the next menu with the arrow keys. Exit initiation with the R-
1 key.
001850

Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. cur-
rent. 0% means full damping, i.e., start current.

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START CURRENT, REVERSE

INIT SLID-CAB 4(6)
Description: Start current to solenoid valve sliding cab backward
START CURRENT
REVERSE (Y6016) at activation of sliding cab. The control current controls the
STORED VALUE XXXmA start speed for sliding cab backward.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
I [mA] Adjust the value with the plus and minus keys. Save the set value with
1 with the R-key.
003001
t [s] Component: Solenoid valve sliding cab backward (Y6017)



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END CURRENT, REVERSE

INIT SLID-CAB 5(6)
Description: Control current to solenoid valve for sliding cab backward
END CURRENT
REVERSE (Y6017) after full ramp time at activation of switch for cab sliding. This
STORED VALUE XXXmA current controls maximum speed cab sliding speed backward.
I [mA] the value with the plus and minus keys. Save the set value with the En-
1 R-key.
2 STORED VALUE indicates stored value for max. current.
t [s] 003022 Component: Solenoid valve sliding cab backward (Y6017)

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–
PROC DAMPING, REVERSE

INIT SLID-CAB 6(6)
Description: Percentage damping of control current to solenoid valve
PROC DAMPING
REVERSE for sliding cab backward (Y6017) when the cab is at the end position
STORED VALUE XXXmA for backward.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for damping. Adjust the
I [mA] value with the plus and minus keys. Save the set value with the Enter
key. Go to the next menu with the arrow keys. Exit initiation with the R-
1 key.
003093
t [s] Component: Solenoid valve sliding cab backward (Y6017)

Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. cur-
rent. 0% means full damping, i.e., start current.

186 8 Control system – 8.5.1.4 STEERING
8.5.1.4 STEERING
INIT STEERING
page
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This function covers initiation of lever steering or mini-wheel.

INITIATION
BOOM ATTACHMENT
SLIDING-CAB STEERING D ANGER
002954
DRIVE-TRAIN
The settings affect the functions joystick control or
mini-wheel. Adjustment can impair functionality. If in
doubt, contact Cargotec Service.
NOTE
INIT STEERING, menu 1

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CHARACTER OF THE STEERING LEVER

INIT STEERING 1(10)
Description: Indicates the responsiveness of the steering lever in ac-
CHARACTER OF THE
STEERING LEVER, 0-31 cordance with 32 predefined curves (0-31) 0 means that linear wheel
STORED VALUE XX angle is uniform in relation to lever angle during the whole lever move-
PRESENT VALUE XX ment. 31 means that the wheel angle is small at the beginning of the
lever movement and large at the end.
U [V] 0
PRESENT VALUE: Indicates the current curve. Change the curve with
the plus and minus keys. Save the set curve with the Enter key. Go to
the next menu with the arrow keys. Exit initiation with the R-key.
31
STORED VALUE: indicates saved curve.
Function: 5.2 Power assisted system (product option joystick control
003130
or mini-wheel)
X Component: -
U = Output signal to solenoid valve
Signal value: XX = 0-31.
X = Lever movement

8 Control system – 8.5.1.4 STEERING 187

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–
BREAK POINT BP1

INIT STEERING 2(10)
Description: Speed for break point 1. Break points are used to adapt
BRAKE POINT BP1
(kph) the steering angle to the machine’s speed. This enables both sensitive
STORED VALUE XX.X steering at low speeds and stable steering at higher speeds.
PRESENT VALUE XX.X PRESENT VALUE: indicates present speed setting for break point 1.
I [mA] Change speed with plus or minus keys. Save set speed with the Enter-
100% key. Go to the next menu with arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved speed for break point 1.
% BP2 Function: 5.2 Power assisted system (product option joystick control
% BP3 or mini-wheel)
003131
V [kph] Component: -
BP1 BP2 BP3
I [mA] = control current to solenoid valve Signal value: XX.X = speed for BP1 in km/h.
V [kph] = machine speed in km/h
BP1 = speed setting for break point 1
%BP2 = percent of control current to solenoid valve at
BP2
BP3

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BREAK POINT BP2

INIT STEERING 3(10)
BRAKE POINT BP2
I [mA] Change speed with plus or minus keys. Save set speed with the Enter-
003132
V [kph] Component: -
BP1 BP2 BP3
BP2
BP3


page
–
BREAK POINT BP3

INIT STEERING 4(10)
BRAKE POINT BP3
I [mA] Change speed with plus or minus keys. Save set speed with the Enter
V [kph] 003133 Component: -
BP1 BP2 BP3
BP2
BP3

page
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PROC REDUCTION, AT PB2

INIT STEERING 5(10)
Description: Percentage reduction of control current to solenoid valve
PROC REDUCTION
AT BP2 for steering right (Y636R) and solenoid valve for steering left (Y636L)
STORED VALUE XXX at BP2.
PRESENT VALUE XXX PRESENT VALUE: Indicates the current value for the reduction. Ad-
I [mA] just the value with the plus and minus keys. Save the set value with
100% the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
% BP2 STORED VALUE: indicates stored value for the reduction.
003134
V [kph] or mini-wheel)
BP1 BP2 BP3
Component: -
I [mA] = control current to solenoid valve
V [kph] = machine speed in km/h Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. cur-
BP1 = speed setting for break point 1 rent. 0% means full damping, i.e., start current.
BP2
BP3

8 Control system – 8.5.1.4 STEERING 189

page
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PROC REDUCTION, AT PB3

INIT STEERING 6(10)
Description: Percentage reduction of control current to solenoid valve
PROC REDUCTION
AT BP3 for steering right (Y636R) and solenoid valve for steering left (Y636L)
STORED VALUE XXX at BP3.
PRESENT VALUE XXX PRESENT VALUE: Indicates the current value for the reduction. Ad-
I [mA] just the value with the plus and minus keys. Save the set value with
100% the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
% BP2 STORED VALUE: indicates stored value for the reduction.
003135
V [kph] or mini-wheel)
BP1 BP2 BP3
Component: -
I [mA] = control current to solenoid valve
V [kph] = machine speed in km/h Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. cur-
BP1 = speed setting for break point 1 rent. 0% means full damping, i.e., start current.
BP2
BP3

page
–
START CURRENT, STEERING RIGHT

INIT STEERING 7(10)
Description: Start current to the solenoid valve for steering right
START CURRENT
STEERING RIGHT (Y636R).
003136
with the R key.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering right (Y636R)

page
–
END CURRENT, STEERING RIGHT

INIT STEERING 8(10)
Description: Control current to the solenoid valve for steering right
END CURRENT
STEERING RIGHT (Y636R) at lever end position.
003137
R key.
Component: Solenoid valve for steering right (Y636R)


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–
START CURRENT, STEERING LEFT

INIT STEERING 9(10)
Description: Start current to the solenoid valve for steering left
START CURRENT
STEERING LEFT (Y636L).
003138
with the R-key.
Component: Solenoid valve for steering left (Y636L)

page
–
END CURRENT, STEERING LEFT

INIT STEERING 10(10)
Description: Control current to the solenoid valve for steering left
END CURRENT
STEERING LEFT (Y636L) at lever end position.
006704
R-key.
Component: Solenoid valve for steering left (Y636L)

8 Control system – 8.5.1.5 DRIVETRAIN 191
8.5.1.5 DRIVETRAIN
INIT DRIVE-TRAIN
page
–
This function handles initialisation of the transmission.

INITIATION
BOOM ATTACHMENT NOTE

SLIDING-CAB STEERING Initiation does not need to be performed in one process but each
003140
DRIVE-TRAIN step can be performed separately, independently of other steps.
The machine must be stationary with applied parking brake to en-
able access to the menus.
After changes have been made, the ignition must be turned off
and on for the changes to be saved and start to apply.
INIT DRIVE-TRAIN, menu 1

page
–
START IN 2ND
INIT DRIVE-TRN 1(6)
Description: Setting to get transmission to start in 2nd gear instead of
START IN 2:ND
0=NO 1=YES in 1st. Kick-down to 1st takes place as needed.
STORED VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
003151
PRESENT VALUE XXX with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Component: -
Signal value: XXX = 1= yes, XXX = 0 = no

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–
VEHICLE SPEED F-R

INIT DRIVE-TRN 2(12)
Description: Setting of highest permitted speed for shifting between
VEHICLE SPEED F-R
forward and reverse.
005051
Component: -
Signal value: XXX = speed in km/h

192 8 Control system – 8.5.1.5 DRIVETRAIN

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ENGINE SPEED F-R

Description: Setting of highest permitted engine speed for shifting be-
ENGINE SPEED F-R
tween forward and reverse.
STORED VALUE XXX
005052
PRESENT VALUE XXX NOTE
If the rpm is set lower than the engine’s idle rpm, shifting will not
be allowed.
PRESENT VALUE: Indicates the current setting. Change the value
Component: -
Signal value: XXX = engine speed (rpm)

page
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ENGINE SPEED N-DIR

Description: Setting of highest permitted engine speed for shifting from
ENGINE SPEED N-DIR
neutral position to gear.
STORED VALUE XXX
005053

This setting takes priority over the setting in INIT DRIVE-TRAIN,
menu 3 page 192. If the engine speed is set lower in this menu
that in menu 3, this engine speed will also apply to switching di-
rection of travel. This occurs because the transmission must shift
into neutral when changing direction of travel.
Component: -
Signal value: XXX = engine speed (rpm)


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ENGINE SPEED, KICKDOWN 1ST

Description: Setting of the lowest engine rpm when conditions for kick-
ENGINE SPEED
KICK DOWN 1:ST down to 1st gear are to be checked.
STORED VALUE XXX
005054
If the rpm is set too low, kick-down may take place before the ma-
chine has used the engagement on the selected gear.
If the rpm is set too high, kick-down takes place slowly or not at
all.
Component: -
Signal value: XXX = speed (km/h)

page
–
VEHICLE SPEED, DECLUTCH

Description: Setting of highest permitted speed for disengaging the
VEHICLE SPEED
DECLUTCH transmission.
005055
Component: -

page
–
Not used.

page
–
Not used.

194 8 Control system – 8.5.1.5 DRIVETRAIN

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–
OPTION SPEED LIMIT

OPTION SPEED LIMIT
(KM/H)
Description: Setting of speed limitation.
STORED VALUE XXX
004935
PRESENT VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
Component: -

page
–
OPTION HIGHEST GEAR AT SPEED LIMIT

OPTION HIGHETS GEAR
AT SPEED LIMIT
Description: Setting of highest permissible gear (speed limitation
STORED VALUE XXX
004936
PRESENT VALUE XXX through blocked gears).

Component: -
Signal value: XXX = gear

page
–
OPTION ENGINE SHUT DOWN

OPTION ENGINE SHUT
DOWN AT IDLE (sec)
Description: Setting of idle time prior to automatic engine shutdown
STORED VALUE XXX
004937
PRESENT VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
Function: 1 Engine
Component: -
Signal value: XXX = time in seconds before engine shutdown.


page
–
F-R WITHOUT ENGINE SPEED REDUCTION

F-R WITHOUT ENGINE
SPEED REDUCTION
Description: Activation or deactivation of automatic engine speed re-
STORED VALUE XXX
004938
PRESENT VALUE XXX duction when changing direction of travel forward - reverse. This
makes it possible to change direction of travel without releasing the ac-
celerator pedal. Engine speed drops to that set in menu 3 (see INIT
DRIVE-TRAIN, menu 3 page 192). If no value is set in menu 3, engine
speed goes to idle speed.
Component: -
Signal value:
X = 1, activated
X = 0, deactivated

196 8 Control system – 8.5.2 Calibration
8.5.2 Calibration
Calibration, description
page
–
Certain functions require calibration in order to operate correctly. The

control system has integrated calibrations for these functions.
SCALE
This menu handles calibration of sensors to weight indication.
CALIBRATION
There are two variants of weight indicator, fixed or dynamic scale, see
SCALE STEERING section 7 Load handling , group 7.10.2 Weight indicator. The current
DRIVE-TRAIN RETURN 000062 option on the machine is programmed and does not need selection,
see:
Weight indicator, calibration (product alternative fixed scale) (only
model year -2008) page 198
Weight indicator, calibration (product alternative dynamic scale) page
200
EL-STEERING
This menu handles calibration of the steering lever for lever steering,
CALIBRATION see:
SCALE STEERING Lever steering, calibration page 202

DRIVE-TRAIN RETURN
000074
NOTE
Calibration does not need to be performed in one process but
each step can be performed separately, independently of other
steps.
DRIVETRAIN
This function handles calibrations for engine and transmission. The
CALIBRATION menu loop contains two different calibrations which are not connected
to each other, see:
SCALE STEERING
DRIVE-TRAIN RETURN Accelerator pedal, calibration page 203
000078
Section 2 Transmission, group 2.8 Control system transmission
NOTE
steps.

8 Control system – 8.5.2 Calibration 197
Calibration menu, explanation

The figure shows an example of a menu, here for calibrating the boom
1 2
extension inner position. The table indicates what a description con-
5
CALIBR SCALE 3(7) tains (which follows in the next section):
BOOM FULLY RETRACTED
Designation: Example Description
STORED VALUE X.XXV
4 3
000063
PRESENT VALUE X.XXV Variable (position 4): BOOM Name of the affected input sig-
FULLY RETRACTED nal/control signal.
1. Menu group
2.Sequence number (the total number of sequences is Description: Setting sensor A short description of what is
indicated in brackets) boom length (R777) for boom ex- calibrated and the meaning of
3.Signal value tension in the innermost position. the variables.
4.STORED indicates stored value, PRESENT indi-
CALIBR VALUE: Indicates
cates current value of the signal to be calibrated
stored signal value from boom
5. Heading of menu figure
length (R777) for boom exten-
sion in the innermost position.
PRESENT VALUE: Indicates the
current signal value from sensor
boom length (R777).
Function: 7.3.11 Sensor, boom Name of current function.

length
Component: Sensor, boom an- Indicates the component

gle (R777) whose signal is the basis for
calibration.
Calibration, work instructions

page
–
Calibration consists of a number of menus (the number of menus de-

pends on the function). All menus are similar in construction and there-
fore the descriptions are similar.
To select a function to calibrate, proceed as follows:
1 Navigate to the service menu.

2 Press Enter.
000056
3 State code for calibration.

1 23
4 5 NOTE
000060

CALIBRATION firm with Enter.
SCALE STEERING Each calibration consists of a sequence of a number of menus.

DRIVE-TRAIN RETURN The first menu for the selected calibration appears in the display.
000062
Select the next menu with key 1 and 2 (arrow function).

198 8 Control system – 8.5.2.1 Calibrate SCALE
8.5.2.1 Calibrate SCALE

Weight indicator, calibration (product alternative fixed
page
–
scale) (only model year -2008)
NOTE
It is very important for accuracy that all steps are performed in the
given order.
1 Park the machine on level ground without load and centre the at-
tachment.
2 Navigate to the service menu and press ENTER.
000056

1 23
4 5 NOTE
000060

4 Scroll to SCALE with the arrow keys and press ENTER.
CALIBRATION
Every calibration consists of a sequence of menus. Scroll be-
SCALE STEERING tween the menus with the arrow keys.
DRIVE-TRAIN RETURN
000062
5 Lower the boom to the lowest position (0°).

CALIBR SCALE 1(X)
6 CALIBR SCALE, menu 1 save the setting with ENTER.
MINIMUM BOOM ANGLE
CALIBR VALUE X.XXV
006798
PRESENT VALUE X.XXV
7 Lift the boom to its highest angle.

CALIBR SCALE 2(x)
8 Scroll to CALIBR SCALE, menu 2 and save the setting with EN-
MAXIMUM BOOM ANGLE
TER.
CALIBR VALUE X.XXV
006799
PRESENT VALUE X.XXV
9 Scroll to CALIBR SCALE, menu 8.

CALIBR SCALE 8(X) 10 Move the boom into measuring position, see section 7 Load han-
BOOM IN MEAS. POS X X
WITHOUT LOAD dling, group 7.10.2 Weight indicator.
LE XX.XV RI XX.XV "BOOM IN MEAS. POS" should show " '1' '1' ", this indicates that
006805
STORED SUM XX.XV measuring position has been achieved for " 'Extension' 'Lift' ".
11 Wait approximately five seconds to stabilise the pressure.

8 Control system – 8.5.2.1 Calibrate SCALE 199
12 Save the setting with ENTER.
NOTE
New values can only be saved when the boom is in the
measuring position.
Negative values indicate shifted contacts on the pressure
sensors.
Large variations between the right and left indicate errors in
sensor signals.
CALIBR SCALE 9(X) 14 Lifting a known reference load and move the boom into measur-
BOOM IN MEAS. POS X X
WITH LOAD XX.XT ing position.
LE XX.XV RI XX.XV "BOOM IN MEAS. POS" should show " '1' '1' ", this indicates that
006806
STORED SUM XX.XV measuring position has been achieved for " 'Extension' 'Lift' ".
16 Enter the weight of the reference load with the + and - keys. Save
the setting with ENTER.
NOTE
New values can only be saved when the boom is in the
measuring position.
I M P OR TA NT
Check that the correct weight for the reference load is
shown in the menu before the setting is saved. Incor-
rectly input weight means that the scale indicates in-
correctly.
Checking calibration
CALIBR SCALE 10(X) 18 Lift a reference weight and check that the control system calcu-
PRESS BUTTON
lates the correct weight of the load that the machine is lifting,
LOAD XX.XT LOAD.
006806
The weight shown in tonnes to one decimal place.

If the weight is not correct, repeat steps 13-16.
19 Operate the machine without a load, stop the machine and check
that LOAD = 00.0± 0.5 tonnes.
NOTE
Check when stationary. (Operating generates dynamic forc-
es.)
20 Back out of calibration with the R-key.

200 8 Control system – 8.5.2.1 Calibrate SCALE
Weight indicator, calibration (product alternative dynamic

page
–
scale)
NOTE
It is very important for accuracy that all steps are performed in the
given order.
1 Warm the hydraulic oil to operating temperature, min. 40 °C.
2 Park the machine on level ground without load and centre the at-
tachment.
000056 3 Navigate to the service menu and press ENTER.

1 23
4 5 NOTE
000060

5 Scroll to SCALE with the arrow keys and press ENTER.
CALIBRATION
Every calibration consists of a sequence of menus. Scroll be-
SCALE STEERING tween the menus with the arrow keys.
DRIVE-TRAIN RETURN
000062
NOTE
Some options, such as height limitation and load centre lim-
itation, mean that bypass must be used to reach the boom’s
end positions.
6 CALIBR SCALE, menu 1.
CALIBR SCALE 1(X)
7 Lower the boom to the lowest position (0°).
MINIMUM BOOM ANGLE
8 Save the setting with ENTER
STORED VALUE X.XXV
011329
PRESENT VALUE X.XXV

CALIBR SCALE 2(x)
10 Lift the boom to its highest angle.
MAXIMUM BOOM ANGLE
STORED VALUE X.XXV
011330
PRESENT VALUE X.XXV

CALIBR SCALE 3(X)
13 Retract the boom completely.
BOOM FULLY RETRACTED
STORED VALUE X.XXV
011331
PRESENT VALUE X.XXV

8 Control system – 8.5.2.1 Calibrate SCALE 201

CALIBR SCALE 4(X)
16 Extend the boom completely.
BOOM FULLY EXTENDED
STORED VALUE X.XXV
011332
PRESENT VALUE X.XXV

CALIBR SCALE 5(X) 19 Retract the boom completely.
LOAD SENSOR BOOM
RETRACTED LE RI 20 Lower the boom and inch towards the end until 2-4 cm remains
STORED XXXX XXXX on the lift cylinders.
011333
PRESENT XXXX XXXX
CALIBR SCALE 6(X)
24 Extend the boom completely.
LOAD SENSOR BOOM 0t
EXTENDED LE RI 25 Wait approximately five seconds to stabilise the pressure.
CALIBR XXXX XXXX
26 Check that "LOAD SENSOR BOOM" is set to 0 t. If not, adjust
010454
PRESENT XXXX XXXX

with the minus key to 0 t and save the setting with ENTER.
I M P OR TA NT
Check that the correct weight is shown in the menu
before the setting is saved. Incorrectly input weight
means that the scale indicates incorrectly.
Checking calibration
CALIBR SCALE 7(X)
28 Lift a reference load and check that the control system calculates
ALLOWED LOAD XXXXXKg
PRESENT LOAD XXXXXKg the correct weight of the load that the machine is lifting.
LOAD STR.AXLE XXXXXKg PRESENT LOAD = Reference load ± 500 kg. Weight is given in
006804
LOAD-CENTER XXX.XXm kg.

If the weight is not correct, repeat the calibration.
29 Operate the machine without a load, stop the machine and check
that PRESENT LOAD = 00000± 500 kg.
Check in various ranges, as illustrated. The boom must not reach
the end positions during checking.
NOTE
Check when stationary. (Operating generates dynamic forc-
010455
es.)
30 Back out of calibration with the R-key. When the code menu ap-
pears, press Enter.

202 8 Control system – 8.5.2.2 Calibrate STEERING
8.5.2.2 Calibrate STEERING

Lever steering, calibration
page
–
NOTE
steps.
1 Start key in operating position.
CALIBR STEERING, menu 1

2 Go into the calibration menus and select CALIBR STEERING,
CALIBR STEERING 1(3) menu 1, see Calibration, work instructions page 197
STEERING LEVER CENTER
POSITION STEERING LEVER CENTRE POSITION
CALIBR VALUE X.XXV Description: Setting the centre position of the lever steering con-
000075
PRESENT VALUE X.XXV trol (R825).

PRESENT VALUE: indicates current signal value from lever
steering control (R825).
STORED VALUE: indicates stored signal value from lever steer-
ing control (R825).
Component: Lever steering control (R825)
Function: 5.1.3 Joystick
3 Move steering lever to required centre position.
4 Store the position with function key for Enter.

5 Select CALIBR STEERING, menu 2.
CALIBR STEERING 2(3)
STEERING LEVER LEFT POSITION
STEERING LEVER LEFT
POSITION Description: Setting of position for max. angle left on lever steer-
CALIBR VALUE X.XXV ing control (R825).
000076
PRESENT VALUE X.XXV

PRESENT VALUE: indicates current signal value from lever
steering control (R825).
ing control (R825).
6 Move steering lever to required position for max. angle left.

8 Control system – 8.5.2.3 Calibrate DRIVETRAIN 203

8 STEERING LEVER RIGHT POSITION
CALIBR STEERING 3(3)
Description: Setting for position for max. angle right on lever
STEERING LEVER RIGHT
POSITION steering control (R825).
CALIBR VALUE X.XXV PRESENT VALUE: indicates current signal value from lever
000077
PRESENT VALUE X.XXV steering control (R825).
ing control (R825).
9 Move steering lever to required position for max. angle right.
8.5.2.3 Calibrate DRIVETRAIN

Accelerator pedal, calibration
page
–
1 Start key in operating position, engine switched off.
DRIVE-TRAIN, menu 1
2 Go into the calibration menus and select DRIVE-TRAIN, menu 1,
CALIBR DRIVE-TRN 1(4) see Calibration, work instructions page 197
ACCELERATOR,
RELEASE THE PEDAL ACCELERATOR, RELEASE THE PEDAL
CALIBR VALUE X.XXV Description: setting accelerator’s pedal zero position.
000079
PRESENT VALUE X.XXV

CALIBR VALUE: Indicates current calibrated control value from
Accelerator pedal (R690).
PRESENT VALUE: Indicates present signal value from Acceler-
ator pedal (R690).
Function: 1.1.2 Accelerator pedal
Component: Accelerator pedal (R690).
3 Release the accelerator pedal.
DRIVE-TRAIN, menu 2
5 ACCELERATOR, THE PEDAL TO FLOOR
CALIBR DRIVE-TRN 2(4) Description: Setting of full-throttle position of Accelerator pedal
ACCELERATOR, (R690).
THE PEDAL TO FLOOR
CALIBR VALUE X.XXV CALIBR VALUE: Indicates current calibrated control value from
000080
PRESENT VALUE X.XXV Accelerator pedal (R690).

PRESENT VALUE: Indicates present signal value from Acceler-
ator pedal (R690).
Function: 1.1.2 Accelerator pedal
Component: Accelerator pedal (R690).
6 Depress the accelerator pedal fully and keep it down until the po-
sition is stored.

204 8 Control system – 8.5.2.3 Calibrate DRIVETRAIN
Transmission, calibration
page
–
D ANGER
Do not leave the machine during calibration. The ma-
chine may start to move.
1 Park the machine on level ground, engage neutral position and

apply the parking brake. Run the engine at idling speed.
2 To select the function to calibrate, first navigate to the service
menu. Then press Enter.
000056

1 23
4 5 NOTE
000060
The code determines which service menu shall be activated

(Diagnostics, Initiation or Calibration).
CALIBRATION firm DRIVE-TRAIN with Enter.
SCALE STEERING
DRIVE-TRAIN RETURN
000062
5 Scroll with the arrow keys (1 and 2) and select DRIVE-TRAIN,

CALIBR DRIVE-TRN 4(4) menu 4.
GEARBOX WARM UP
MODE X 6 Check that the oil temperature is at least 61 °C.
ACTUAL TEMP XXX If the oil temperature is too low then go to DRIVE-TRAIN, menu 4.
000082
TARGET TEMP XXX

A. Apply the footbrake so that the machine is stationary.
B. Select travel direction forward and apply full throttle for 20
seconds.
C. Engage neutral position, apply full throttle for 10 seconds
and then run the engine at idling speed.
D. Repeat steps B and C until the oil is hot.
The engine speed may be reduced towards the end of heating as
the oil from the gearbox is too hot. If this occurs, maintain neutral
position and maintain an engine speed of 1200 rpm for 20 sec-
onds.
When the temperature is correct, MODE changes from 0 to 1.

8 Control system – 8.5.2.3 Calibrate DRIVETRAIN 205
7 Select DRIVE-TRAIN, menu 3.

CALIBR DRIVE-TRN 3(4)
GEARBOX TUNING
CLUTCH TUNING
PHASE X SUB-PH X Description: Calibration of transmission couplings.
CLUTCH X STATUS X
000081
ACTION X XXXXrpm PHASE: Indicates current phase in the calibration.
0. Pre-filling of clutch
1. Calibration of clutch
4. Calibration complete
5. Calibration incorrect
6. Calibration paused
CLUTCH: Indicates which clutch shall be calibrated.

F. Clutch forward
R. Clutch reverse
1. Clutch gear 1
2. Clutch gear 2
3. Clutch gear 3
4. Clutch gear 4
ACTION: Indicates action from mechanics (in the event of a

fault)
0. No action (normal condition if no malfunction).
1. Increase throttle application.
2. Reduce throttle application.
3. Select neutral position.
4. Select travel direction forward.
5. Stop the vehicle (depress the brake if the machine
starts to move).
6. Heat the transmission, see step 4.
7. No action; the engine is controlled via Control unit,
transmission.
8. Keep the accelerator pedal in its current position.
9. Check error codes.
10. Apply the parking brake.
SUB-PH: Internal value for sub-phase 1 or 0.
STATUS: Calibration status.

0. Calibration not in progress.
3. Calibration in progress
8 Check that the gear selector is in neutral position.

9 Start calibration by pressing Enter.

206 8 Control system – 8.5.2.3 Calibrate DRIVETRAIN
10 Calibration starts (takes approx. 15 minutes) and engine speed is

raised to approx. 770 rpm.
The transmission will activate different gears during calibration.
NOTE
If the machine starts to move during calibration, use the foot-
brake to keep the machine stationary.
I M P OR TA NT
Calibration can be interrupted at any time by selecting
travel direction reverse.
11 When the engine speed decreases to idling and PHASE = 4 then

calibration is complete.
12 Switch off the ignition to store the values.

9 Frame, body, cab and accessories 1
9 Frame, body, cab and accessories
Table of Contents 9 Frame, body, cab and accessories

mm mm mm mm mm mm
9 Frame, body, cab and accessories............................................................... 5

9.1.1 Gear selector and multi-function lever ................................................. 12
9.1.22 Switch, direction indicators .................................................................. 13
9.2 Safety and emergency equipment ............................................................ 14
9.2.1 Safety switch ........................................................................................ 14
9.2.2 Seat belt ............................................................................................... 14
9.2.3 Fire extinguisher .................................................................................. 14
9.2.4 Buzzer .................................................................................................. 14
9.3 Seat .......................................................................................................... 15
9.3.1 Seat cushion ........................................................................................ 19
9.3.2 Back cushion ....................................................................................... 19
9.3.3 Electric heater ...................................................................................... 20
9.3.4 Shock absorbers .................................................................................. 21
9.3.5 Air suspension ..................................................................................... 21
9.3.6 Mechanical seat adjustment ................................................................ 22
9.3.7 Passenger seat .................................................................................... 22
9.3.8 Armrest ................................................................................................ 22
9.3.9 Sensor operator in seat ....................................................................... 23
9.4 Heating, ventilation and air conditioning ................................................... 24
9.4.1 Fresh air filter ....................................................................................... 32
9.4.2 Fresh air and recirculation damper ...................................................... 33
9.4.3 Cab fan ................................................................................................ 36
9.4.4 Heat exchanger heat ........................................................................... 39
9.4.5 Water valve .......................................................................................... 42
9.4.6 Engine temperature sensor ................................................................. 43
9.4.7 Compressor ......................................................................................... 43
9.4.8 Condenser ........................................................................................... 46
9.4.9 Moisture filter ....................................................................................... 48
9.4.10 Pressure switch ................................................................................... 48
9.4.11 Expansion valve ................................................................................... 49
9.4.12 Sensor temperature refrigerant ............................................................ 51
9.4.13 Heat exchanger cooling ....................................................................... 52
9.4.14 Air distributor ........................................................................................ 53
9.4.15 Air vents ............................................................................................... 54
9.4.16 Sensor temperature outlet fan ............................................................. 55
9.4.17 Sensor cab temperature ...................................................................... 56
9.4.18 Sensor outdoor temperature ................................................................ 57
9.5 Wiper/washer system ............................................................................... 58
9.5.1 Wiper front ........................................................................................... 58
9.5.2 Wiper roof ............................................................................................ 58
9.5.3 Wiper rear ............................................................................................ 58
9.5.4 Washer motor and reservoir ................................................................ 58
9.5.5 Wiper motor, front ................................................................................ 59

2 9 Frame, body, cab and accessories
9.5.6 Wiper motor, roof .................................................................................. 60

9.5.7 Wiper motor, rear ................................................................................. 61
9.6 Lighting system ......................................................................................... 63
9.6.1 Headlights ............................................................................................ 68
9.6.2 Running light ........................................................................................ 68
9.6.3 Tail light ................................................................................................ 68
9.6.4 Brake light ............................................................................................ 69
9.6.5 Reversing light ...................................................................................... 69
9.6.6 Driving direction indicator ..................................................................... 69
9.6.7 Flashing hazard lights .......................................................................... 70
9.6.8 Revolving beacon ................................................................................. 70
9.6.9 Working lights, cab ............................................................................... 70
9.6.10 Working lights, boom ............................................................................ 71
9.6.11 Work lights, attachment ........................................................................ 72
9.6.12 Interior lighting ...................................................................................... 72
9.7 Signalling system ...................................................................................... 73
9.7.1 Horn ...................................................................................................... 76
9.7.2 Flashing hazard lights .......................................................................... 76
9.7.3 Revolving beacon ................................................................................. 76
9.7.4 Warning parking brake ......................................................................... 76
9.7.5 Reverse alarm ...................................................................................... 76
9.8 Entertainment and communication ........................................................... 77
9.9 Glass/windows/mirrors .............................................................................. 78
9.9.1 Windscreen .......................................................................................... 79
9.9.2 Side window ......................................................................................... 81
9.9.3 Roof window ......................................................................................... 84
9.9.4 Rear window ......................................................................................... 85
9.9.5 Rearview mirror .................................................................................... 85
9.9.6 Reversing camera ................................................................................ 85
9.9.7 Monitor, reversing camera .................................................................... 86
9.10 Cab structure and suspension .................................................................. 87
9.10.1 Cab frame ............................................................................................. 87
9.10.2 Doors .................................................................................................... 88
9.10.3 Cab undercarriage ................................................................................ 88
9.10.4 Sliding cab ............................................................................................ 90
9.10.5 Vertically adjustable cab ..................................................................... 101
9.11 Cab interior ............................................................................................. 113
9.11.1 Instrument and control panels ............................................................ 113
9.11.2 Interior details, plastic ......................................................................... 114
9.11.3 Interior details, textile ......................................................................... 114
9.11.4 Floor covering ..................................................................................... 114
9.11.5 Insulation ............................................................................................ 114
9.11.6 Sun blinds ........................................................................................... 115
9.11.7 Terminal console ................................................................................ 115
9.11.8 Writing desk ........................................................................................ 115
9.12 Frame ...................................................................................................... 116
9.13 Body ........................................................................................................ 117

9.13.1 Wings ................................................................................................. 117

9.13.2 Hood engine compartment ................................................................ 117
9.13.3 Footstep and rail ................................................................................ 118
9.13.4 Counterweights .................................................................................. 118
9.14 Central lubrication .................................................................................. 119
9.14.1 Pump unit ........................................................................................... 121
9.14.2 Distribution block ............................................................................... 122
9.14.3 Lines .................................................................................................. 122
9.15 Paint/coatings ......................................................................................... 123

4 9 Frame, body, cab and accessories

9 Frame, body, cab and

mm mm mm mm mm mm
accessories
Controls and instruments, overview
page
–
Overview
1 2 3 4 5
15
12 13 12 11 10 9 8 7 6
004852
14
1 Left-hand instrument panel

2 Gear and multi-function lever (S162)
3 Steering wheel panel
4 Steering wheel
5 Switch direction indicators (S161)
6 Panel for load handling functions
7 Switch control switch (S250)
8 Switch parking brake (S107)
9 Control lever (S815)
10 Driver’s seat
11 Accelerator pedal (B690)
12 Brake pedal
13 Clutch-release pedal (S220-1)
14 Electrical distribution box with fuses
15 Hour meter (P708)
A Steering lever or mini-wheel

6 9 Frame, body, cab and accessories – 9.1 Controls and instruments
Left-hand instrument panel

16 Switch fan (S118)
17 Switch temperature (S139)
18 Switch air distribution (S117)
29 30 31 19 Switch work lights cab roof (S105-1)
24..28
20 Switch working lights attachment (S105-2)
19..23
21 Switch working lights boom (S105-3)
18
17 22 Switch rotating beacon (S110)
013031
16 23 Switch hazard lights (S109)
Left-hand instrument panel 24 Switch headlights (S100)
25 Switch seat heater (S143)
26 Switch rearview mirror defroster (S199-4)

27 Spare
28 Switch, pause heater (S199-1)

29 Spare
30 Spare
31 Socket 24 VDC (E804)

9 Frame, body, cab and accessories – 9.1 Controls and instruments 7
Steering wheel panel

36
35 32 Warning lamp, low battery charge
34
33 33 Warning lamp, low brake pressure
32
34 Indicator, active error codes
35 Warning lamp, bypass of hydraulic functions
36 Indicator light for activated steering with lever or mini-wheel

37..41 49
37 Warning lamp, high coolant temperature
42..46 38 Warning lamp, low oil pressure in engine
47 48 39 Indicator lamp, preheating
40 Warning lamp, low engine coolant level
41 Warning lamp, high transmission fluid temperature
50 51 52 53 42 Warning lamp, low fuel level
43 Warning lamp, high hydraulic oil temperature
44 Indicator light high beam
45 Indicator light direction indicator
46 Indicator lamp, parking brake
47 Indicator light locked twistlocks
48 Indicator light alignment
64
54 49 Indicator light unlocked twistlocks
63
55 50 Panel, warning and indicator lamps
62
56 51 Display, control system
000399
61 60 59 58 57 52 Indicator, control system

53 Ignition switch (S150)
Steering wheel panel for warning and indicator lamps
54 Switch, defroster
55 Switch, windscreen wiper at roof, interval
56 Switch, windscreen wiper at roof, continuous
57 Switch interior lighting
58 Switch, rear window wiper, interval
59 Switch, rear window wiper, continuous
60 Function keys, control system
61 Travel direction indicator, Forward Neutral Reverse
62 Switch, shifting program A, automatic shifting
63 Switch, shifting program 1, locked to first gear
64 Switch, shifting program 2, locked to second gear

Panel for load handling functions
65 Switch for lowering front jacks (S1006)

65 66 67 68
66 Switch for lowering rear jacks (S1007)
67 Switch for bypassing rotation stop (S1014)
69..72 Switch for bypassing height limit (S1015)
Switch for bypassing LC-limitation (load centre) (S1015)
68 Switch, automatic cab tilt (S199-5)

73
69 Switch, lock twistlocks (S1003)
74
76 70 Switches clamp/loosen clamping position, jacks (S1008)
75 013032
Switch overheight jacks (S1031)

Panel for load handling functions 71 Switch, stop at 30' or 35' (S1004)
72 Switch hydraulic sliding cab (S177)
Switch hydraulic vertically adjustable cab (S177)
Switch hydraulically tiltable cab (S177)
73 Indicator light support jacks down (H517)
74 Switch support jacks (S1013)
75 Switch for automatic spreading 20'-40' (S1012)

76 Bypass switch (S1005)

Operating menus, overview
1 2 3 4
12
5
11 6
10 9 8 7
005080
13 14 15 16
1. Operating menu engine and transmission 9.

Operating menu, printer
2. 10.
Operating menu dynamic scale Operating menu control of dynamic scale
3. Operating menu engine 11. Operating menu service
4. Operating menu, transmission and hydraulics 12. Operating menu heating and air conditioning
5. Operating menu electrical system 13.
Operating menu statistics, operating hours
6. 14.
Operating menu, container counter Operating menu statistics, fuel consumption
7. 15.
Operating menu service interval Operating menu statistics, driving distance
8. 16.
Operating menu statistics Operating menu, statistics, lift statistics

Event menus overview
1 2 3 4
15 6
14 7
13 8
006734
12 11 10 9
1. Event menu start interlock 9.

Event menu, height limitation
2. Event menu overload forward 10.
Event menu fixed scale
3. Event menu overload on steering axle 11.
Event menu open door
4. 12.
Event menu overload on steering axle Event menu rotation stop
5. Event menu, top lift alignment 13.
Event menu tilt lock
6. 14.
Event menu bottom lift alignment Event menu levelling lock
7. Event menu, twistlocks 15.
Event menu automatic spreading 20'-40'
8.
Event menu support jacks

Switch, replacement
page
–
NOTE
The instructions apply to switches in general.

2 Remove the dashboard panel.
3 Detach the connector from the switch.

4 Remove the switch from the instrument panel. Use a screwdriver
to bend in the tabs.
5 Replace the switch.

12 9 Frame, body, cab and accessories – 9.1.1 Gear selector and multi-function lever
9.1.1 Gear selector and multi-function

lever
Gear and multi-function lever, description
page
–
The following functions are handled by the gear and multi-function

2 lever (position 2).
3 1
0
Move- Function
ment
Forward/ Travel direction (for selecting shifting program and
Reverse travel direction, see section 2 Transmission).
000338
Inward, Washing of windscreen, roof window and rear win-
handle dow.
The signal can be checked from the diagnostic menu,
see section 8 Control system , group 8.4.3.1 CAB,
menu 1.
Rotation Windscreen wiper front.

0 – No wiping front windscreen. If wiper rear or roof
are active, these run at slow interval wiping.
1 – Slow interval wiping windscreen, controls slow in-
terval wiping for roof window and rear window.
2 – Fast interval wiping front windscreen, controls fast
interval wiping for roof window and rear window.
3 – Continuous wiping front windscreen. If wiper rear
or roof are active, these run at fast interval wiping.
The signal can be checked from the diagnostic menu,
menu 2.
Upward Light signal
Down- High beams (on/off)

ward With headlights on: Gear and multi-function lever is
used to switch between high and low beams.
With headlights off: Gear and multi-function lever is
000339
A
used to flash with the headlights.
The signal can be checked with the diagnostic menu,
see section 8 Control system , group 8.4.2.6 LIGHTS,
menu 6.
Inward, Horn (position A).

button The signal can be checked from the diagnostic menu,
menu 5.

9 Frame, body, cab and accessories – 9.1.22 Switch, direction indicators 13
Gear and multi-function lever, replacement

page
–
1 Separate the dashboard panel.

6 attaching bolts and 2 bolts to the steering wheel shaft.
Remove the steering wheel, see Dashboard panel, replacement
page 113.
2 Undo the attaching bolts (2 x hexagonal socket bolts).
3 Unplug the connector from the KIT control unit (D790-2).
4 Fit a new lever and refit the dashboard panel.
9.1.22 Switch, direction indicators

Switch, direction indicators, replacement
page
–

2 Remove the steering wheel and open the steering wheel panel.
3 Detach the direction indicator wiring harness.

4 Press together the clips on the direction indicator and detach it
from the steering wheel panel.
5 Replace the direction indicator, fitting it in the reverse order.

14 9 Frame, body, cab and accessories – 9.2 Safety and emergency equipment
9.2 Safety and emergency

equipment
9.2.1 Safety switch
Emergency stop, description
page
–
See section 11 Common electrics, group 11.5.1.4 Emergency stop

switch voltage.
9.2.2 Seat belt

Seat belt, description
page
–
The seat belt is a two or a three-point belt, depending on the type of

seat fitted in the machine. The seat belt is mounted on the seat.
9.2.3 Fire extinguisher

Fire extinguisher, description
page
–
The fire extinguisher is located at the entry on the left frame beam. Us-
age instructions are found on the fire extinguisher.
9.2.4 Buzzer
Seat buzzer, description
page
–
See Sensor operator in seat, description page 23.

9 Frame, body, cab and accessories – 9.3 Seat 15
9.3 Seat
Seat, general
page
–
There are three versions of operator’s seat:

• Seat, description (product alternative standard seat) page 15
• Seat, description (product alternative BE-GE 9120) page 16
• Seat, description (product alternative Isringhausen 6800)

page 17
As an option, the machine can be equipped with a fold-down passen-

ger seat to the left of the operator.
Seat, description (product alternative standard

page
–
seat)
The seat’s function is to give the operator a good sitting position and
contribute to a good work environment. The cab’s seat has several ad-
justment possibilities and meets high comfort standards.
1 2 The seat has the following equipment:
• mechanical adjustment
3
• right armrest
• seat belt (option until model year 2007)
4
• left armrest
• seat heating
• head restraint
5
8 6
006825
7
Controls, standard seat
1. Lumbar support adjustment
2. Right armrest adjustment
3. Left armrest adjustment
4. Backrest rake adjustment
5. Springing adjustment
6. Seat cushion angle adjustment
7. Seat height adjustment
8. Front/rear adjustment

16 9 Frame, body, cab and accessories – 9.3 Seat
Seat, description (product alternative BE-GE

page
–
9120)
BE-GE 9120 is the same as the standard seat, but is equipped with air
1 2 suspension. Air suspension automatically adjusts seat height and
springing to the operator’s weight. Air suspension is supplied by a spe-
cial compressor installed on the underside of the cab.
3
4
The seat has the following equipment:
• mechanical adjustment
• air suspension (with external compressor)
5 • right armrest
• seat belt (option until model year 2007)
8 6
006826
• left armrest
7
Controls BE-GE 9120 • seat heating
2. Right armrest adjustment • head restraint
3. Left armrest adjustment

4. Backrest rake adjustment
5. Springing adjustment
6. Seat cushion angle adjustment
7. Seat height adjustment

9 Frame, body, cab and accessories – 9.3 Seat 17
Seat, description (product alternative

page
–
Isringhausen 6800)
The Isringhausen 6800 seat has the following equipment:
• head restraint
• armrest
• air suspension (with external compressor)
• air-adjusted lumbar support
• seat belt
• seat heating
11
10
34 567
004691
9 8 2
Controls, Isringhausen 6800
2. Seat cushion adjustment
3. Seat height lowering
4. Seat cushion angle
5. Seat height raising
6. Backrest rake
7. Damping adjustment
8. Seat heating
9. Level damping OFF/ON
11. Armrest

18 9 Frame, body, cab and accessories – 9.3 Seat
Seat, changing
page
–

2 Slide back the seat to its rear position, remove the front attaching
bolts.
3 Slide the seat to its front position, remove the rear attaching bolts.
4 Disconnect the seat’s connectors from the machine’s cabling.
5 Remove the seat.

9 Frame, body, cab and accessories – 9.3.1 Seat cushion 19
9.3.1 Seat cushion

Seat cushion, description
page
–
The function of the seat cushion is to provide comfort to the operator.

The seat cushion houses the operator’s seat frame and a breaker for
the buzzer. There may also be a heating coil ( ).
For location, see Seat, general page 15.
Seat cushion, changing (product alternative BE-GE)

page
–

2 Loosen the rubber bellows by removing the plastic clips (position
1).
3 Unhook the upholstery’s rails (position 2) from the seat frame (po-
2 5 sition 3) and remove the upholstery.
4 Remove the padding (position 4).
4
If the seat is equipped with seat heater.
Unplug the connector for the heating coil before the padding is re-
moved.
NOTE
The seat’s heating coil is glued to the padding. Be careful if
3
the padding is to be replaced but the heating coil is to be re-
used, or if only the coil is to be replaced.
5 Assemble in reverse order.
1
006276
1. Plastic clip, rubber bellows

2. Upholstery
3. Seat frame
4. Padding
5. Heat coil
9.3.2 Back cushion

Back cushion, description
page
–
The function of the back cushion is to provide comfort to the operator.

The back cushion houses the operator’s seat frame. There may also
be a heating coil ( ).
For location, see Seat, general page 15.

20 9 Frame, body, cab and accessories – 9.3.3 Electric heater
Back cushion, changing (product alternative BE-GE)

page
–

2 Detach the rubber bellows on the rear of the seat by removing the
plastic clips and folding down the rubber bellows. See Seat cush-
ion, changing (product alternative BE-GE) page 19.
3
3 Remove the backrest by first removing the attaching bolts
(position1) on the right and left side of the seat and then remove
4 the attaching bolts for the seatbelt (position 2) on the right and left
side of the seat.
4 If the seat is equipped with 3-point seatbelt.

Remove the belt guide (position 3) by removing the cover and the
attaching bolt (position 4).
5 5 If the seat is equipped with armrest (position 5).

Remove the armrest by removing the attaching bolts (position 6).
6 Place the backrest on the seat and install the attaching bolts (po-
sition 1), do not tighten. Then install the attaching bolts for the
6 seatbelt (position 2).
Tighten the attaching bolts for the seatbelt (position 2) with torque
42 Nm , then tighten the attaching bolts (position 1) with torque
33 Nm.
7 If the seat is equipped with 3-point seatbelt or armrest.

Cut holes in the upholstery for seatbelt and armrest on the new
006278
1 2 backrest before armrest or seatbelt is installed.

1. Attaching bolt, backrest 8 Fit in the reverse order.
2. Attaching bolt, seat belt
3. Cover, belt guide
4. Attaching bolt, belt guide
5. Armrest
6. Attaching bolt, armrest
9.3.3 Electric heater

Electric heater, description
page
–
The heating coil’s function is to warm the back and seat cushions in
the operator’s seat. The heating coil is located under the upholstery on
the seat.
The heating coil (E803) is supplied voltage upon warm-up of the cab
control unit (D790-1) by the seat heating relay (K383). The signal can
be checked with the diagnostic menu, see section 8 Control system ,
group 8.4.3.8 CAB, menu 8.
Heating coil, changing (product alternative BE-GE)

page
–
See Seat cushion, changing (product alternative BE-GE) page 19.

9 Frame, body, cab and accessories – 9.3.4 Shock absorbers 21
9.3.4 Shock absorbers

Shock absorbers, description
page
–
Shock absorbers are integrated in the suspension unit in the seat’s

bracket and are self-adjusting, that is, they adjust themselves accord-
ing to the operator’s body weight.
Shock absorber, changing (product alternative BE-

page
–
GE)
2 1 Machine in service position, see section B Safety.

2 Remove the operator’s seat from the bracket and lift it out of the
machine. See Seat, changing page 18.
3 Remove the seat cushion; see Seat cushion, changing (product
alternative BE-GE) page 19.
1 4 Remove the back cushion; see Back cushion, changing (product
alternative BE-GE) page 20.
5 Remove the shock absorber’s attaching bolts (position 2 and 3).
6 Replace shock absorber (position 1).
006277
3 7 Assemble in reverse order.

1. Shock absorbers
2. Attaching bolt
3. Attaching bolt
9.3.5 Air suspension

Air suspension, description
page
–
The air-suspended operator’s seat consists of a seat with rubber bel-

lows and compressor. Air suspension is self-adjusting, that is, adjust
automatically to the operator’s body weight. The compressor provides
air for the suspension unit.
9.3.5.1 Compressor, air suspension

Compressed air-suspended seat, description
page
–
BE-GE 9120:
The compressor is part of the air-suspended operator’s seat and is lo-

cated inside the seat’s suspension unit.
001621
Isringhausen 6800:
Compressed air-suspended seat
The compressor is an external part for the air-suspended operator’s

seat that is installed on the cab floor’s underside.

22 9 Frame, body, cab and accessories – 9.3.6 Mechanical seat adjustment
9.3.6 Mechanical seat adjustment

Mechanical seat adjustment, description
page
–
Seat adjustment is all mechanical and is adapted by the operator with

different controls to obtain a good sitting position.
See:
• Seat, description (product alternative standard seat) page 15
• Seat, description (product alternative BE-GE 9120) page 16
• Seat, description (product alternative Isringhausen 6800) page 17
9.3.7 Passenger seat

Passenger seat, description
page
–
The passenger seat is collapsible (vertically) and is located on the left-

hand side of the operator’s seat.
001627
Passenger seat with bracket
9.3.8 Armrest
Armrests, description
page
–
The arm rest is fixed to the backrest and is individually adjustable ver-
tically (around the attachment point). Depending on options there is
also an arm rest for the left-hand side:
• Mini-wheel
• Joystick control

9 Frame, body, cab and accessories – 9.3.9 Sensor operator in seat 23
9.3.9 Sensor operator in seat

Sensor operator in seat, description
page
–
Sensor, operator in seat (S230) senses if the driver’s seat suspension

is depressed which indicates for the control and monitoring system
1 that the operator is sitting in the driver’s seat. This is used to give to
the control system the facility to indicate with the buzzer for operator
in seat (H853) if the operator leaves the machine without applying the
parking brake.
2
From and including model year 2009 - the signal from the sensor for
operator in seat (S230) is also used to put the transmission in neutral
position if the operator leaves the seat. In an emergency situation the
machine can be operated by bypassing the safety system. Activate the
switch for bypass, select the travel direction and drive the machine to
the workshop. The speed is limited to 10 km/h.
008220
Seat, view from underneath D ANGER

1. Sensor, operator in seat (S230)
2. Buzzer (H853)
Bypassing the safety systems results in a risk of tip-
ping. Use at your own risk.
The operator-in-seat sensor (S230) is supplied voltage by and sends

a voltage signal to Control unit, cab (ECU 790-1). The signal can be
checked with the diagnostic menu, see section 8 Control system ,
group 8.4.3.6 CAB, menu 6.

24 9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning
9.4 Heating, ventilation and air

conditioning
Heating, ventilation and air conditioning,
page
–
description
The heating system controls heating and ventilation of the cab. The
F cab can also be equipped with a climate control system ( ).
The temperature in the cab is thermostat-controlled by the cab control
unit (D790-1). The cab temperature is regulated to the set tempera-
2 ture. The temperature can be set between 16 and 28 °C. The unit is
4 operated with controls on the instrument panel.
D
C Heating system (EHC)
The heating system (EHC) handles heating and ventilation. (The heat-
E E
ing system cannot provide cooling.)
3
The heating system uses heat from the engine’s cooling system via a
heating coil to heat ambient air. The fan forces the ambient air through
the heating coil on through ducts in the cab interior. It is then directed
to the windscreen (defroster) or the feet.
6 A B Climate control system (ECC)
The climate control system (ECC) is responsible for heating, ventila-

tion, cooling and drying. The air is heated in the same way as for the
heating system (EHC).
1 During cooling, ambient air is forced through the evaporator, which
5 G cools the air. The air can then be directed in the same way as for the
000762
heating system.
Principle illustration, climate control system The function of the climate control system is to:
1. Fluid reservoir/filter dryer with integrated pressure • heat the air when it is cold
switch
• dehumidify the air when it is damp
2. Heating element and evaporator
3. Fan • clean the air of impurities
4. Expansion valve • cool the air when it is hot
5. Condenser
• defrost (defroster function)
6. Compressor
A. High-pressure gas
B. High-pressure fluid
C. Low-pressure fluid
D. Low-pressure gas
E. Outdoor air for cab ventilation
F. Heated or cooled air to the cab
G. Outdoor air for eliminating heat

9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning 25

page
–
2 1 D3 3 26
D1
25
D4 D2
4 ˚C D23
D6
˚C
D5 D15 6
7 D790-1 D790-2 D795
D9
15 D15 D797-R D794
M 16 D21 12 D10
14 22 23
5 ˚C Pa ˚C
M D17
D14 21
19 20 C 24
13
M 18
D13 17
D9 9
M
10
˚C
8 11
006416
1 The temperature switch (S139) sends a Raise: U = 2.0–2.5 V Controls and instruments, overview page 5
voltage signal to the cab control unit Unaffected: U = 0-0.5 V D1: Diagnostic menu, see section 8 Control
(D790-1). system , group 8.4.4.5 CLIMATE, menu 5
Lower: U = 4.5-5.0 V
2 The fan switch (S118) sends a voltage Raise: U = 2.0–2.5 V Controls and instruments, overview page 5
signal to the cab control unit (D790-1). Unaffected: U = 0-0.5 V D2: Diagnostic menu, see section 8 Control
Lower: U = 4.5-5.0 V system , group 8.4.4.5 CLIMATE, menu 5
3 The air distribution switch (S117) sends Scroll up: U = 2.0–2.5 V Controls and instruments, overview page 5
a voltage signal to the cab control unit Unaffected: U = 0 V D3: Diagnostic menu, see section 8 Control
(D790-1). system , group 8.4.4.5 CLIMATE, menu 5
Scroll down: U = 4.5-5.0V
4 The cab temperature sensor (B775-1) R = 10 kΩ at 25 °C Sensor, cab temperature, description page
sends the cab control unit (D790-1) a 56
voltage signal proportional to the tem- D4: Diagnostic menu, see section 8 Control
perature. system , group 8.4.4.1 CLIMATE, menu 1


5 The blower fan temperature sensor R = 10 kΩ at 25 °C Sensor, temperature outlet fan, description
(B775-2) sends the cab control unit page 55
(D790-1) a voltage signal proportional to D5: Diagnostic menu, see section 8 Control
temperature. system , group 8.4.4.2 CLIMATE, menu 2
6 The ambient temperature sensor (B774) R = 10 kΩ at 25 °C Sensor, ambient temperature, description

sends the cab control unit (D790-1) a page 57
voltage signal proportional to tempera- D6: Diagnostic menu, see section 8 Control
ture. system , group 8.4.4.2 CLIMATE, menu 2
7 The cab control unit (D790-1) regulates Checked by control sys- Section 11 Common electrics, group
temperature and air distribution with sig- tem, error shown with er- 11.5.3.1 Cab control unit
nals from sensors and controls. ror code.
8 The engine produces heat when run- - -

ning. It is cooled with the cooling sys-
tem. The heat from the cooling system is
used to heat the cab air.
9 The cab control unit (D790-1) controls U = 0.5–4.5 V Water valve, description page 42
the water valve (Y673), which directs D9: Diagnostic menu, see section 8 Control
hot water to heat exchanger heating. system , group 8.4.4.7 CLIMATE, menu 7
The water valve’s opening (%) is sent and 8.4.4.4 CLIMATE, menu 4
back to the cab control unit (D790-1).
This gives information for controlling the
water valve’s position.
10 The engine temperature sensor sends Checked by control sys- Section 1 Engine
the engine control unit (D794) a voltage tem, error shown with er- D10: Diagnostic menu, see section 8 Con-
signal proportional to engine tempera- ror code. trol system , group 8.4.4.2 CLIMATE,
ture. menu 2
11 Heat exchanger heat adds heat to the - Heat exchanger heat, description page 39
cab air. Heat is transferred from the en-
gine’s cooling system to the cab air.
engine temperature in the cooling system, error shown with er- 11.5.3.10 Engine control unit
tem on the CAN bus. ror code.
13 The cab control unit (D790-1) controls Checked by control sys- Fresh air filter or recirculation damper, de-
the recirculation actuator motor (M612) tem, error shown with er- scription page 33
which sets the fresh air or recirculation ror code. D13: Diagnostic menu, see section 8 Con-
damper in the required position. trol system , group 8.4.4.6 CLIMATE, menu
6
14 The cab control unit (D790-1) controls Checked by control sys- Cab fan, description page 36
the fan motor (M657), which increases tem, error shown with er- D14: Diagnostic menu, see section 8 Con-
airflow in the cab. ror code. trol system , group 8.4.4.6 CLIMATE, menu
6


15 The cab control unit (D790-1) controls U = 0.5–4.5 V Air distributor, description page 53
the actuator motor (Y672), which sets D15: Diagnostic menu, see section 8 Con-
the air distributor to the required posi- trol system , group 8.4.4.8 CLIMATE,
tion. menu 8 and 8.4.4.4 CLIMATE, menu 4
The air distributor’s position is sent back
to the cab control unit (D790-1). This
gives information for controlling the air
distributor’s position.
16 The rear frame control unit (D797-R) Checked by control sys- Section 11 Common electrics, group
controls AC compressor engagement. tem, error shown with er- 11.5.3.3 Control unit, frame rear
ror code.
17 The rear frame control unit (D797-R) U = 24 V Compressor air conditioning, description
supplies voltage to the compressor’s so- (engine alternative Volvo) page 43
lenoid valve (645). D17: Diagnostic menu, see section 8 Con-
trol system , group 8.4.4.6 CLIMATE, menu
6
18 The compressor draws gaseous refrig- - Compressor air conditioning, description

erant from the evaporator, compresses (engine alternative Volvo) page 43
it, and forces it on to the condenser.
19 The condenser cools the refrigerant. - Condenser, description page 46

The gaseous refrigerant condenses to
liquid form and is pumped on in the cir-
cuit.
20 The moisture filter absorbs any moisture - Moisture filter, description page 48
from the cooling circuit. The fluid reser-
voir stores the refrigerant.
21 The pressure switch (S246) sends a sig- U = 24 V Pressure switch, description page 48
nal to the rear frame control unit D21: Diagnostic menu, see section 8 Con-
(D797-R) if the pressure in the system trol system , group 8.4.4.3 CLIMATE,
becomes abnormally high or low. menu 3
22 The expansion valve adjusts the amount - Expansion valve, description page 49
of refrigerant that is let in to the evapora-
tor. If the temperature in the evapora-
tor’s outlet pipe increases, the
evaporator valve increases flow of re-
frigerant so that heat dissipation in the
evaporator increases.
23 The refrigerant circuit temperature sen- R = 10 kΩ at 25 °C Sensor temperature refrigerant, description

sor sends the cab control unit (D790-1) page 51
a voltage signal proportional to temper- D23: Diagnostic menu, see section 8 Con-
ature. trol system , group 8.4.4.2 CLIMATE, menu
2.


24 Heat exchanger cooling dissipates heat - Evaporator, description page 52
from the cab air. Heat is transferred from
the air to the refrigerant and transforms
the refrigerant to a gaseous state.
25 The defroster switch on the KIT control Checked by control sys- Section 11 Common electrics, group
unit (D790-2) activates the defroster tem, error shown with er- 11.5.3.11 Control unit KIT
program of the climate control system ror code.
for six minutes.
26 The KID control unit (D795) shows the Checked by control sys- Section 11 Common electrics, group
heating and ventilation settings in the tem, error shown with er- 11.5.3.12 KID control unit
display. ror code.

page
–
checking
2 Navigate to the service menu and press Enter.
000056
3 Enter code for diagnosis. Code is obtained from Cargotec Sup-

port.
1 23
4 5 NOTE
000060
The code decides which service menu is to be activated

(Diagnostic test, Initiation, Calibration, or Service indica-
tion).
4 Select CLIMATE.
DIAGNOSIS
CAN/POWER LIGHTS CAB Menu 1
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
000131
OP EXTRA HIST
5 Check of desired temperature, inside temperature sensor and

DIAG CLIMATE 1(8) water valve.
REQUIRED TEMP XXX REQUIRED TEMP: 160 (16.0 °C) for max. cooling and 280
PRESENT TEMP XXX (28.0 °C) for max. heating. The setting is changed with the tem-
000132
WATER VALVE FEEDB. XXX perature switch.

PRESENT TEMP shows the temperature inside the cab. This is
measured by Sensor cab temperature (located down to the right
on the instrument panel, behind the rubber bushing). Blowing
through the hole should increase the value.
WATER VALVE FEEDB. should show 0 (closed) when the re-
quested temperature is 160 and 100 (open) when the requested
temperature is 280. The water valve is located under the cab.

Menu 2
6 Check of Sensor temperature outlet fan (B775-2), engine temper-
DIAG CLIMATE 2(8) ature, Sensor outdoor temperature (B774), Check of Sensor tem-
TEMP COIL XXX perature refrigerant (B775-1).
TEMP COOLANT XXX
TEMP AMBIENT XXX TEMP COIL: temperature that the air has in the air distributor is
000133
TEMP DE-ICE XXX measured by Sensor temperature outlet fan (B775-2).
TEMP COOLANT: engine temperature sent on the CAN-bus.
TEMP AMBIENT: outdoor temperature measured by Sensor out-
door temperature (B774).
TEMP DE-ICE: cooling circuit’s temperature measured by Sen-
sor temperature refrigerant (B775-1). If the compressor is activat-
ed the value will be low. However, if heat has been selected and
the compressor is deactivated, the value will almost be equal to
TEMP COIL.
Menu 3
7 (Only machines with ECC)

DIAG CLIMATE 3(X)
PRESENT INPUT SIGNAL Checks that refrigerant circuit is filled.
PRESSURE SWITCH X PRESSURE SWITCH: 0 = not filled 1 = filled.
OPT DOOR SWITCH X
006865
The sensor is located on the dryer filter which is fitted right rear in
the frame.
Menu 4
8 Checks Water valve (Y673) and Air distributor (Y642).
DIAG CLIMATE 4(8)
WATER VALVE: should work between 1.0-1.24 V and 2.95-3.2
WATER VALVE XX.XXV V. This is checked by turning the temperature control and chang-
DRAUGHT VALVE XX.XXV ing temperature setting from min. to max.
000135
DRAUGHT VALVE: should work in the range 1.0-4.0 V. The dif-

ference between min. and max. should be approx. 1 V. This is
checked by changing the air distribution from floor to front wind-
screen. At the same time, feel with your hand so that air blows
through different vents.
NOTE
Air to the round panel vents is not controlled by the air con-
ditioning unit.
Menu 5
9 Checks switches for temperature, air distribution and fan speed.
DIAG CLIMATE 5(8)
REQUIRED TEMP: home position U = 0 V; raise U = 2-2.5 V; low-
REQUIRED TEMP XX.XXV er U = 4.5-5 V.
REQ. DRAUGHT XX.XXV REQ. DRAUGHT: home position U = 0 V; against windscreen U
000136
REQ. FAN SPEED XX.XXV = 2-2.5 V; against floor U = 4.5-5 V.

REQ. FAN SPEED: home position U = 0 V; raise U = 2-2.5 V; low-
er U = 4.5-5 V.

Menu 6
10 Checks cab fan (M657), fresh air and recirculation damper
DIAG CLIMATE 6(8)
PRESENT OUTPUT SIGNAL (M612) and compressor’s electromagnetic clutch (M645) .
FAN SPEED XXX FAN SPEED: increase and decrease fan speed, value should in-
RECIRKULATION XY crease from 0 to 255 in steps.
000137
COMPRESSOR XY
RECIRCULATION: press in the bypass switch (S1005) (on the
panel for load handling functions). When checking, the display
should show "11". Check that the damper really moves as it
should by removing the fresh air filter at the front of the climate
control system casing and feeling with your hand.
(Only machines with ECC)

COMPRESSOR: lower temperature setting to max. cooling, after
approx. 45 seconds the compressor will be activated and the dis-
play should show "11".
NOTE
Compressor activation can only be tested when the engine
is running and the system is filled.
Menu 7
11 Checks direction selector for Water valve (Y673).
DIAG CLIMATE 7(8) CLOCKWISE: When temperature is increased and the water
OUTPUT WATER VALVE valve opens shows "CLOCKWISE 11 11" and "COUNTER-
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY CLOCKWISE 00 11".
COUNTER-CLOCKWISE: When temperature is lowered and the
water valve closes shows "CLOCKWISE 00 11" and "COUNTER-
24V CLOCKWISE 11 11".
NOTE
The ones are only showed for a moment when the water
valve changes position, zeros are shown when the valve is
M not changing position. The water valve does not open if en-
gine temperature is low, or if outdoor temperature is high.
000138
0V

Menu 8
12 Checks direction selector for air distributor.
DIAG CLIMATE 8(8)
CLOCKWISE: when the air is directed against the windscreen
OUTPUT DRAUGHT VALVE
CLOCKWISE XY XY and the air distributor changes position shows "CLOCKWISE 00
ANTI-CLOCKWISE XY XY 11" and "COUNTER-CLOCKWISE 11 11".
COUNTER-CLOCKWISE: when the air is directed against the
feet and the air distributor changes position shows "CLOCKWISE
24V 11 11" and "COUNTER-CLOCKWISE 00 11".
NOTE
The ones are only shown for a moment when the air distrib-
utor changes position, zeros are shown when the air distrib-
M utor is not changing position.
000139
0V
Pause heater, description

page
–
1 Pause heating is an option for the heating unit, which uses residual
heat in the engine's cooling system to keep the cab warm.
An extra electrically operated water pump pumps the coolant through
the heater unit when the engine is stopped. The cabin fan forces air
into the cab. The pause heater is automatically switched off when the
temperature in the cab is six degrees below the value set on the cli-
mate control system. The pause heater is activated with the pause
heater switch when the ignition is on.
3 2
004909
1. Switch, pause heater (S0_OPT-1)

2. Control unit cab (D790-1)
3. Circulation pump, pause heater (M667)

32 9 Frame, body, cab and accessories – 9.4.1 Fresh air filter
9.4.1 Fresh air filter

Fresh air filter, description
page
–
The fresh air filter is located under a cover in the external unit for fresh
air intake into the cab - in front of the cab fan. A finer filter can be used
( ), but the maximum airflow may be affected.
2
003208
Fresh air intake, cab

1. Fresh air filter
2. Fresh air and recirculation damper

9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper 33
9.4.2 Fresh air and recirculation damper

Fresh air filter or recirculation damper, description
page
–
The damper is controlled electrically and controls the air between fully
open for fresh air to recirculation of air. The damper is located in the
external unit for fresh air intake into the cab.
Control system , group 8.4.4.6 CLIMATE, menu 6.
2
003208

1. Fresh air filter
2. Fresh air and recirculation damper

34 9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper
Motor, fresh air filter or recirculation damper,

page
–
replacement
2 Remove the wiper arms.
3 Remove the nuts which hold the wiper motor in the protective
plate.
4 Remove the protective plate.
5 Remove the fresh air filter.

9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper 35
6 Remove the bolts which secure the arm and motor in the plate.
7 Detach the connector from the motor.
8 Replace the motor.
9 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.

36 9 Frame, body, cab and accessories – 9.4.3 Cab fan
9.4.3 Cab fan

Cab fan, description
page
–
The cab fan is located in the external unit for fresh air intake into the
cab. The fan consists of two single fans that are driven by a motor.
Control system , group 8.4.4.6 CLIMATE, menu 6.
1
003209

1. Cab fan
Cab fan, replacement

page
–


9 Frame, body, cab and accessories – 9.4.3 Cab fan 37
3 Remove the bolts which secure the wiper motor in the protective
plate.
5 Detach the washer hose from the protective plate.

38 9 Frame, body, cab and accessories – 9.4.3 Cab fan
7 Remove the bolts which secure the plate and cab fan.
8 Detach the connector from the cab fan.

9 Remove the cab fan.
10 Replace the cab fan.

9 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat 39
9.4.4 Heat exchanger heat

Heat exchanger heat, description
page
–
The heat from the engine’s coolant is transmitted to the cab via the
heat exchanger. The heat exchanger is located behind the fan in the
external unit for fresh air intake into the cab.
1, 2
3
003210

1. Heat exchanger heat
2. Heat exchanger cooling
3. Refrigerant expansion valve and temperature
sensor

40 9 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat
Heat exchanger, cooling/heating, replacement

page
–
WARN IN G
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see sec-

tion B Safety.

2 Drain the AC system of R134a refrigerant.
I M P OR TA NT
Working on the air conditioning requires special au-
thorisation.
3 Detach the AC system hoses and the coolant hoses.

5 Remove the nuts which hold the wiper motor in the protective
plate.

9 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat 41
9 Remove the plate frame.
10 Remove the cab fan.
11 Remove the heat exchanger cover plate.

42 9 Frame, body, cab and accessories – 9.4.5 Water valve
12 Detach all fluid inlets and outlets from the heat exchanger.
13 Lift out the heat exchanger carefully.
14 Replace the heat exchanger.
16 Check for leaks and refill the AC-system with refrigerant R134a,
with the intended equipment.
For volume, see section F Technical data.
I M P OR TA NT
thorisation.
9.4.5 Water valve

Water valve, description
page
–
The water valve controls the climate control system’s capacity for
heating from 0 (closed valve) to 100% (open valve). The water valve
is electrically controlled.
The signal can be checked from the diagnostic menu, see 8 Control
system , group 8.4.4.1 CLIMATE, menu 1 , 8.4.4.4 CLIMATE, menu 4
and 8.4.4.7 CLIMATE, menu 7.
002229
Water valve position under cab floor (from below)

9 Frame, body, cab and accessories – 9.4.6 Engine temperature sensor 43
Water valve, replacement

page
–

2 Detach the connector from the water valve.
3 Stop the flow of fluid to and from the water valve using hose
pinch-off pliers.
4 Detach the coolant hoses from the water valve.
5 Remove the water valve from the cab floor.
6 Replace the water valve.
8 Check coolant level.
1. Water valve
2. Steering valve
9.4.6 Engine temperature sensor

Sensor, engine temperature, description
page
–
The coolant temperature sensor sits on the engine and detects engine
coolant temperature. See supplier documentation, engine.
8 Control system , group 8.4.4.2 CLIMATE, menu 2.
For location, see section 1 Engine.
9.4.7 Compressor
Compressor air conditioning, description (engine
page
–
alternative Volvo)
The compressor drives the climate control system by working as a

pump. It draws in cold, low-pressure gas from the evaporator, com-
presses the gas which then becomes warm, and then forces out high-
pressure gas to the condenser.
The compressor is driven by V-belts directly by the machine’s engine.
Activation and deactivation of the compressor is handled by an elec-
tromagnetic clutch, which is controlled by a thermostat.
001242

44 9 Frame, body, cab and accessories – 9.4.7 Compressor
Compressor, replacement (engine alternative Volvo)

page
–
WARN IN G

tion B Safety.

I M P OR TA NT
thorisation.
3 Detach the coolant hoses from the compressor.

4 Loosen the belt tensioner so that the compressor belt is released.
5 Remove the bolts which secure the compressor.
1. Alternator, belt tensioner 6 Replace the compressor.
2. Compressor
I M P OR TA NT
thorisation.

9 Frame, body, cab and accessories – 9.4.7 Compressor 45
Compressor air conditioning, description (engine

page
–
alternative Cummins QSM11)
The compressor drives the climate control system by working as a

pump. It draws in cold, low-pressure gas from the evaporator, com-
presses the gas which then becomes warm, and then forces out high-
pressure gas to the condenser.
1
The compressor is driven by V-belts directly by the machine’s engine.
Activation and deactivation of the compressor is handled by an elec-
tromagnetic clutch, which is controlled by a thermostat.
2 The signal can be checked from the diagnostic menu, see section
005000
1. Compressor air conditioning

2. Turnbuckle
Compressor, replacement (engine alternative

page
–
Cummins QSM11)
WARN IN G
1 Read the safety instructions for refrigerant, see sec-
tion B Safety.
2 1 Machine in service position, see section B Safety.

005000
1. Compressor air conditioning

2. Turnbuckle I M P OR TA NT
thorisation.
3 Detach the coolant hoses from the compressor.

4 Loosen the turnbuckle so that the compressor belt is released.
5 Remove the bolts which secure the compressor.
6 Replace the compressor.

46 9 Frame, body, cab and accessories – 9.4.8 Condenser
I M P OR TA NT
thorisation.
9.4.8 Condenser
Condenser, description
page
–
The condenser is located on the radiator in the engine compartment.

The function of the condenser is to convert the hot, high-pressure gas
from the compressor to liquid form. Pipes and cooling fins in the con-
denser battery absorb the heat, which is dissipated with a fan.
The temperature of the refrigerant in the condenser varies from ap-
prox. 50 °C to 70 °C and the pressure varies between 12 and 14 bar
depending on ambient temperature and airflow through the condens-
er. When the refrigerant has been condensed to liquid, it is directed on
to the fluid reservoir/filter dryer.
002228

9 Frame, body, cab and accessories – 9.4.8 Condenser 47
Condenser, replacement
page
–
WARN IN G

tion B Safety.
1. Radiator 2 Drain the AC system of R134a refrigerant.

2. Condenser
I M P OR TA NT
thorisation.
3 Detach the inlet and outlet hoses from the condenser.

4 Remove the bolts which secure the condenser at the top edge
and lift the condenser out in a suitable way.
5 Replace the condenser, fitting it in the reverse order.
I M P OR TA NT
thorisation.

48 9 Frame, body, cab and accessories – 9.4.9 Moisture filter
9.4.9 Moisture filter

Moisture filter, description
page
–
The moisture filter collects the liquid refrigerant, binds moisture and fil-
ters impurities. The reservoir functions as an expansion tank in the
1 2 cooling circuit.
When the refrigerant has passed through the dryer in the bottom of the
fluid reservoir, it rises through a standpipe. Through a sight glass, it is
possible to check that flow is without bubbles and that the system is
adequately filled with refrigerant.
002227
1. Fluid reservoir, moisture filter

2. Pressure switch
9.4.10 Pressure switch

Pressure switch, description
page
–
The pressure switch cuts off the current to the compressor’s electro-
magnetic clutch if the pressure in the cooling circuit becomes abnor-
1 2 mally high or low.
002227
1. Fluid reservoir, moisture filter

2. Pressure switch

9 Frame, body, cab and accessories – 9.4.11 Expansion valve 49
Pressure switch, replacement

page
–
WARN IN G
1 2 Personal injury, environmental damage.

tion B Safety.

2 Drain the machine of refrigerant, R134a.
I M P OR TA NT
thorisation.
002227
3 Disconnect the connector from the pressure switch.

1. Fluid reservoir, moisture filter. 4 Unscrew the pressure switch from its mounting.
2. Pressure switch.
5 Replace the pressure switch.
I M P OR TA NT
thorisation.
9.4.11 Expansion valve

Expansion valve, description
page
–
The expansion valve is the part in the circuit that separates the high-
pressure side from the low-pressure side. The refrigerant arrives at the
expansion valve under high pressure and leaves it under low pres-
sure. After the expansion valve, the refrigerant converts to a gaseous
state and is transported to the compressor once again.
The amount of refrigerant that passes the evaporator varies depend-
ing on the heat load. The valve works from fully open to fully closed
and searches between these for an optimal evaporation point.

50 9 Frame, body, cab and accessories – 9.4.11 Expansion valve
Expansion valve, replacement

page
–
WARN IN G

tion B Safety.

2 Drain the AC system of refrigerant.
I M P OR TA NT
thorisation.
3 Detach the AC system hoses.

4 Detach the coolant hoses.
5 Remove the heat exchanger for cooling/heating to access the ex-
pansion valve, see Heat exchanger, cooling/heating, replace-
ment page 40.
6 Replace the expansion valve.
I M P OR TA NT
thorisation.

9 Frame, body, cab and accessories – 9.4.12 Sensor temperature refrigerant 51
9.4.12 Sensor temperature refrigerant

Sensor temperature refrigerant, description
page
–
Refrigerant temperature sensor (position 2) detects the refrigerant

temperature in the heat exchanger cooling. This is used to control the
air conditioning.
1
3
002226
2
1. Sensor cab temperature

2. Sensor temperature refrigerant
3. Sensor temperature outlet fan
Sensor, refrigerant temperature, replacement

page
–
WARN IN G

tion B Safety.
NOTE
Requires special authorisation.
2 Drain the AC system of refrigerant.
I M P OR TA NT
thorisation.
3 Detach the AC system hoses from the heat exchanger.

4 Detach the coolant hoses from the heat exchanger.
5 Detach the heat exchanger to access the refrigerant temperature
sensor, see Heat exchanger, cooling/heating, replacement page
40.
6 Replace the temperature sensor.

52 9 Frame, body, cab and accessories – 9.4.13 Heat exchanger cooling
I M P OR TA NT
thorisation.
9.4.13 Heat exchanger cooling

Evaporator, description
page
–
The heat exchanger for cooling consists of pipes and cooling fins. The
cab air is cooled as it passes through the cooling heat exchanger. The
heat exchanger is located behind the fan in the external unit for fresh
air intake into the cab.
1, 2
3
003210

1. Heat exchanger heat
2. Heat exchanger cooling
3. Refrigerant expansion valve and temperature
sensor

9 Frame, body, cab and accessories – 9.4.14 Air distributor 53
Heat exchanger cooling, replacement

page
–
See Heat exchanger, cooling/heating, replacement page 40.
9.4.14 Air distributor

Air distributor, description
page
–
The air distributor controls the air between defroster and floor and is
located behind the panel inside the cab. The damper is controlled elec-
trically by the control system.
8 Control system , group 8.4.4.4 CLIMATE, menu 4 and 8.4.4.5 CLI-
MATE, menu 5 and 8.4.4.8 CLIMATE, menu 8.
002230
Air distributor, replacement

page
–

3 Remove the steering wheel shaft cover.
4 Detach the steering wheel shaft and angle it back against the op-
erator’s seat.
5 Remove the lower cover in front of the pedal bracket.
6 Detach the air hoses from the air distributor and detach the
connector.
1. Instrument panel
2. Steering column adjustment
3. Lower protective cover
7 Remove the air distributor from its mounting.
8 Replace the air distributor, fitting it in the reverse order.
Air distributor

54 9 Frame, body, cab and accessories – 9.4.15 Air vents
9.4.15 Air vents

Air vents, description
page
–
There are a number of fixed air vents in the cab’s interior: at the front
of the doors and the defroster for the windscreen. There are also two
adjustable air vents (flow and direction) in the instrument panel’s out-
side corners.
There is an air inlet towards the cab’s lower part (floor).
001839
Defroster nozzles, replacement

page
–

2 Remove the air damper manually.
3 Remove the bolts which hold the other part of the defroster noz-
zle in the dashboard.

9 Frame, body, cab and accessories – 9.4.16 Sensor temperature outlet fan 55
4 Detach the air hose from the defroster nozzle.

5 Replace the defroster nozzle.
9.4.16 Sensor temperature outlet fan

Sensor, temperature outlet fan, description
page
–
The outlet fan temperature sensor (position 3) detects the temperature

of the air that blows out in the defroster nozzles. The air conditioning
is controlled by signals from the following sensors:
1 3. Sensor temperature outlet fan
3 The signal can be checked from the diagnostic menu, see section
002226
Outlet fan temperature sensor, replacement

page
–

3 Remove the lower protective cover in front of the steering wheel
shaft.
4 Detach the steering wheel shaft and angle it back against the op-
erator’s seat.
1. Instrument panel
2. Steering column adjustment
3. Lower protective cover

56 9 Frame, body, cab and accessories – 9.4.17 Sensor cab temperature
5 Detach the temperature sensor from the air distributor.

Air distributor including temperature sensor.
9.4.17 Sensor cab temperature

Sensor, cab temperature, description
page
–
The cab temperature sensor (position 1) detects the temperature of

the air in the cab.
1
3
002226

3. Sensor temperature outlet fan
Cab temperature sensor, replacement

page
–


9 Frame, body, cab and accessories – 9.4.18 Sensor outdoor temperature 57
3 Detach the hose from the temperature sensor.

4 Detach the connector from the temperature sensor.
5 Remove the temperature sensor.
9.4.18 Sensor outdoor temperature

Sensor, ambient temperature, description
page
–
The ambient temperature sensor detects the temperature of the air

outside the cab.
Sensor outdoor temperature
Ambient temperature sensor, replacement

page
–

2 Detach the connector from the temperature sensor.
3 Remove the temperature sensor from its mounting in the cab.

58 9 Frame, body, cab and accessories – 9.5 Wiper/washer system
9.5 Wiper/washer system

9.5.1 Wiper front
Wiper, front, description
page
–
The front wiper is the parallel wiper type, i.e. the wiper blade is moved
in a constant vertical manner over the windscreen.
9.5.2 Wiper roof

Wiper, roof, description
page
–
Wiper roof are of the type sector wiper. Wiping angle is approx. 180
degrees.
9.5.3 Wiper rear

Wiper, rear, description
page
–
The rear wiper is a sector wiper type. The wiping angle is approx.
180 degrees.
9.5.4 Washer motor and reservoir

Washer motor and reservoir, description
page
–
Washer motors are located on the washer fluid reservoir. There are
non-return valves on the lines from the reservoir to the washer noz-
zles, preventing the washer fluid from draining back in the line be-
tween washings. This minimises the time from activation of switch
washing and washer fluid spraying on the windscreen.
The washer nozzles are mounted on the wiper arms.
8 Control system , group 8.4.3.1 CAB, menu 1.
004924

9 Frame, body, cab and accessories – 9.5.5 Wiper motor, front 59
Washer motor and container, replacement

page
–

2 Remove the protection over the washer fluid reservoir.
3 Drain the washer fluid from the container.
4 Remove the washer motors from the fluid reservoir.
5 Remove the bolts which secure the fluid container in the cab wall.
6 Change the washer fluid reservoir. Change the washer motor, if
needed.
003619
A B
Washer fluid reservoir without protective plate.
A. Washer fluid reservoir
B. Washer motors
9.5.5 Wiper motor, front

Wiper motor, front, description
page
–
The wiper motor drives the front windscreen wiper. The wiper arm is
mounted on the motor. The motor produces the movement of the
wiper.
Front wiper motor, replacement

page
–

3 Remove the nuts which hold the motor in the protective plate.

60 9 Frame, body, cab and accessories – 9.5.6 Wiper motor, roof
6 Remove the nuts which hold the motor in the cab.

7 Detach the connector from the wiper motor.
8 Replace the motor.
9 Fit in the reverse order. Tighten the wiper arms to 16-20 Nm.
9.5.6 Wiper motor, roof

Wiper motor, roof, description
page
–
The wiper motor drives the roof window’s wiper. The wiper arm is
wiper.
Wiper motor (roof), replacement

page
–

2 Remove the plastic cover.
3 Detach the washer hose and the connector to the wiper motor.

9 Frame, body, cab and accessories – 9.5.7 Wiper motor, rear 61
4 Undo the lock nut securing the wiper arm and disconnect the
washer fluid hose.
5 Remove and replace the wiper motor.
9.5.7 Wiper motor, rear

Wiper motor, rear, description
page
–
The wiper motor drives the rear window wiper. The wiper arm is
wiper.
Rear wiper motor, replacement

page
–

2 Remove the panels behind the operator’s seat.
3 Remove the screws holding the motor’s plastic cover.
4 Detach the connector from the motor.

5 Raise the plastic cover and remove the nut securing the wiper
arm. Disconnect the washer hose.

62 9 Frame, body, cab and accessories – 9.5.7 Wiper motor, rear
6 Remove the screws securing the motor and the lock nut on the
motor.
7 Replace the wiper motor.
8 Fit in the reverse order. Tighten the wiper arms to 16-20 Nm.

9 Frame, body, cab and accessories – 9.6 Lighting system 63
9.6 Lighting system

Lighting system, function description
page
–
The lights are shut off automatically after 5 minute’s idling in order to
prevent discharge of the batteries. Extra working lights are shut off af-
ter 2 minutes. Lighting is activated automatically again when the oper-
ator sits in the seat, a gear is selected or the accelerator pedal is
pressed.
NOTE
It is important that the right type of bulb is used for each area. See
1 2 3 5 4
D4
D5
D1 D3 8
D2 9
14 10
D9
6 D6 15 D8
D17
D16 17 13 D10
16 M D13
D790-1 D790-2
26 7, 12 19 11 33
D32 D27 D797-R D797-F D791-1
D31 18 D18 D22 D23
Pa D34 D35
D29
24
D30 D21 34
32 D28 35
007417
D20 25
27 28 29 30 31 20 21 22 23

1 The switch for cab working lights (S105-1) Switch in ON position: U D1: Diagnostic menu, see section 8
sends a voltage signal to the cab control unit = 24 V Control system group 8.4.2.1 LIGHTS,
(D790-1). menu 1
2 The switch for attachment work lights (S105-2) Switch in ON position: U D2: Diagnostic menu, see section 8
(D790-1). menu 2
3 The switch for boom working lights (S105-3) Switch in ON position: U D3: Diagnostic menu, see section 8
(D790-1). menu 3
4 The headlights switch (S100) sends a voltage Switch in ON position: U D4: Diagnostic menu, see section 8
signal to the cab control unit (D790-1). = 24 V Control system group 8.4.2.4 LIGHTS,
menu 4
5 The revolving beacon switch (S110) sends a Switch in ON position: U D5: Diagnostic menu, see section 8
voltage signal to the cab control unit (D790-1). = 24 V Control system , group 8.4.2.9
LIGHTS, menu 9

64 9 Frame, body, cab and accessories – 9.6 Lighting system
6 The door NC switch (S226-LE & S226-RI) Door open: U = 24 V Interior lighting cab, description page
sends a voltage signal to the cab control unit 72
(D790-1). D6: Diagnostic menu, see section 8
Control system group 8.4.2.12
LIGHTS, menu 12
7 The cab control unit (D790-1) transmits a Checked by control sys- Section 11 Common electrics, group
"switch on lights" message on the CAN bus. tem, error shown with 11.5.3.1 Cab control unit
error code.
8 The multi-function lever (S162) sends a volt- Lever in high beam posi- Gear and multi-function lever, descrip-
age signal to the KIT control unit (D790-2). tion: US162/56a = 24 V tion page 12
Control system group 8.4.2.6 LIGHTS,
menu 6
9 The direction indicator lever (S161) sends a Left: US161/6 = 24 V D9: Diagnostic menu, see section 8
voltage signal to the KIT control unit (D790-2). Control system group 8.4.2.7 LIGHTS,
Right: US161/1 = 24 V
menu 7
10 The interior lighting switch of the KIT control Checked by control sys- D10: Diagnostic menu, see section 8
unit (D790-2) sends a voltage signal to the KIT tem, error shown with Control system group 8.4.2.12
control unit (D790-2). error code. LIGHTS, menu 12
11 The KIT control unit (D790-2) transmits a Checked by control sys- Section 11 Common electrics, group
"switch on lights" message on the CAN bus. tem, error shown with 11.5.3.11 Control unit KIT
error code.
12 The cab control unit (D790-1) supplies voltage Checked by control sys- Section 11 Common electrics, group
to the lights in and around the cab. tem, error shown with 11.5.3.1 Cab control unit
error code.
13 The cab working lights (E404-1L & E404-1R) Light on: U = 24 V Working lights, cab, description page
are switched on when the cab working lights 70
are activated. D13: Diagnostic menu, see section 8
menu 1
14 Relay extra working lights boom (K304) is acti- UK304/30 = 24 V Working lights, boom, lights page 71
vated when the boom working lights are acti-
UK304/85 = 0 V
vated and supplies voltage to the extra working
lights boom (E404-5L & E404-5R). Working lights boom
switched on:
UK304/86 = 24 V
UK304/87 = 24 V
Working lights boom

switched off:
UK304/86 = 0 V
UK304/87 = 0 V
15 Extra working lights boom (E404-5L & E404- Light on: U = 24 V Working lights, boom, lights page 71
5R) are switched on when boom working lights
are activated.

16 Rotating beacon (H428) is lit when rotating Light on: U = 24 V Revolving beacon, description page 70
work light is activated. D16: Diagnostic menu, see section 8
menu 9
17 Interior lighting comes on when a door is Light on: U = 24 V Interior lighting cab, description page
opened or if activated when the switch on the 72
KIT control unit (D790-2). D17: Diagnostic menu, see section 8
LIGHTS, menu 12
18 NO switch, brake lights (S216) sends a voltage Brake pressure over 0.2 Section 4 Brakes, group 4.3.8 NO
signal to Control unit, frame front (D797-F). MPa: U = 24 V (normally open) switch, brake lights
LIGHTS, menu 10
19 Control unit frame front (D797-F) supplies Checked by control sys- Section 11 Common electrics, group
power to the front lights on the machine. tem, error shown with 11.5.3.2 Control unit, frame front
error code.
20 The front direction indicators (H422 & H423) Light on: U = 24 V Driving direction indicator, description
come on when they or the warning lights are page 69
activated. D20: Diagnostic menu, see section 8
menu 8
21 The front running lights (H416-1 & H417-1) Light on: U = 24 V Running lights, description page 68
come on together with the headlights. D21: Diagnostic menu, see section 8
menu 5
22 Headlights low beams (E400L & E400R) are lit Light on: U = 24 V Headlights, description page 68
when headlights are activated. D22: Diagnostic menu, see section 8
menu 6
23 Headlights high beam (E402L & E402R) are lit Light on: U = 24 V Headlights, description page 68
when high beam is activated. D23: Diagnostic menu, see section 8
menu 6
24 Extra working lights front (E404-7L & E404- Light on: U = 24 V

7R) are switched on at the same time as high
beam.
25 Extra working lights front (E404-8L & E404- Light on: U = 24 V

8R) are switched on at the same time as high
beam.
26 Control unit frame rear (D797-R) supplies pow- Checked by control sys- Section 11 Common electrics, group
er to the rear lights on the machine. tem, error shown with 11.5.3.3 Control unit, frame rear
error code.

66 9 Frame, body, cab and accessories – 9.6 Lighting system
27 Tail lights (H412L & H412R) red are lit when Light on: U = 24 V Tail light, description page 68
headlights are activated. D27: Diagnostic menu, see section 8
menu 5
28 Brake lights (H411L & H411R) are lit when the Light on: U = 24 V Brake light, description page 69
brake is activated. D28: Diagnostic menu, see section 8
LIGHTS, menu 11
29 The rear direction indicators (H426 & H427) Light on: U = 24 V Driving direction indicator, description
come on when they or the warning lights are page 69
activated. D29: Diagnostic menu, see section 8
menu 8
30 The rear running lights (H416-2 & H417-2) are Light on: U = 24 V Running lights, description page 68
switched on when the headlights are activated. D30: Diagnostic menu, see section 8
menu 5
31 The white reversing lights (E405L & E405R) Light on: U = 24 V Reversing light, description page 69
come on when reverse gear is selected. D31: Diagnostic menu, see section 8
Control system , group 8.4.2.11
LIGHTS, menu 11
32 Working lights boom (E404-3L & E404-3R) are Light on: U = 24 V Working lights, boom, lights page 71
switched on when boom working lights are ac- D32: Diagnostic menu, see section 8
tivated. Control system group 8.4.2.3 LIGHTS,
menu 3
33 The attachment control unit (D791-1) supplies Checked by control sys- Section 11 Common electrics, group
voltage to the attachment’s lights. tem, error shown with 11.5.3.5 Control unit, attachment
error code.
34 Working lights attachment (E406-L & E406R) Light on: U = 24 V Attachment work lights, description
are switched on when the attachment’s work- page 72
ing lights are activated. D34: Diagnostic menu, see section 8
menu 2
35 Extra working lights attachment (E404-4L & Light on: U = 24 V Attachment work lights, description
E404-4R) are switched on when the attach- page 72
ment’s working lights are activated. D35: Diagnostic menu, see section 8
menu 2

Lighting system, component positions

page
–
The purpose of lighting is to increase safety during operation and load

handling. The machine has the following lights:
NOTE
1 2 3 4 5 6 7 8
21, 22, 23, 24
006426
20 18, 19 17 16 15 14 13, 12, 11 10 9
1. Rotating beacon (H428) 13. Headlights, low beam (E400L & E400R)
Headlights, high beam (E402L & E402R)
2. Interior lighting 14. NO switch, brake lights (S216)
3. Control unit KIT (D790-2) 15. Control unit, frame front (D797-F)
4. Multi-function lever (S162) 16. Switch, see section 9 Frame, body, cab and accessories,
group 9.1 Controls and instruments
5. Cab working lights (E404-1L & E404-1R) 17. Door NC (normally closed) switch (S226-LE & S226-RI)
6. 18. Control unit cab (D790-1)
Extra working lights boom (E404-5L & E404-5R)
7. Working lights boom (E404-3L & E404-3R) 19.
Relay extra working lights boom (K304)
8. Attachment control unit (D791-1) 20. Control unit, frame rear (D797-R)
9. Working lights attachment (E406-L & E406R) 21. Rear running lights (H416-2 & H417-2)
Extra working lights attachment (E404-4L & E404-4R)
10. Extra working lights front (E404-7L, E404-8L, E404-7R & 22. Reversing lights (E405L & E405R), white
E404-8R)
11. Direction indicators front (H422 & H423) 23. Tail lights (H421L & H412R), red
Brake lights (H411L & H411R)
12. Front running lights (H416-1 & H417-1) 24. Direction indicators rear (H426 & H427)

68 9 Frame, body, cab and accessories – 9.6.1 Headlights
9.6.1 Headlights
Headlights, description
page
–
Headlights are located in the front of the machine to give the operator
enhanced vision when operating in darkness, and to provide surround-
ing traffic and the environment an indication of the machine’s position.
Headlights have high beam and low beam (for meeting other traffic).
Switch between low and high beam with the gear and multi-function le-
ver. The signal goes to the cab control unit (D790-1).
The low and high beam signals can be checked from the diagnostic
menu, section 8 Control system , group 8.4.2.6 LIGHTS, menu 6.
9.6.2 Running light

Running lights, description
page
–
The running lights are located on the right and left-hand sides of the
machine to provide surrounding traffic and the environment an indica-
tion of the machine’s position and direction of travel.
The running lights are controlled by selecting with the headlight switch.
The signal travels to the cab control unit (D790-1).
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.5 LIGHTS, menu 5.
As an option the machine can be equipped with running lights of the

LED type. These are replaced as a complete unit.
9.6.3 Tail light

Tail light, description
page
–
Tail lights are located in the rear of the machine to provide surrounding
traffic and the environment an indication of the machine’s position, and
a limited enhancement of the view for the operator in darkness.
The tail lights are controlled by selecting with the headlight switch. The
signal travels to the cab control unit (D790-1).
As an option the machine can be equipped with combined direction in-

dicators rear and brake lights of the LED type. These are replaced as
a complete unit.

9 Frame, body, cab and accessories – 9.6.4 Brake light 69
9.6.4 Brake light

Brake light, description
page
–
The brake lights are located in the rear of the machine to provide sur-
rounding traffic and the environment an indication that the machine is
braking and consequently slowing down.
The brake lights are regulated by brake pedal position (via actuated
NC switch). The signal travels to the front frame control unit (D797-F),
which supplies power to the brake lights.

a complete unit.
9.6.5 Reversing light

Reversing light, description
page
–
The reversing lights are located in the rear of the machine to provide
surrounding traffic and the environment an indication that the machine
is travelling backwards. In addition, this provides the operator en-
hanced view when operating in darkness.
Reversing lights are controlled by the selected travel direction with the
gear selector and multi-function lever (S162) that sends a voltage sig-
nal to the KIT control unit (D790-2).
The reversing lights are supplied voltage by Control unit, frame rear
(D797-R).
9.6.6 Driving direction indicator

Driving direction indicator, description
page
–
The direction indicators are located on both the front and rear of the
machine to provide surrounding traffic and the environment an indica-
tion that the machine is changing direction, i.e. turning.
The direction indicators are controlled by selecting with the switch for
direction indicators (S161) that sends a voltage signal to the KIT con-
trol unit (D790-2).
The direction indicators are supplied voltage by Control unit, frame
front (D797-F) and Control unit, frame rear (D797-R).

a complete unit.

70 9 Frame, body, cab and accessories – 9.6.7 Flashing hazard lights
9.6.7 Flashing hazard lights

Hazard lights, description
page
–
Hazard lights (hazard) are used to warn the surroundings, hazard

lights activate all direction indicators at the same time.
The flashing hazard lights are controlled by selecting with the switch
for flashing hazard lights. The signal travels to the control unit
(D790-2).
Control system , group 8.4.2.8 LIGHTS, menu 8.
Machines for the North American market are equipped with flashing
brake lights front and rear during operation.
9.6.8 Revolving beacon

Revolving beacon, description
page
–
A rotating beacon is located at a high level on the machine’s boom

(rear section). This is used to provide surrounding traffic and the envi-
ronment an indication that a working vehicle is moving and at work. An
indication to bystanders to exercise caution.
The rotating beacon is controlled by selecting with the rotating beacon
switch. The signal travels to the cab control unit (D790-1).
9.6.9 Working lights, cab

Working lights, cab, description
page
–
Work lights on the cab provide visibility when handling a load in dark-
ness.
The work lights are controlled by selecting with the switch for cab roof
work lights. The signal travels to the cab control unit (D790-1) which in
turn supplies power to the work lights.

9 Frame, body, cab and accessories – 9.6.10 Working lights, boom 71
Work lights, changing (product alternative Xenon

page
–
lights)
D ANGER
Xenon lights are activated with high voltage. Always
turn off the main electric power before working on xe-
non lights.
Handle the headlights with care since the light is un-
der gas pressure and may explode.
NOTE
The xenon light is filled with different gases and metals. Replaced
xenon headlights should be considered as hazardous waste and
should be deposited for recycling.
9.6.10 Working lights, boom

Working lights, boom, lights
page
–
Working lights on the boom provide increased visibility when handling

a load in darkness.
The working lights are controlled by selecting with the switch for boom
working lights. The signal travels to the cab control unit (D790-1).
The lifting boom can be equipped with two extra working lights ( ).

page
–
lights)
See Work lights, changing (product alternative Xenon lights) page 71.

72 9 Frame, body, cab and accessories – 9.6.11 Work lights, attachment
9.6.11 Work lights, attachment

Attachment work lights, description
page
–
Work lights on the attachment provide enhanced view when load han-
dling in darkness.
The work lights are controlled by selecting with the attachment work
light switch. The signal travels to the cab control unit (D790-1).
The attachment can be equipped with two extra working lights ( ).

page
–
lights)
See Work lights, changing (product alternative Xenon lights) page 71.
9.6.12 Interior lighting

Interior lighting cab, description
page
–
The interior lighting illuminates the cab when the doors are opened or
when activated with the interior lighting switch.
There is background illumination in all switches, function keys and ro-
tary controls. This is so that the driver will be able to read their func-
tions and settings in darkness. Brightness is controlled by the plus and
minus keys.

9 Frame, body, cab and accessories – 9.7 Signalling system 73
9.7 Signalling system

Signalling system, function description
page
–
NOTE
1 2 3
D2 5
D1 D3 6
18
16
17 D6
D18 D19 D5
D14 19
14
15 M
7 20
D15 D790-1 4 D790-2 D795
8
D797-R D797-F D791-1
D9 D10 12 21
9 10 D11 D13 D22
13 22
11
007418
Pos Description Signal description Reference
1 The revolving beacon switch Switch in ON position: U = D1: Diagnostic menu, see section 8 Control
(S110) sends a voltage signal to 24 V system group 8.4.2.9 LIGHTS, menu 9
the cab control unit (D790-1).
2 The switch for warning lights (haz- Switch in ON position: U = D2: Diagnostic menu, see section 8 Control
ard) (S109) sends a voltage signal 24 V system group 8.4.2.8 LIGHTS, menu 8
to the cab control unit (D790-1).
3 The parking brake switch (S107) Switch in ON position: U = D3: Diagnostic menu, see section 8 Control
sends a voltage signal to the cab 24 V system group 8.4.5.4 HYD, menu 4
4 The cab control unit (D790-1) Checked by control system, Section 11 Common electrics, group 11.5.3.1
transmits activation messages on error shown with error code. Cab control unit
the CAN bus
5 The multi-function lever (S162) Signal button pressed in: Gear and multi-function lever, description
sends a voltage signal to the KIT US162/H = 24 V page 12
control unit (D790-2). D5: Diagnostic menu, see section 8 Control
system , group 8.4.3.5 CAB, menu 5
6 The direction indicator lever (S161) Left: US161/6 = 24 V D6: Diagnostic menu, see section 8 Control
sends a voltage signal to the KIT system group 8.4.2.7 LIGHTS, menu 7
Right: US161/1 = 24 V

74 9 Frame, body, cab and accessories – 9.7 Signalling system

7 The KIT control unit (D790-2) trans- Checked by control system, Section 11 Common electrics, group
mits activation messages on the error shown with error code. 11.5.3.11 Control unit KIT
CAN bus.
8 Control unit frame rear (D797-R) Checked by control system, Section 11 Common electrics, group 11.5.3.3
supplies power to the rear lights error shown with error code. Control unit, frame rear
and buzzer on the machine.
9 The rear direction indicators (H426 Light on: U = 24 V Driving direction indicator, description page
& H427) come on when the warning 69
lights are activated. D9: Diagnostic menu, see section 8 Control
system group 8.4.2.8 LIGHTS, menu 8
10 The reversing lights (E405L & Light on: U = 24 V Reversing light, description page 69
E405R) come on when reverse D10: Diagnostic menu, see section 8 Control
gear is selected. system group 8.4.2.11 LIGHTS, menu 11
11 Back-up alarm (H965) is activated Reverse gear engaged: U = Reverse alarm, description page 76
when reverse gear is selected. 24 V D11: Diagnostic menu, see section 8 Control
12 Control unit frame front (D797-F) Checked by control system, Section 11 Common electrics, group 11.5.3.2
supplies power to the front lights on error shown with error code. Control unit, frame front
the machine.
13 The front direction indicators (H422 Light on: U = 24 V Driving direction indicator, description page
& H423) come on when they are 69
activated. D13: Diagnostic menu, see section 8 Control
14 Horn (H850) sounds when the horn Horn active: U = 24 V Horn, description page 76
is activated. D14: Diagnostic menu, see section 8 Control
system , group 8.4.3.5 CAB, menu 5
15 Rotating beacon (H428) is lit when Light on: U = 24 V Revolving beacon, description page 76
hazard lights are activated. S15: Diagnostic menu, see section 8 Control
system , group 8.4.2.9 LIGHTS, menu 9
16 Relay loud horn (K3016) is activat- UK3016/30 = 24 V Horn, description page 76

ed when horn is activated.
UK3016/85 = 0 V
Horn activated:
UK3016/86 = 24 V
UK3016/87 = 24 V
17 Loud horn (H850-1) sounds when Horn active: U = 24 V Horn, description page 76
the horn is activated.
18 The operator-in-seat NO switch Operator in seat: U = 24 V Sensor operator in seat, description page 23
(S230) sends a voltage signal to D18: Diagnostic menu, see section 8 Control
the cab control unit (D790-1) when system group 8.4.3.6 CAB, menu 6
there is a load on the operator’s
seat.

9 Frame, body, cab and accessories – 9.7 Signalling system 75

19 In the event of warnings, the cab Checked by control system, D19: Diagnostic menu, see section 8 Control
buzzer (H853) is supplied voltage error shown with error code. system , group 8.4.3.6 CAB, menu 6
by the KIT control unit (D790-2) to
draw the operator’s attention to the
warning message.
20 In the event of warnings, the KID A clicking sound is audible Section 11 Common electrics, group
control unit (D795) activates the when then termination resis- 11.5.3.12 KID control unit
warning light to draw the operator’s tor is activated.
attention to the warning message.
21 The attachment control unit (D791- Checked by control system, Section 11 Common electrics, group 11.5.3.5
1) supplies voltage to the automatic error shown with error code. Control unit, attachment
spreading buzzer during automatic
spreading.
22 The automatic spreading buzzer Buzzer active: U = 24 V Section 7 Load handling group 7.5.13 Buzz-
(H9003) is activated when auto- er, automatic spreading 20’-40’
matic spreading 20'-40' is D22: Diagnostic menu, see section 8 Control
activated. system , group 8.4.9.15 ATTACH, menu 15
Signalling system, component position

page
–
1 2 3 4 5
16, 17
6
006427
15 13, 14 12 11 10 9 8 7
1. Rotating beacon (H428) 10. Switch, see section 9 Frame, body, cab and accesso-
2. Control unit KIT (D790-2) ries, group 9.1 Controls and instruments
3. Buzzer cab (H853) 11. Horn (H850)
4. Control unit KID (D795) 12. Make-contact operator in seat (S230)
5. Attachment control unit (D791-1) 13. Control unit cab (D790-1)
6. 14.
Automatic spreading buzzer (H9003) Relay loud horn (K3016)
7. Direction indicators front (H422 & H423) 15. Control unit, frame rear (D797-R)
8. Control unit, frame front (D797-F) 16. Direction indicators rear (H426 & H427)
9. 17. Back-up alarm (H965)
Loud horn (H850-1)

76 9 Frame, body, cab and accessories – 9.7.1 Horn
9.7.1 Horn
Horn, description
page
–
The horn is electromagnetic. Air horn can be selected ( ).

The horn is activated from the gear and multi-function lever. The horn
can also be activated with the switch for open twistlocks on the control
lever, when the attachment does not have contact with a container.
001247
The horn is located under the cab (the compressed air horn is located
in the rear edge of the cab roof).
Control system , group 8.4.3.5 CAB, menu 5..
As an option the machine can be equipped so that the twistlocks

button on the control lever controls the horn when there is no contact.
9.7.2 Flashing hazard lights

Hazard lights, description
page
–
See Hazard lights, description page 70.
9.7.3 Revolving beacon

Revolving beacon, description
page
–
See Revolving beacon, description page 70.
9.7.4 Warning parking brake

Warning parking brake, description
page
–
If the operator leaves the machine without applying the parking brake,
a buzzer sounds to alert the operator, i.e. to ensure the operator ap-
plies the parking brake.
A sensor in the operator’s seat (see Sensor operator in seat, descrip-
tion page 23) indicates to the control system if the operator leaves the
seat.
The buzzer is located in the steering wheel panel.
Control system , group 8.4.3.6 CAB, menu 6..
9.7.5 Reverse alarm

Reverse alarm, description
page
–
When reverse is selected, a warning sound and the back-up lights are
activated. This is to give others in traffic an indication that the machine
is reversing. Indication to bystanders to take caution.
Control system , group 8.4.2.11 LIGHTS, menu 11.

9 Frame, body, cab and accessories – 9.8 Entertainment and communication 77
9.8 Entertainment and

communication
Entertainment and communication, general
page
–
The machine is prepped with a connector for customer accessories,

see section 11 Common electrics, group 11.5.2.1 Electronic box, cab.
Entertainment and communication, repair

page
–
Repairs should be left to authorised personnel.

78 9 Frame, body, cab and accessories – 9.9 Glass/windows/mirrors
9.9 Glass/windows/mirrors
Glass/windows/mirrors, description
page
–
The windows are designed to both enclose the cab and provide the op-
C erator with a good view.
The windows on the Spirit Delta cab are made of tinted hardened
D
glass, except the roof window which is made of polycarbonate plastic.
As an option, the cab can be equipped with windows of laminated

glass.
The rearview mirrors are of the convex mirror type. There is an interior
rearview mirror on all machines.
001512
A E B
A. Side windows
B. Windscreen (front window)
C. Roof window
D. Rear window
E. Windscreen (front side window)
Silicone adhesive, handling advice

page
–
The window panes are secured with key adhesive and silicone adhe-
sive.
NOTE
The purpose of this instruction is to describe how silicone adhe-
sive 923854.0100 should be handled in connection with replace-
ment of the windscreen and roof window on the Spirit Delta cab.
• Silicone adhesive 923854.0100 is a quick-hardening, two-
component silicone adhesive that can withstand tempera-
tures between -50 °C and +200 °C. The hardening properties
of the adhesive are extremely dependent on the ambient
temperature. An increase of 10 °C cuts hardening time in
half.
Silicone adhesive 923854.0100 is mixed at a ratio of 1:10 in
a static mixer. Change mixer after every interruption that
lasts more than 5 minutes. The short setting time means that
work has to be planned carefully to avoid undesired harden-
ing.
Fixing time:
10-20 minutes at 20 °C
approx. 5 minutes at 60 °C
Hardening time:
approx. 24 hours at 20 °C
approx. 1 hour at 60 °C
Full strength is obtained after 7 days.

9 Frame, body, cab and accessories – 9.9.1 Windscreen 79
• In warm climates, it is advantageous to cool the container to

increase hardening time. The silicone adhesive should not
be used at temperatures above +75 °C.
• In cold climates, the hardening time can be shortened by
covering the joints so that cooling is prevented. The window
pane can be warmed with defroster or cab heater.
• The recommended storage temperature is between -30 °C
and +20 °C. Storage in a refrigerator or a colder environment
is recommended.
9.9.1 Windscreen
Windscreen, description
page
–
The windscreen consists of the front window and side windows. The
windscreen is attached to the cab with a key strip and is glued to the
roof window with silicone adhesive. Front and side windows are joined
with silicone adhesive to give good allround visibility from the opera-
tor’s station.
For location, see Glass/windows/mirrors, description page 78.
Windscreen, replacement
page
–
NOTE
Read the handling advice for silicone adhesive before starting
work. See Silicone adhesive, handling advice page 78.

2 Remove the key strip.
3 Remove the broken window pane and check that no glass or oth-
er particles remain in the window pane’s groove on the strip. Cut
apart silicone joints with a sharp tool.
NOTE
Make sure that no silicone adhesive remains between the
window pane and the strip by the window pane’s lower front
edge.
If the roof window is to be changed, then all bolts must be
removed before the silicone adhesive is cut away.
C AUTION
Figure 1: Removing key strip
Acetone may not come into contact with a roof win-
dow made of polycarbonate plastic. Acetone has a
chemical effect on the polycarbonate plastic which
reduces the roof window’s strength.
4 Clean all surfaces thoroughly. Remove old remains of silicone

with a razor blade or similar.

80 9 Frame, body, cab and accessories – 9.9.1 Windscreen
5 Fit masking tape on the inside and outside of the window panes
by the surfaces that are to be glued.
6 When the windscreen or a side window is to be changed, then the
1 2 3
window panes must be adjusted so that the upper edge on the
side window has the same height as the top edge of the roof (see
figure 2) and so that the distance between windscreen and side
window is as shown in figure 3.
Use spacers against the roof member to ensure that the distanc-
es are obtained.
006268
1,0
1
Figure 2: Adjusting side window - cab roof
1. Side window
2. Rubber strip
3. Cab frame/door opening
006269
1,0
Figure 3: Adjusting side window - windscreen

1. Masking tape
7 Install the key strip around the whole window pane.
8 Apply silicone adhesive 923854.0100 around the window panes.
Make the new joint wider than the old one to create a good seam.
The silicone should be applied from the outside of the joints, to
give a full and smooth joint.
NOTE
There must be silicone between the window panes, to avoid
contact between the window panes.

9 Frame, body, cab and accessories – 9.9.2 Side window 81
9 Remove excess silicone adhesive from the outer vertical corners

with a tool made of cardboard as shown in figure 4. Smooth out
the joints on the inside with a finger, wet with water or soapy
water.
10 Apply silicone adhesive 923854.0100 between the strip and win-
dow pane at the bottom edge of the front corners, so-called top
sealing.
11 If the roof window is to be replaced, apply silicone adhesive
923854.0100 by the cab frame (where it was glued earlier).
12 Lay the roof window into place and check that there is a uniform
distance of one or several millimetres along the window pane’s
edges and by the protection over the frame’s sides. Then tighten
the corner bolts for the window pane.
006272
13 Apply silicone adhesive 923854.0100 by the edges and smooth
out the joints with a finger, wet with water or soapy water.
Figure 4: Tool template for silicone joint, scale 1:1

I M P OR TA NT
Mark the window panes with "New adhesive. Do not
touch.".
14 Remove the masking tape immediately after applying adhesive to

avoid edge formation. Hardening time is dependent on ambient
temperature, plan the change so that downtime is minimised.
9.9.2 Side window

Side window, description
page
–
The side windows are secured in the cab and doors with key strips.
For further details, see Glass/windows/mirrors, description page 78.
Side window, replacement

page
–
NOTE
The method describes a general procedure.

82 9 Frame, body, cab and accessories – 9.9.2 Side window
2 Use special tools to detach the wedge strip.
3 Remove the wedge strip which runs around the whole window.
4 Carefully remove any glass remains from the rubber strip.
5 Fit the new window, securing it at the bottom edge.

9 Frame, body, cab and accessories – 9.9.2 Side window 83
6 Spray soap solution on the window and rubber strip to facilitate

fitting.
7 Thread the rubber strip around the whole window; use special
tools.
8 Secure the wedge strip with a special tool.

9 Pull the wedge strip around the whole window.

84 9 Frame, body, cab and accessories – 9.9.3 Roof window
10 Cut off the wedge strip approx. 2 cm too long.

11 Fit the other end of the wedge strip edge to edge.
12 Adjust the wedge strip so that the correct fit is obtained.
9.9.3 Roof window

Roof window, description
page
–
The roof window is made of polycarbonate plastic, which is a safety

feature for the operator, intended to protect the operator from falling
objects. The polycarbonate plastic is elastic.
Safety is maintained within a temperature interval of 120 °C to -45 °C
(becomes brittle at -110 °C, glass conversion temperature 145 °C).
The roof window has a patented surface layer that increases its resist-
ance to wear, UV light and chemicals.
The roof window is joined with the windscreen. Joints between the win-
dow panes and between roof window and cab are sealed with silicone
adhesive. Lay a new seal of silicone adhesive when replacing.
For location, see Glass/windows/mirrors, description page 78.
WARN IN G
The strength of the roof window may be significantly
reduced in case of exposure to substances contain-
ing: aromatic hydrocarbons, ketones, esters and
chlorinated hydrocarbons.
Check the roof window’s surface at regular intervals,
and only clean with washer fluid or mild cleaning
agents. Rinse with lukewarm water. Replace the roof
window if it is damaged, cracked, or scratched!
Roof window, replacement

page
–
See Windscreen, replacement page 79 for the general procedure.

The roof window is combined with the windscreen. The joint is sealed
with silicone. Add a new silicone seal when replacing.

9 Frame, body, cab and accessories – 9.9.4 Rear window 85
9.9.4 Rear window

Rear window, description
page
–
The rear window is attached to the cab with a key strip.
On machines with hydraulic sliding cab or hydraulic vertically ad-

justable cab, the rear window can be opened to provide an emergency
exit.
For further details, see Glass/windows/mirrors, description page 78.
Rear window, replacement

page
–
See Side window, replacement page 81 for the general procedure.
9.9.5 Rearview mirror

Rearview mirror, description
page
–
The cab has a rearview mirror (position A) located in the cab as well
as rearview mirrors (position B) on left and right front wing. The func-
tion of the rearview mirror is to give the operator vision around the ma-
chine.
001510
A B As an option the machine can be equipped with electrically controlled

and heated exterior rearview mirrors.
A. Rearview mirror
B. External mirror
9.9.6 Reversing camera

Reversing camera, description
page
–
The reversing camera is located at the rear edge of the horizontal

counterbalance weight, furthest back on the machine. It is designed to
provide improved vision when reversing. The reversing camera is wa-
tertight and has a microphone and infrared lighting for night vision. In
addition, the camera is equipped with automatic heating which is acti-
vated at ambient temperatures below +10 °C.
1
2 The reversing camera sends colour images and audio to the monitor
in the cab; see Monitor, reversing camera, description page 86.
1
007425
3
1. IR diodes
As an option the machine can be equipped with an extra camera at the
2. Camera
front of the machine for improved vision in front of the machine.
3. Microphone
Switching between the display of the image from the front and rear
cameras is controlled with a button on the monitor.

86 9 Frame, body, cab and accessories – 9.9.7 Monitor, reversing camera
9.9.7 Monitor, reversing camera

Monitor, reversing camera, description
page
–
The monitor shows picture and sound from the back-up camera. The
CA.SE
L
1 picture is shown in colour and light intensity is automatically adjusted
according to light conditions in the cab. The monitor can handle sig-
MENU
2 nals from two different cameras.

VOL
The monitor is mounted on a hinged bracket to the left in front of the
3 door in the cab.
BRI
4 007416
5
1. Selection of camera
2. Menu
3. Brightness
4. Volume setting
5. Switching ON/OFF

9 Frame, body, cab and accessories – 9.10 Cab structure and suspension 87
9.10 Cab structure and

suspension
Cab structure and suspension, description
page
–
The cab is mounted in a cab undercarriage via strong rubber insulators

located on the underside of the cab. This minimises vibrations from the
frame to the cab. There is an insulator at four points - one at each cor-
1 ner. Each insulator mounting has one rubber bushing and one bolt.
3
003206
4
Cab Spirit Delta
1. Cab frame
2. Door
3. Cab suspension
4. Cab undercarriage
9.10.1 Cab frame

Cab frame, description
page
–
The cab frame is made of high-strength steel sheet profiles. The cab
is dimensioned to handle impacts and, to some degree, dropped
loads. The frame must not be modified!
002210
Cab Spirit Delta

88 9 Frame, body, cab and accessories – 9.10.2 Doors
9.10.2 Doors
Doors, description
page
–
The cab has two doors - the left is the operator’s door and the right is
the emergency exit. The door has:
• rail
• handle
• key lock
• openable window (passenger door )

Switches in the doors’ locks sense if the door is open. The switch is
used to light the interior lighting and warn of an open door.
8 Control system , group 8.4.2.12 LIGHTS, menu 12 or 8.4.11.2
SLIDING CAB, menu 1.
9.10.3 Cab undercarriage

Cab substructure, description
page
–
The cab is mounted on a cab undercarriage via strong rubber insula-

tors located on the underside of the cab. This is to minimise vibrations
from the frame to the cab.
The cab undercarriage is fitted on the machine’s chassis (frame) via a
mounting. The chassis mounting depends on whether the machine is
equipped with:
• manual sliding cab
• hydraulic sliding cab
• hydraulic vertically adjustable cab
• hydraulically tiltable cab.
9.10.3.1 Cab undercarriage, sliding cab

Cab undercarriage, sliding cab, description
page
–

mounting. The mounting to the chassis consists of four ball bearing
metal rollers which run in rails above the machine’s frame.

9 Frame, body, cab and accessories – 9.10.3.2 Cab undercarriage, vertically adjustable cab 89
9.10.3.2 Cab undercarriage, vertically

adjustable cab
Cab undercarriage, vertically adjustable cab, description
page
–
1 2 3
mounting. The mounting runs in a lift mast which is secured in the ma-
chine’s chassis behind the right-hand front wing which means that the
cab is positioned above the right-hand drive wheel.
The lift mast consists of outer mast, inner mast lift cylinder and chains.
The inner mast runs in the outer mast on ball bearing rollers.
4
001873
1. Hydraulic cylinder, vertically adjustable cab

2. Mast, vertically adjustable cab
3. Cab undercarriage, vertically adjustable cab
4. Safety lock

90 9 Frame, body, cab and accessories – 9.10.4 Sliding cab
9.10.4 Sliding cab

Manual sliding cab, description
page
–
Manual sliding cab means that the cab can be moved forward to facil-
itate access for service and maintenance in the engine compartment.
The cab is pushed for and aft by hand. Two cable chains on each side
ensure that hoses and electric cabling to and from the cab are not
damaged when the cab is moved. The cab is secured in the rear posi-
tion during operation with two lock handles at the rear edge of the cab.
A
D ANGER
The cab may start to move.
Fatal danger!
The cab is heavy and the machine must absolutely

not be moved without first securing the cab. Secure
the cab with both lock handles before operating the
machine.
000270
B C
A. Position, lock handle WARN IN G
B. Lock pin
It is important to that the lock handles are intact! They
should be checked regularly. However, it is not in-
cluded as part of the service schedule for preventive
maintenance!

9 Frame, body, cab and accessories – 9.10.4 Sliding cab 91
Hydraulic sliding cab, function description

page
–

value
Doors Closed Doors, description page 88.
D1 2
D2
1
3, 13
D790-1
D12
D797-O
4,14
5
D4
P1
A 12
7 LS
TP 11, 17
T1 B
8 6, 9, 15 10, 16
006901
1 Switch (S177) sliding cab sends a voltage U = 24 V Controls and instruments, overview page 5
signal to Control unit, cab (D790-1). D1: Diagnostic menu, see section 8 Control
system , group 8.4.11.2 SLIDING CAB,
menu 1
2 Contact closed door, sends signal to con- U = 24 V Doors, description page 88

trol unit cab when door is closed. D2: Diagnostic menu, see section 8 Control
system , group 8.4.11.2 SLIDING CAB,
menu 1
3 The cab control unit (D790-1) sends cab Checked by control Section 11 Common electrics, group 11.5.3.1
forward or cab backward on the CAN bus. system, error shown Cab control unit
with error code.
4 Control unit frame option (D797-O) sup- I = 435–650 mA Section 11 Common electrics, group 11.5.3.4
plies voltage to servo valve sliding cab for- Control unit, frame option
ward or servo valve sliding cab backward D4: Diagnostic menu, see section 8 Control
on control valve option frame. system , group 8.4.11.2 SLIDING CAB, menu
3 and 4

92 9 Frame, body, cab and accessories – 9.10.4 Sliding cab
5 Servo valve sliding cab forward or servo - Control valve, option frame, description page
valve sliding cab backward pressurises 93
the sliding cab slide in control valve, op- D4: Diagnostic menu, see section 8 Control
tion frame. system , group 8.4.11.2 SLIDING CAB, menu
3 and 4
6 Control valve, option frame sends control - Control valve, option frame, description page
signal to shuttle valve option. 93
7 The shuttle valve sends the strongest con- - Shuttle valve, frame option, description page
trol signal to main pumps if several func- 97
tions are activated at the same time.
8 The main pumps pump oil from the tank. Pressure plate "Max. Section 10 Common hydraulics, group 10.4.2
pressure hydraulic oil Axial piston pump with variable displacement
pumps" on left frame
member.
9 Control valve, option frame pressurises - Control valve, option frame, description page
valve block sliding cab. 93
10 Valve block sliding cab pressurises hy- - Valve block, manual sliding cab, description
draulic motor for sliding cab. page 97
11 Hydraulic motor, sliding cab pulls the cab - Hydraulic motor, sliding cab, description page
forward or backward. 97
12 Sensor end position (B769-2) sends a U = 24 V Sensor, end position damping, description
voltage signal to the cab control unit page 100
(D790-1) when cab is close to the end po- D12: Diagnostic menu, see section 8 Control
sition. system , group 8.4.11.2 SLIDING CAB, menu 2
13 The cab control unit (D790-1) transmits Checked by control Section 11 Common electrics, group 11.5.3.1
"dampen sliding cab" on the CAN bus. system, error shown Cab control unit
with error code.
14 Control unit, frame option (D797-O) re- - Section 11 Common electrics, group 11.5.3.4
duces control current to servo valve, slid- Control unit, frame option
ing cab forward or servo valve, sliding cab D4: Diagnostic menu, see section 8 Control
backward in control valve, option frame. system , group 8.4.11.2 SLIDING CAB, menu
3 and 4
15 Control valve, option frame reduces the - Control valve, option frame, description page
hydraulic pressure to valve block sliding 93
cab. D4: Diagnostic menu, see section 8 Control
system , group 8.4.11.2 SLIDING CAB, menu
3 and 4
16 Valve block sliding cab lets pressure - Valve block, manual sliding cab, description
through to hydraulic motor sliding cab. page 97
17 Hydraulic motor sliding cab reduces the - Hydraulic motor, sliding cab, description page
speed of sliding cab. 97
Hydraulic diagram, sliding cab

Hydraulic diagram, sliding cab + support jacks

9 Frame, body, cab and accessories – 9.10.4.1 Cab cradle 93
9.10.4.1 Cab cradle

Cab cradle, description
page
–
The cab is secured on a cradle which runs on wheels in rails on the

frame. See Cab substructure, description page 88.

Hydraulic oil pump, description
page
–
The hydraulic sliding cab is pressurised from hydraulic oil pump 1 and
2, see section 10 Common hydraulics , group 10.4.2 Axial piston pump

page
–
The hydraulic sliding cab is controlled by a separate section in control

valve, option frame.
pressure and reducing valves convert electrical current to servo pres-
sure. The servo pressure controls the spring-centred valve slides,
which control pressure and flow for the function in question. The valve
slides have flow limits so that several functions can be activated simul-
taneously.
The control valve is located at the front of the engine compartment and
is controlled by Control unit, frame option (D797-O). Control valve, op-
tion frame is made up of several sections, each section controls one
function. The following functions are controlled by control valve, option
frame:
• Support jacks
• Sliding cab / Vertically adjustable cab
• Cab tilt

94 9 Frame, body, cab and accessories – 9.10.4.3 Control valve, option frame
Valve slide, sliding cab

1 The valve slide controls direction and speed of sliding cab by control-
ling hydraulic motor pressure, sliding cab.
6 2
The valve slide is controlled by servo valve forward and servo valve
backward.
5 3
Servo valve sliding cab forward
4 Servo valve sliding cab forward controls servo pressure to valve slide
sliding cab so that this controls oil pressure to hydraulic motor sliding
cab forward.
Servo valve sliding cab forward regulates electrically with the solenoid
valve sliding cab forward (Y6016), which is activated by Control unit,
Control system , group 8.4.11.2 SLIDING CAB, menu 3.
000624
Servo valve sliding cab backward
1. Load signal (LS) Servo valve sliding cab backward controls servo pressure to valve
slide steering so that this controls oil pressure to hydraulic motor slid-
ing cab forward.
3. Tank return (T1)
4. Connection hydraulic motor (B) Servo valve sliding cab backward regulates electrically with the sole-
5. Tank return (TP) noid valve sliding cab backward (Y6017), which is activated by Control
6. Connection hydraulic motor (A) unit, frame option (D797-O).

9 Frame, body, cab and accessories – 9.10.4.3 Control valve, option frame 95

page
–
NOTE
Safety.
Safety.
1
NOTE
4
NOTE
tact and in place.
NOTE
000624

1. Load signal (LS)
up.
3. Tank return (T1) 7 Mark up the servo valves on the new control valve.
4. Connection hydraulic motor (B) 8 Fit the valve.
5. Tank return (TP)
6. Connection hydraulic motor (A)
marking.
with the marking.
NOTE

NOTE
C AUTION

010475

C AUTION
product damage.

C AUTION


9 Frame, body, cab and accessories – 9.10.4.4 Shuttle valve, frame option 97
9.10.4.4 Shuttle valve, frame option

Shuttle valve, frame option, description
page
–
See section 10 Common hydraulics, group 10.5.3 Shuttle valve.
9.10.4.5 Valve block, manual sliding cab

Valve block, manual sliding cab, description
page
–
Valve block sliding cab is fitted on hydraulic motor sliding cab and pre-
vents the motor rotating when sliding cab is not activated.
9.10.4.6 Hydraulic motor, sliding cab

Hydraulic motor, sliding cab, description
page
–
1 2 3 4 5 6
The hydraulic motor is located furthest forward on the right-hand side
of the cab chain. The hydraulic motor pulls the chain which in turn pulls
the cab forward and backward.
001862
1. Sensor, damping (rear edge of cab on left-hand

side)
2. Indicator plate, damping
3. Chain, sliding cab
4. Hydraulic motor, sliding cab
5. Control valve, sliding cab

98 9 Frame, body, cab and accessories – 9.10.4.6 Hydraulic motor, sliding cab
Hydraulic motor, sliding cab, replacement

page
–
NOTE
Safety.
2 Depressurise the hydraulic systems, See section B Safety.
3 Remove the protective cover.
4 Slacken the chain, loosen the chain tensioner and the adjusting
screw.
5 Detach the chain from its mounting.
6 Detach the hydraulic hoses from the motor.
7 Remove the ring gear.
8 Remove the hydraulic motor from its mounting.
1. Protective cover
9 Replace the hydraulic motor.
2. Hydraulic motor
3. Chain tensioner
NOTE
C AUTION

010475

9 Frame, body, cab and accessories – 9.10.4.7 Chain, sliding cab 99
C AUTION

9.10.4.7 Chain, sliding cab

Chain, sliding cab, description
page
–
1 2 3 4 5 6
The chain pulls the cab forward and backward and is secured in the
front and rear edges on the cab undercarriage. The chain tension is
adjusted by moving the hydraulic motor for sliding cab.
001862
1. Sensor, damping (rear edge of cab on left-hand

side)
3. Chain, sliding cab
4. Hydraulic motor, sliding cab
5. Control valve, sliding cab
Chain and chain wheel, sliding cab, replacement

page
–

2 Slacken the chain, loosen the chain tensioner and the adjusting
screw.
3 Detach the chain at the front edge.
4 Detach the chain at the rear edge.
5 Replace the chain.
7 Adjust the chain with the adjusting screw.
8 Tighten the chain tensioner.

100 9 Frame, body, cab and accessories – 9.10.4.8 Sensor, end position damping
9.10.4.8 Sensor, end position damping

Sensor, end position damping, description
page
–
Sensor end position damping indicates when the cab is near the end
position and is used to activate end position damping.
8 Control system , group 8.4.11.2 SLIDING CAB, menu 2.

page
–

9 Frame, body, cab and accessories – 9.10.5 Vertically adjustable cab 101
9.10.5 Vertically adjustable cab

Vertically adjustable cab, function description
page
–

Doors Closed. Doors, description page 88.
If the door is open with lifted cab, the lift and lower func-
tions for the boom are limited.
2
D1
D2
1
3, 16, 22 D15
D790-1
D797-O D13 15
4, 14, 17
D4 D17
10
5 18
12, 21
11, 20 13
P1 A
LS B
TP
7
T1 T3
6, 9, 19
8
013033
1 Switch vertically adjustable cab U = 24 V Controls and instruments, overview page 5
(S177) sends a voltage signal to D1: Diagnostic menu, see section 8 Control sys-
Control unit, cab (D790-1). tem , group 8.4.11.2 SLIDING CAB, menu 1
2 Contact closed door, sends a signal U = 24 V Doors, description page 88

to the cab control unit (D790-1) D2: Diagnostic menu, see section 8 Control sys-
when door is closed. tem , group 8.4.11.2 SLIDING CAB, menu 1
3 The cab control unit (D790-1) sends Checked by control sys- Section 11 Common electrics, group 11.5.3.1
cab up or cab down on the CAN tem, error shown with er- Cab control unit
bus. ror code.

102 9 Frame, body, cab and accessories – 9.10.5 Vertically adjustable cab

4 Control unit, frame option (D797-O) I = 435–650 mA Section 11 Common electrics, group 11.5.3.4
supplies voltage to servo valve Control unit, frame option
raise cab (Y6016) or servo lower D4: Diagnostic menu, see section 8 Control sys-
valve cab (Y6017) on control valve, tem , group 8.4.11.2 SLIDING CAB, menu 3 and
option frame. 4
5 Servo valve, raise cab (Y6016) or - Control valve, option frame, description page
servo valve, lower cab (Y6017) 104
pressurises the sliding cab slide in D4: Diagnostic menu, see section 8 Control sys-
control valve, option frame. tem , group 8.4.11.2 SLIDING CAB, menu 3 and
4
6 Control valve, option frame sends a - Control valve, option frame, description page
control signal to shuttle valve op- 104
tion.
7 The shuttle valve sends the strong- - Shuttle valve, frame option, description page 97
est control signal to main pumps if
several functions are activated at
the same time.
8 The main pumps pump oil from the See pressure plate on left Section 10 Common hydraulics, group 10.4.2
tank. frame beam. Axial piston pump with variable displacement
9 Control valve, option frame pressu- - Control valve, option frame, description page
rises the accumulator and the load 104
control valve.
10 The accumulator stores pressure. - Accumulator, vertically adjustable cab, descrip-

tion page 105
11 The load control valve lets the pres- - Load control valve, description page 105
sure through to hydraulic cylinder
for vertically adjustable cab.
When lowering, the load control
valve changes position and restricts
flow from hydraulic cylinder for ver-
tically adjustable cab.
12 Hydraulic cylinder for vertically ad- - Hydraulic cylinder, vertically adjustable cab, de-
justable cab lifts or lowers the cab. scription page 106
13 Sensor lowered cab (B777-2) stops U = 24 V Sensor, lowered cab, description page 110
sending a voltage signal to Control D13: Diagnostic menu, see section 8 Control
unit, frame option (D797-O) when system , group 8.4.11.2 SLIDING CAB, menu 2
the cab leaves the lowest position.
14 Control unit, frame option (D797-O) Checked by control sys- Section 11 Common electrics, group 11.5.3.4
sends "cab up" on the CAN bus. tem, error shown with er- Control unit, frame option
ror code.
15 Sensor end position damping U = 24 V Sensor, end position damping, description page
(B769-2) sends a voltage signal to 111
the cab control unit (D790-1) when D15: Diagnostic menu, see section 8 Control
cab is close to the end position. system , group 8.4.11.2 SLIDING CAB, menu 2

9 Frame, body, cab and accessories – 9.10.5.1 Hydraulic oil pump 103

mits "cab lift" on the CAN bus. tem, error shown with er- Cab control unit
ror code.
17 Control unit, frame option (D797-O) - Section 11 Common electrics, group 11.5.3.4
reduces the control current to servo Control unit, frame option
valve raise cab (Y6016) or servo D17: Diagnostic menu, see section 8 Control
lower valve cab (Y6017) in control system , group 8.4.11.2 SLIDING CAB, menu 3
valve, option frame. and 4
18 Servo valve, raise cab (Y6016) or - Control valve, option frame, description page
servo valve, lower cab (Y6017) con- 104
trols the pressure to the sliding cab D17: Diagnostic menu, see section 8 Control
slide in control valve, option frame. system , group 8.4.11.2 SLIDING CAB, menu 3
and 4
19 Control valve, option frame reduces - Control valve, option frame, description page
hydraulic pressure to valve block 104
vertically adjustable cab.
20 Valve block lift cylinder for vertically - Load control valve, description page 105
adjustable cab lets pressure
through to hydraulic cylinder for ver-
tically adjustable cab.
21 Hydraulic cylinder for vertically ad- - Hydraulic cylinder, vertically adjustable cab, de-
justable cab reduces the speed of scription page 106
raising or lowering the cab.
22 When the cab is lifted the cab con- Maximum speed: 5 km/h. Section 11 Common electrics, group 11.5.3.1
trol unit (D790-1) activates speed Cab control unit
limitation.
Hydraulic diagram, cab lift and support jacks

Hydraulic oil pump, description
page
–
The hydraulic sliding cab is pressurised from hydraulic oil pump 1 and
2, see section 10 Common hydraulics , group 10.4.2 Axial piston pump


page
–
1
The vertically adjustable cab is controlled by a separate section in con-
trol valve, option frame, for details see Control valve, option frame, de-
6 2
scription page 93.
5 3 Valve slide raise/lower cab

The valve slide controls the direction and speed of raising and lower-
4 ing the cab by controlling the hydraulic pressure for hydraulic cylinder,
vertically adjustable cab.
The valve slide is controlled by servo valve raise cab and servo valve
lower cab.
Servo valve raise cab

Servo valve raise cab controls servo pressure to valve slide raise/low-
er cab so that this controls oil pressure to hydraulic cylinder, vertically
adjustable cab, for raising the cab.
000624
Servo valve raise cab regulates electrically with the solenoid valve
1. Load signal (LS) raise cab (Y6016), which is activated by Control unit, frame option
2. Pressure supply (P) (D797-O).
3. Tank return (T1) The signal can be checked from the diagnostic menu, see section 8
4. Connection, hydraulic cylinder (B) Control system , group 8.4.11.2 SLIDING CAB, menu 3.
5. Tank return (TP)
6. Connection, hydraulic cylinder (A) Servo valve lower cab
Servo valve lower cab controls servo pressure to valve slide raise/low-
er cab so that this drains hydraulic cylinder, vertically adjustable cab,
for lowering the cab.
Servo valve lower cab regulates electrically with the solenoid valve
raise cab (Y6017), which is activated by Control unit, frame option
(D797-O).
Servo valve lower cab can be checked from the diagnostic menu, see
section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 4.

page
–
See Control valve, option frame, replacement page 95.
9.10.5.3 Shuttle valve, frame option

Shuttle valve, frame option, description
page
–

9 Frame, body, cab and accessories – 9.10.5.4 Accumulator, vertically adjustable cab 105
9.10.5.4 Accumulator, vertically adjustable cab

Accumulator, vertically adjustable cab, description
page
–
The accumulator stores pressure so that the cab does not lower if the
engine stops and the machine becomes depressurised.
9.10.5.5 Load control valve

Load control valve, description
page
–
The load control valve reduces the speed when lowering the cab.
When the pressure is released behind the valve, the valve slide chang-
000621 es position and restricts the channel through the valve.

106 9 Frame, body, cab and accessories – 9.10.5.6 Hydraulic cylinder, vertically adjustable cab
9.10.5.6 Hydraulic cylinder, vertically

adjustable cab
Hydraulic cylinder, vertically adjustable cab, description
page
–
1 2 3
The hydraulic cylinder lifts the inner mast and thus the cab.
4
001873

4. Safety lock
Hydraulic cylinder, vertically adjustable cab, replacement

page
–
NOTE
Safety.
1 Raise the cab so high to secure its position with both lock lugs
(position A).
Lower the cab so that it rests on the safety brackets.
C AUTION
Risk of fatal danger under raised cab.
A Secure the cab with the lock lugs (position A) on both
sides of the cab frame.
001977
A. Lock lug 2 Machine in service position, see section B Safety.

Safety.
4 Mark up and detach the hydraulic hoses from the extension
cylinder.
NOTE

9 Frame, body, cab and accessories – 9.10.5.6 Hydraulic cylinder, vertically adjustable cab 107
5 Release the upper cylinder mounting (position 1) from the moving

part of the cab frame.
008206
1. Upper mounting hydraulic cylinder

2. Retaining bracket hydraulic cylinder
6 Remove the load control valve and compress the hydraulic
cylinder.
NOTE
7 Attach hoisting equipment to the hydraulic cylinder.
8 Remove the hydraulic cylinder’s retaining brackets from the fixed
part of the cab frame.
9 Tilt and lift the hydraulic cylinder out upwards.
10 Transfer parts to the new hydraulic cylinder.
11 Fit the hydraulic cylinder in the reverse order.
000621
Load control valve

108 9 Frame, body, cab and accessories – 9.10.5.6 Hydraulic cylinder, vertically adjustable cab
NOTE
C AUTION

010475
C AUTION


page
–

9 Frame, body, cab and accessories – 9.10.5.7 Mast, vertically adjustable cab 109
9.10.5.7 Mast, vertically adjustable cab

Mast, vertically adjustable cab, description
page
–
1 2 3
The mast holds the cab secure and enables raising and lowering.
4
001873

4. Safety lock

110 9 Frame, body, cab and accessories – 9.10.5.8 Sensor, lowered cab
9.10.5.8 Sensor, lowered cab

Sensor, lowered cab, description
page
–
The sensor indicates when the cab is completely lowered. When the
cab is raised, the machine’s speed is reduced and the transmission is
1 blocked in second gear.
2
000618
1. Sensor, end position damping

2. Sensor, end position lowered cab

page
–

9 Frame, body, cab and accessories – 9.10.5.9 Sensor, end position damping 111
9.10.5.9 Sensor, end position damping

Sensor, end position damping, description
page
–
Sensor damping end position indicates when the cab is close to end
position. This is used to activate end-position damping. When the cab
1 is raised, the machine’s speed is reduced and the transmission is
blocked in second gear.
2
8 Control system , group 8.4.11.2 SLIDING CAB, menu 2.
000618
1. Sensor, end position damping

2. Sensor, end position lowered cab

page
–

112 9 Frame, body, cab and accessories – 9.10.5.10 Emergency lowering valve
9.10.5.10 Emergency lowering valve

Emergency lowering valve, description
page
–
The emergency lowering valve (position A) opens a connection be-

tween the hydraulic cylinder’s piston side and tank, and makes it pos-
sible to lower the cab if the machine becomes depressurised or de-
energised.
A
001978
A. Location, emergency lowering valve
9.10.5.11 Safety lock, vertically adjustable cab

Safety lock, vertically adjustable cab, description
page
–
On the mast are two lock lugs which are used to secure the cab in the
raised position during maintenance work with raised cab.
A
001977
A. Lock lug

9 Frame, body, cab and accessories – 9.11 Cab interior 113
9.11 Cab interior

9.11.1 Instrument and control panels
Dashboard panel, description
page
–
The dashboard panel is secured to the steering column and contains

warning and indicator lamps, display (KID), function keys (KIT) and
switches.
Left-hand dashboard panel, description

page
–
Left instrument panel is located in the left corner of the cab. It contains
rotary controls, switches, and ventilation.
Panel for load handling functions, description

page
–
The panel is mounted on the driver’s seat. The panel includes switch-
es for load handling functions and safety switches to interrupt ongoing
load handling functions. The control lever is located next to the panel.
Dashboard panel, replacement

page
–

2 Remove the steering wheel centre cover.
3 Remove the nut and the steering wheel.
4 Remove the bolts on the underside of the dashboard panel.

114 9 Frame, body, cab and accessories – 9.11.2 Interior details, plastic
5 Remove the bolts on the top of the dashboard panel.
6 Unplug the connector from the multi-function levers, ignition

switch, KIT control unit (D790-2) and KID control unit (D795).
7 Transfer the components to the new steering wheel cover.
9.11.2 Interior details, plastic

Interior plastic components, description
page
–
The interior of the cab consists of recyclable material.
9.11.3 Interior details, textile

Interior textile components, description
page
–
The interior of the cab consists of recyclable material.
9.11.4 Floor covering

Floor covering, description
page
–
The floor covering is a wear-resistant and recyclable material.
9.11.5 Insulation
Insulation, description
page
–
The cab insulation consists of recyclable material.

9 Frame, body, cab and accessories – 9.11.6 Sun blinds 115
9.11.6 Sun blinds

Sun blinds, description
page
–
Sun blinds can be chosen for the front window (windscreen) and the
roof window.
1. Sun visor, front window: Can be raised and lowered using a cord
on the right-hand side. Stops in selected position.
2. Sun visor, roof window: Extends forward to fasten in two hooks in
the front edge of the window.
9.11.7 Terminal console

Terminal console, description
page
–
The function of terminal desk is to provide a work surface for a com-

puter/terminal. It is located to the right of the steering wheel, easily ac-
cessible for the operator.
008227
9.11.8 Writing desk

Writing desk, description
page
–
The writing table with reading light is located on a flexible attachment

to the right in front of the door in the cab. That is where work orders,
etc. can be fastened.
008228

116 9 Frame, body, cab and accessories – 9.12 Frame
9.12 Frame
Frame, description
page
–
The frame is a modular construction and consists of front section, rear

section and a beam pair. This construction provides advantages in
terms of rigidity and strength.
There are mounting points in the frame for engine, transmission, drive
axle, steering axle, fuel and hydraulic tanks, cab, boom and body
parts.
The space in the rear section of the frame is used for counterweights,
the number of which is adapted to the machine in question. The coun-
terweights are designed to allow as good a view rearwards as
possible.
The front wings are bolted into the frame (which has advantages when
delivering the machine).
4
6 7 8
3 2
001511
1
1. Frame’s front part with drive axle mounting

2. Cab mounting (4 points)
3. Steering axle mounting
4. Frame’s rear part with counterweights
5. Boom mounting
6. Engine compartment with mountings for engine and transmission
7. Beam pair
8. Mounting for front wing

9 Frame, body, cab and accessories – 9.13 Body 117
9.13 Body
Body, description
page
–
The body’s components comprise:
3
2 1
002213
1. Wings
2. Hood engine compartment
3. Counterweight
9.13.1 Wings
Wings, description
page
–
There are wings over the wheels to protect from dirt thrown up by the
wheels during operation. The design of the counterweight (see Coun-
terweight, description page 118) acts as a mudguard for the rear
wheels.
The wings can be equipped with extra mudguards when the machine’s
work environment requires such ( ).
9.13.2 Hood engine compartment

Hood engine compartment, description
page
–
The machine’s engine compartment is protected by tread plates which

function as an engine hood. The tread plates are divided into five sec-
tions and are secured with retaining bolts. The tread plates are de-
signed to be walked on and are ribbed to provide sure footing.

118 9 Frame, body, cab and accessories – 9.13.3 Footstep and rail
9.13.3 Footstep and rail

Steps and rails, description
page
–
The cab has steps and handrails for easy access.
Railing is also available on the front wings ( ).
9.13.4 Counterweights
Counterweight, description
page
–
The machine has counterweights to balance the machine’s lift capac-

ity and may therefore vary in quantity and weight.
The counterweights are located at the very back of the frame for max-
imal leverage.
The machine has counterweights in the following places:
• 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 the frame, there are smaller
counterweights whose dimensions and quantity are adapted to
balance the machine’s lifting capacity.
• Upper horizontal counterweight.
Under the horizontal counterweight, there are smaller counter-
weights whose dimensions and quantity are adapted to balance
the machine’s lifting capacity.
D ANGER
The counterweights are factory fitted and are adapted
according to the machine's properties.
The machine's operating characteristics are changed!
Never change the quantity of counterweights.

9 Frame, body, cab and accessories – 9.14 Central lubrication 119
9.14 Central lubrication

Central lubrication, checking
page
–
1 Check that no grease has been forced out through the safety
valve (position 2).
If grease has been forced out through the safety valve it means
that there is a stop in the system. Determine which line is clogged
by feeling the connections at the distribution blocks. A clogged
hose remains pressurised and the connection becomes hard.
NOTE
If several distribution blocks are connected in series, a
clogged line will be pressurised all the way to the first distri-
bution block.
2 Turn the start key to position I.
3 Operate the pump manually and check that the indicator pin
moves in and out on the distribution blocks.
To operate the pump, loosen the cover and press in the switch for
manual operation (position 5).
If the indicator pin does not move even when the pump is running,
Overview - central lubrication pump unit and distribu-
troubleshoot the pump unit.
tion block. Example illustration.
1. Lubricant nipple, lubricating grease filler orifice
2. Safety valve
NOTE
3. Lubricant nipple, manual system lubrication The system can be lubricated manually through the grease
4. Indicator pin nipple on the distribution block (position 3).
5. Switch, manual operation 4 Fill grease in the pump unit through the filler nipple, see section
F Technical data.

120 9 Frame, body, cab and accessories – 9.14 Central lubrication
Central lubrication, adjusting lubrication times

page
–
The central lubrication’s pause and run-time must be set after replace-
ment, the setting is unique to each machine, depending on the ma-
chine’s equipment. At replacement, the new pump unit should be set
in the same way as the old one.
If the machine is not lubricated correctly, pause and run-time can be
adjusted. Primarily, run-time should be adjusted so that all lubrication
points on the machine are greased every time. If large amounts of
grease are pressed out at all lubrication points, pause-time can be
increased.
NOTE
Adjust only one step each time. Small adjustments make a big
difference.
Test or extra greasing

Central lubrication can be operated manually by holding in the button
for manual operation (position 3) for 2 seconds. This starts an extra lu-
brication cycle.
Pause-time
Example illustration
Pause-time is the length of the interval between greasings. The inter-
1. Pause time setting (red)
val is adjusted in whole hours between 1 and 15 hours. Pause-time is
2. Run time setting (blue)
adjusted with the red handle (position 1).
3. Manual pump operation
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Pause-time [hours] 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Run-time
Run-time is how long the pump is activated every time. Run-time can
be adjusted between 2 and 30 minutes. Pause-time is adjusted with
the blue handle (position 2).
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Run-time [minutes] 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

9 Frame, body, cab and accessories – 9.14.1 Pump unit 121
9.14.1 Pump unit

Pump unit, description
page
–
The pump unit consists of containers with stirrer, pump housing with
built-in motor, timer, pump element, filler nipple, and safety valve.
The central lubrication works with lubrication cycles (pause and run-
ning time as well as read-in time). In the pump there is a circuit board
with a timer with which one can set the pump motor’s run and pause
time.
When the central lubrication works, it greases the lubrication points
one at a time in series. If a stop should occur in a lubrication point, the
pressure will increase and the safety valve will release grease and
also the following lubrication points will not be greased.
NOTE
The safety valve will press out grease if a grease point cannot be
greased. If a grease point is not greased, none of the following
grease points will be greased Therefore, it is very important to
check the safety valve.
Example illustration, central lubrication components

1. Pump unit
2. Safety valve
3. Distribution block

122 9 Frame, body, cab and accessories – 9.14.2 Distribution block
9.14.2 Distribution block

Distribution block, description
page
–
The distribution blocks distribute grease from the pump unit to grease
points or on to other distribution blocks. The number of distribution
blocks can vary depending on how may (and which) grease points
have been selected.
The distribution blocks consist of pistons that meter out grease to each
grease point. The pistons are driven by the grease and do not have
springs and gaskets. It is the grease that drives the pistons inside the
distributor. The shape of the pistons and channels in the distribution
block enable the pistons to move in a predetermined way. Each piston
must have completed its motion before the next piston can move. The
pistons are dependent on each other. It is technically impossible to
skip any connected grease point. If a grease point cannot be greased,
the whole system is blocked and grease is pressed out through the
safety valve.
The system’s first distribution block (i.e. the block closest to the pump)
has an indicator pin. If the pin moves forward and backward (in time
with the piston movements), this indicates that grease is pumped
Example illustration, central lubrication components through the system. If a distribution block is unable to supply grease
1. Pump unit to any of its lubrication points, the pin stops and accordingly the entire
2. Safety valve system.
3. Distribution block
If there is clogging in the system, that line will be pressurised, from the
pump to the stop, through all the distribution blocks on the way. This
makes it easy to find a block in the system. By feeling the distribution
blocks’ connections and feeling which connection is stiff, the blockage
can be traced. Keep in mind that several distribution blocks may be
connected in series.
9.14.3 Lines
Lines, description
page
–
Central lubrication works under very high pressure, only use lines that
meet the following specifications.
Main hose
Diameter 8.4 mm
Explosion pressure min. 60.0 MPa

9 Frame, body, cab and accessories – 9.15 Paint/coatings 123
9.15 Paint/coatings
Paint/coatings, description
page
–
The machine is painted with an alkyd-based mono-component paint

that is applied with a brush or a sprayer. For paint codes (RAL), see
machine card.
Check the machine frequently for stone chips, dents and paint scratch-
es, rectify them at once to prevent corrosion on the underlying metal.
Only use touch-up paint for small stone chips and scratches. More ex-
tensive paint damage should be repaired by a paint workshop.
NOTE
Touching up, the surfaces to be touched up must be thoroughly
cleaned.
Please contact Cargotec for information about other surface treatment
and material colours.

124 9 Frame, body, cab and accessories – 9.15 Paint/coatings

10 Common hydraulics 1
Table of Contents 10 Common hydraulics

mm mm mm mm mm mm
10 Common hydraulics....................................................................................... 3
10.2 Safety valves .............................................................................................. 3
10.2.1 Accumulator drain valve ........................................................................ 3
10.2.2 Attachment relief valve .......................................................................... 4
10.2.3 Pipes and hoses .................................................................................... 4
10.3 Tanks and accumulators ............................................................................ 5
10.3.1 Tank ....................................................................................................... 5
10.3.2 Pipes and hoses .................................................................................... 5
10.4 Pumps ........................................................................................................ 6
10.4.1 Gear pump with fixed displacement ....................................................... 6
10.4.2 Axial piston pump with variable displacement ..................................... 12
10.4.3 Pipes and hoses .................................................................................. 30
10.5 Hoses, pipes and valves .......................................................................... 31
10.5.1 Pipes and hoses .................................................................................. 31
10.5.2 Priority valve ........................................................................................ 32
10.5.3 Shuttle valve ........................................................................................ 32
10.5.4 Collection block, filtered returns ........................................................... 34
10.5.5 Collection block, unfiltered returns ....................................................... 34
10.6 Temperature control, cleaning and hydraulic oil ....................................... 35
10.6.1 Tank heater .......................................................................................... 36
10.6.2 Hydraulic oil cooler .............................................................................. 37
10.6.3 Cooling fan ........................................................................................... 38
10.6.4 Sensor hydraulic oil temperature ......................................................... 39
10.6.5 Radiator bypass valve ......................................................................... 40
10.6.6 Breather filter hydraulic oil tank ........................................................... 42
10.6.7 Oil filter ................................................................................................. 43
10.6.8 Hydraulic oil ......................................................................................... 47
10.6.9 Hydraulic oil fine-filter .......................................................................... 47
10.6.10 Pipes and hoses .................................................................................. 48
10.7 Auxiliaries ................................................................................................. 49
10.7.1 Hydraulic cylinders ............................................................................... 49

2 10 Common hydraulics

10 Common hydraulics 3
mm mm mm mm mm mm
10.2 Safety valves

10.2.1 Accumulator drain valve
Accumulator drain valve, description
page
–
The accumulator drain valve is located on the accumulator charging

valve. See section 4 Brakes , group 4.3.3 Accumulator charging valve.
000434

4 10 Common hydraulics – 10.2.2 Attachment relief valve
10.2.2 Attachment relief valve

page
–
The relief valve is located on the lift cylinder beam. See section 7 Load
handling, group 7.4.8 Attachment relief valve.
002269

Pipes and hoses, general
page
–
See Pipes and hoses, general page 31.

10 Common hydraulics – 10.3 Tanks and accumulators 5
10.3 Tanks and accumulators

10.3.1 Tank
Tank, description
page
–
The hydraulic oil tank forms part of the side panel on the right-hand
1 2 1 3 4
side of the machine. The oil filters for the working hydraulics are fitted
inside the tank. These are accessible through hatches on top of the
tank.
Hydraulic oil is filled directly into the tank through the filler caps on the
filter manhole covers. For oil capacity and grade, see section F Tech-
nical data. The entire filter unit can be removed to facilitate access for
cleaning. There is a drain plug at the bottom of the tank.
The tank has filtered venting which allows changes in the tank volume
due to usage and temperature variations.
5 5
The oil level is checked on the level glass on the tank’s side when all
hydraulic cylinders are in the bottom position.
001457
1. Hydraulic oil filler plug

2. Cover for hydraulic oil filter
3. Sight glass, hydraulic oil
4. Breather filter hydraulic oil tank
5. Drain plugs, hydraulic oil

page
–

6 10 Common hydraulics – 10.4 Pumps
10.4 Pumps
10.4.1 Gear pump with fixed displacement
Gear pump with fixed displacement, description
page
–
There are two gear pumps with fixed displacement. One (position 1)
supplies the brake system with pressure, see section 4 Brakes , group
4.3.1 Brake oil pump. The other gear pump (position 2) circulates hy-
draulic oil for working hydraulics through the cooler and filter.
The gear pump pumps oil using two gear wheels that rotate opposite
each other. One is driven by the pump’s input shaft and the other ro-
tates freely. The gear pump’s flow is directly dependent on the speed
of the input shaft.
The cooling pump is fitted on the right main pump and is driven by the
main pump shaft from the transmission’s power take-off. Pump speed
1 is directly dependent on engine speed. Pump flow increases and en-
gine speed increases.
2
000006
The illustration shows hydraulic oil pump alternative

Rexroth
1. Brake fluid pump
2. Pump cooling and filtration
Gear pump, replacement (hydraulic oil pump

page
–
NOTE
Safety.
Safety.
3 Mark up and release the hydraulic hoses from the gear pump.

10 Common hydraulics – 10.4.1 Gear pump with fixed displacement 7
4 Remove the gear pump.

Remove the attaching bolts, pull the pump out backwards and lift
it away.
5 Transfer the connection adapters to the new gear pump.
6 Remove the spacer ring from the gear pump or axial piston pump.
Clean the O rings’ contact surfaces on the spacer ring.
7 Check the O-rings and replace as needed. Install the O-rings on
the gear pump, see section F Technical data.
NOTE
Only use silicone on the side facing the gear pump.
8 Fit the spacer ring on the axial piston pump.

8 10 Common hydraulics – 10.4.1 Gear pump with fixed displacement
9 Brush sealing silicone on the gear pump’s sealing face against

10 Fit the gear pump on the axial piston pump.
Fit the pump and check that the gear grips the shaft and that the
spacer ring is directly against the gear pump. Fit the pump’s re-
taining bolts.
11 Connect the hydraulic hoses to the gear pump.
NOTE
C AUTION
010475


15 Check that the hose connections and seal between gear pump
and axial piston pump are airtight.
16 Check the oil level in the brake or hydraulic system, depending
on which pump ahs been changed, fill if necessary.
C AUTION

NOTE
and filters as well.
17 If the brake fluid pump is replaced:
Check the brake pressure; see section 4 Brakes, group 4.3.1
Brake fluid pump.
Gear pump with fixed displacement, replacement

page
–
(hydraulic oil pump alternative Sauer-Danfoss)
NOTE
Safety.
2 Depressurise the brake and hydraulic systems, see Workshop
Manual section B Safety.
NOTE

10 10 Common hydraulics – 10.4.1 Gear pump with fixed displacement
it away.
pump.
6 Brush sealing silicone on the brake pump’s sealing surface, see

Workshop Manual section F Technical data.
Position the pump and check that the pump’s splines engage in
the shaft in the main pump.
NOTE

9 Close the drain valve and tighten the lock ring on the accumulator
charging valve.
C AUTION

010475

13 If the brake fluid pump is replaced:
Check the brake pressure; see section 4 Brakes, group 4.3.1
Brake fluid pump.
14 Check the oil level in the brake or hydraulic system, depending
on which pump ahs been changed, fill if necessary.
C AUTION

NOTE
and filters as well.

12 10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement
10.4.2 Axial piston pump with variable

displacement
Axial piston pump with variable displacement,
page
–
description (hydraulic oil pump alternative Rexroth)

The hydraulic oil pumps are of the type variable axial piston pump, and
1 2 3 4 5 6
are controlled by load signals depending on the flow demand from
each function.
The hydraulic oil pumps are assembled in pairs with an inlet section
for the suction line. The inlet section leads oil to and from the pumps.
At the inlet section is a connection block containing test outlets for
checking pump pressure. On the connection block are non-return
valves that prevent the oil being pumped around between the pumps
instead of out into the hydraulic system.
10 One of the left-hand pumps’ connection blocks also contains a branch-
ing unit to the attachment hydraulics with a separate non-return valve.
8 7
000528
Hydraulic oil pump unit

1. Adjusting screw standby pressure front pump
2. Adjusting screw max. pressure front pump
3. Test outlet pump pressure rear pump
4. Connection pressure side rear pump
5. Connection pressure side front pump
6. Test outlet pump pressure front pump
7. Left hydraulic oil pump unit
8. Right hydraulic oil pump unit
9. Adjusting screw max. pressure rear pump
10. Adjusting screw standby pressure rear pump

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement 13

page
–
description (hydraulic oil pump alternative Sauer-

Danfoss)
The hydraulic oil pumps are of the type variable axial piston pump, and
7 5
are controlled by load signals depending on the flow demand from
6 each function.
The left hydraulic oil pump (pump 2, position 2) supplies the control
valve for lift and extension and also supplies the attachment’s control
valve. At boom in pump 2 is disconnected.
The right hydraulic oil pump (pump 1, position 1) supplies the control
system as well as the control valve for lift and extension. The priority
3
4 valve ensures that there is always pressure to the control system, the
3 4 residual flow is led to the control valve for lift and extension.
On the pumps’ pressure side is a connection block. On the connection
2 block are non-return valves that prevent the oil being pumped around
between the pumps instead of out into the hydraulic system.
On the right pump’s connection block is a branching unit to the attach-
1
ment hydraulics with a separate non-return valve. On the connection
block there is also a test outlet for checking pump pressure.
On the left pump’s connection block is a branching unit to pressure re-
duction. On this branching unit there is also a test outlet for this pump.
011055
Hydraulic oil pump unit

1. Right hydraulic oil pump
2. Left hydraulic oil pump
3. Adjusting screw standby pressure pump
4. Adjusting screw max. pressure pump
5. Spacer block pressure side pump
6. Test outlet pump pressure left pump
7. Test outlet pump pressure right pump


page
–
function description (hydraulic oil pump alternative

Rexroth)
D790-1
1
D797-R 7, 16 12
P P
P1
LS D16 LS
P
2, 13 EF CF
LS 15
P
8
4, 17 5, 9 C15
C3 C14
C6 C10
No 1 No 2 No 3 No 4
11
006417
6 6, 10 3, 14 3, 14

1 The lift and extension control valve sends a See pressure plate Servo Section 7 Load handling, group 7.2 Lift-
load signal when a function is activated. pressure lift and exten- ing/lowering
sion on left frame
member.
2 Control signal goes to the shuttle valve that See pressure plate Servo Shuttle valve, description (hydraulic oil
sends the load signal on to hydraulic oil pressure lift and exten- pump alternative Rexroth) page 32
pumps No. 3 and No 4. sion on left frame
member.
3 Hydraulic oil pumps No. 3 and No. 4 in- See pressure plate Max. Axial piston pump with variable displace-
crease the flow. pressure hydraulic oil ment, description (hydraulic oil pump al-
pumps on left frame ternative Rexroth) page 12
member.
4 Solenoid valve, unloading main pump See pressure plate Servo Section 7 Load handling, group 7.3.9
(Y6062) leads load signal on to hydraulic oil pressure lift and exten- Valve block pump unloading
pump No. 1 and the shuttle valve sion on left frame
(position 5). member.
5 The shuttle valve sends load signal on to See pressure plate Servo Shuttle valve, description (hydraulic oil
hydraulic oil pump No. 2. pressure lift and exten- pump alternative Rexroth) page 32
sion on left frame
member.


6 Hydraulic oil pumps No. 1 and No. 2 in- See pressure plate Max. Axial piston pump with variable displace-
crease the flow. pressure hydraulic oil ment, description (hydraulic oil pump al-
member.
7 If any attachment function is activated the U = 24 V Section 11 Common electrics, group

Control unit frame rear (D797-R) activates 11.5.3.3 Control unit, frame rear
Solenoid valve top hydraulics (Y6003). Diagnostic menu, see section 8 Control
system , group 8.4.5.6 HYD, menu 6.
8 Solenoid valve top hydraulics (Y6003) con- - Section 7 Load handling, group 7.4.2
trols an unloaded constant pressure to hy- Valve block top lift hydraulics
draulic oil pump No. 2, this functions as a
load signal.
9 The shuttle valve sends load signal on to - Shuttle valve, description (hydraulic oil
hydraulic oil pump No. 2. pump alternative Rexroth) page 32
10 Hydraulic oil pump No. 2 increases the See pressure plate Max. Axial piston pump with variable displace-
flow. pressure hydraulic oil ment, description (hydraulic oil pump al-
member.
11 When Solenoid valve top hydraulics - Section 7 Load handling, group 7.4.2
(Y6003) is not activated, the unloaded Valve block top lift hydraulics
pressure is directed to tank.
12 The steering valve sends a load signal - Section 5 Steering, group 5.2.3 Steering
when the steering wheel is turned. valve
13 The shuttle valve sends load signal on to - Shuttle valve, description (hydraulic oil
hydraulic oil pumps No. 3 and 4. pump alternative Rexroth) page 32
14 Hydraulic oil pumps No. 3 and No. 4 in- See pressure plate Steer- Axial piston pump with variable displace-
crease the flow. ing pressure, on left ment, description (hydraulic oil pump al-
frame member. ternative Rexroth) page 12
15 The priority valve controls the pressure See pressure plate Steer- Section 5 Steering, group 5.2.2 Priority
from the pumps to the steering valve. ing pressure, on left valve
frame member.
16 For boom in Control unit frame rear U = 24 V Section 11 Common electrics, group
(D797-R) activates Solenoid valve pump 11.5.3.3 Control unit, frame rear
unloading (Y6062). Diagnostic menu, see section 8 Control
system , group 8.4.8.2 BOOM, menu 2
17 Solenoid valve pump unloading (Y6062) - Section 7 Load handling, group 7.3.9
leads the pressure from the control valve to Valve block pump unloading
the tank.


page
–
function description (hydraulic oil pump alternative

Sauer-Danfoss)
D790-1
1 12
D797-R
P P
7, 16
LS
LS P1
D7 D7 P
2, 13 EF CF
LS 15
P
4, 17 5, 9 C15
C6 C6
8, 11, 18
6, 10 3, 14
No 1 No 2
011051
1 The lift and extension control valve See pressure plate Servo Section 7 Load handling, group 7.2 Lifting/
sends a load signal when a function is pressure lift and exten- lowering
activated. sion on left frame mem-
ber.
2 Control signal goes to the shuttle valve See pressure plate Servo Shuttle valve, description (hydraulic oil pump
that sends the load signal on to hydrau- pressure lift and exten- alternative Rexroth) page 32
lic oil pump No. 2. sion on left frame mem-
ber.
flow. pressure hydraulic oil ment, description (hydraulic oil pump alter-
pumps on left frame native Sauer-Danfoss) page 13
member.
4 Solenoid valve, unloading main pump See pressure plate Servo Section 7 Load handling, group 7.3.9 Valve
(Y6062) leads load signal on to hydrau- pressure lift and exten- block pump unloading
lic oil pump No. 1 and the shuttle valve sion on left frame mem-
(position 5). ber.
5 The shuttle valve sends load signal on to See pressure plate Servo Shuttle valve, description (hydraulic oil pump
hydraulic oil pump No. 1. pressure lift and exten- alternative Rexroth) page 32
sion on left frame mem-
ber.


pumps on left frame native Rexroth) page 12
member.
7 If any attachment function is activated U = 24 V Section 11 Common electrics, group

the Control unit frame rear (D797-R) ac- 11.5.3.3 Control unit, frame rear
tivates Solenoid valve top hydraulics Diagnostic menu, see section 8 Control sys-
(Y6003). tem , group 8.4.5.6 HYD, menu 6.
8 Solenoid valve top hydraulics (Y6003) - Section 7 Load handling, group 7.4.2 Valve
controls an unloaded constant pressure block top lift hydraulics
to hydraulic oil pump No. 1, this func-
tions as a load signal.
9 The shuttle valve sends load signal on to - Shuttle valve, description (hydraulic oil pump
hydraulic oil pump No. 1. alternative Rexroth) page 32
pumps on left frame native Rexroth) page 12
member.
11 When Solenoid valve top hydraulics - Section 7 Load handling, group 7.4.2 Valve
(Y6003) is not activated, the unloaded block top lift hydraulics
12 The steering valve sends a load signal - Section 5 Steering, group 5.2.3 Steering
when the steering wheel is turned. valve
13 The shuttle valve sends load signal on to - Shuttle valve, description (hydraulic oil pump
hydraulic oil pump No. 2. alternative Rexroth) page 32
14 Hydraulic oil pump No. 2 increases the See pressure plate Steer- Axial piston pump with variable displace-
flow. ing pressure, on left ment, description (hydraulic oil pump alter-
frame member. native Rexroth) page 12
15 The priority valve controls the pressure See pressure plate Steer- Section 5 Steering, group 5.2.2 Priority
from the pumps to the steering valve. ing pressure, on left valve
frame member.
16 For boom in Control unit frame rear U = 24 V Section 11 Common electrics, group
(D797-R) activates Solenoid valve 11.5.3.3 Control unit, frame rear
pump unloading (Y6062). Diagnostic menu, see section 8 Control sys-
tem , group 8.4.8.2 BOOM, menu 2
17 Solenoid valve pump unloading (Y6062) - Section 7 Load handling, group 7.3.9 Valve
leads the pressure from the control block pump unloading
valve to Solenoid valve (Y6003).
18 When Solenoid valve top hydraulics - Section 7 Load handling, group 7.3.9 Valve
(Y6003) is not activated, the unloaded block pump unloading

Hydraulic oil pump, checking (hydraulic oil pump

page
–
NOTE
Safety.
es operating temperature, approx. 50 °C.
2 Stop the engine
3 Connect a pressure gauge to measuring outlet on hydraulic oil
pump 1.
5 Check the standby pressure for one pump at a time in the follow-
ing order:
Hydraulic oil pump 1: 1.8 MPa
1. Hydraulic oil pump 1 The settings apply to standard machine, certain machines can
2. Hydraulic oil pump 2 have higher standby pressure. For correct standby pressure, see
3. Hydraulic oil pump 3 pressure plate. However, the difference in pressure between the
4. Hydraulic oil pump 4 different pumps must always be maintained.
6 Increase engine speed to approx. 1100 rpm and run extension
function against end-position (overflow).
Run out the boom to max and continue to request max. extension
with the control lever. This will cause the overflow of the exten-
sion function.
7 Check the max. pressure on hydraulic oil pump 1, the pressure
should match the value on the pressure plate.
MPa All pumps should give the same pressure. The order between the
pumps is of no importance.
8 Stop the engine
MPa
9 Transfer the pressure gauge to the next pump and repeat steps
MPa
3–8 on all four pumps.
MPa MPa MPa
MPa
MPa
MPa MPa
001028
920643.0024

Axial piston pump, checking (hydraulic oil pump

page
–
NOTE
Read the safety instructions for oil before working, see Workshop
Manual section B Safety.
es operating temperature, approx. 50 °C.
2 Stop the engine
3 Connect a pressure gauge to measuring outlet on hydraulic oil
pump 1.
5 Check the standby pressure for one pump at a time in the follow-
ing order:
The settings apply to standard machine, certain machines can
1. Hydraulic oil pump 1 have higher standby pressure. For correct standby pressure, see
2. Hydraulic oil pump 2 pressure plate. However, the difference in pressure between the
different pumps must always be maintained.
6 Increase engine speed to approx. 1100 rpm and run extension
function against end-position (overflow).
Run out the boom to max and continue to request max. extension
with the control lever. This will cause the overflow of the exten-
sion function.
7 Check the max. pressure on hydraulic oil pump 1, the pressure
should match the value on the pressure plate.
MPa Both pumps should give the same pressure. The order between
the pumps is of no importance.
MPa
8 Stop the engine

9 Transfer the pressure gauge to pump 2 and repeat steps 3–8.
MPa
MPa
MPa MPa MPa MPa MPa MPa MPa
A49195.0400


page
–
replacement (hydraulic oil pump alternative Rexroth)
NOTE
Safety.
1 Park the machine with the cab in the rearmost position and the
boom fully raised, and half extended.
C AUTION
Make sure that the oil level in the hydraulic oil tank is
below the mouth of the axial piston pump’s suction
hose.
If there is not enough room to lift the boom, the hydraulic oil tank
must be drained; see Hydraulic oil, changing page 47.
2 Disconnect the main power supply.
B Safety.
4 Release the brake fluid pump or cooling pump from the hydraulic
oil pump depending on the pump to be replaced.
5 Suspend the gear pump.
6 Use a plastic bag or similar to protect the connection to the gear
pump.
7 Mark up and detach the hydraulic hoses from the axial piston
pump.
NOTE
contamination.

8 Attach lifting equipment to the axial piston pump.

9 Remove the axial piston pump.
Remove the attaching bolts and lift the pump away.
10 Clean the flange on the gearbox, removing all silicone remnants.
C AUTION
Be careful and make sure that no gasket remains fall
down into the gearbox.
Gasket remains may fall into the gearbox and cause

product damage.
11 Transfer the connection adapters to the new axial piston pump.
NOTE
12 Apply sealing silicone on the axial piston pump flange where it
mates with the gearbox, see section F Technical data.
13 Install the axial piston pump.
Position the axial piston pump so that the pump shaft engages
the gearbox transmission. Install the attaching bolts.
14 Connect the suction hose to the axial piston pump.
15 Fill the pump with oil through the connections on the top.

16 Connect the hydraulic hoses to the axial piston pump in accord-

NOTE
17 If the spacer ring is still on the axial piston pump. Remove the
spacer ring between the gear pump and axial piston pump.
If the spacer ring remains in place on the gear pump, go to step
20.
Clean the O rings’ contact surfaces on the spacer ring.
18 Check the O-rings and replace as needed. Install the O-rings on
the gear pump, see section F Technical data.
NOTE
Only use silicone on one side, the side facing the brake
pump.
19 Fit the spacer ring on the axial piston pump.

20 Brush sealing silicone on the gear pump’s sealing face against

The illustration shows a separate pump.

21 Fit the gear pump in place.
Fit the gear pump on the axial piston pump and install the attach-
ing bolts. Be careful so that the O-ring on the spacer ring is locat-
ed correctly and that the gear pump’s shaft engages the axial
piston pump’s output shaft.
22 Vent the axial piston pump, see Axial piston pump with variable
displacement, bleeding (hydraulic oil pump alternative Rexroth)
page 29.
C AUTION
Vent the axial piston pump before starting the engine.
The oil in the axial piston pump may cavitate and

cause product damage.

C AUTION
010475

27 Check the pump pressures, see Hydraulic oil pump, checking
(hydraulic oil pump alternative Rexroth) page 18.
28 Check the hydraulic oil level with the lift cylinders completely
down and the extension cylinder completely in. The oil level
should be at the top of the level glass. Top up if necessary, for
grade see section F Technical data.
NOTE
and filter in the hydraulic system as well.
C AUTION



page
–
replacement (hydraulic oil pump alternative Sauer-

Danfoss)
NOTE
Safety.
1 Park the machine with the cab in the rearmost position and the
boom fully raised, and half extended.
C AUTION
Make sure that the oil level in the hydraulic oil tank is
below the mouth of the axial piston pump’s suction
hose.
If there is not enough room to lift the boom, the hydraulic oil tank
must be drained; see Hydraulic oil, changing page 47.
2 Disconnect the main power supply.
Safety.
4 Release the brake fluid pump or cooling pump from the hydraulic
oil pump depending on the pump to be replaced.
5 Suspend the gear pump.
6 Use a plastic bag or similar to protect the connection to the gear
pump.
Axial piston pump 2 (left)

Axial piston pump 1 (right) 7 Mark up and detach the hydraulic hoses from the axial piston
pump.

NOTE
contamination.
8 Attach lifting equipment to the axial piston pump.
9 Remove the axial piston pump.
Remove the attaching bolts and lift the pump away.
10 Clean the flange on the gearbox, removing all silicone remnants.
C AUTION
Be careful and make sure that no gasket remains fall
down into the gearbox.
Gasket remains may fall into the gearbox and cause

product damage.
11 Transfer the connection adapters to the new axial piston pump.
NOTE
12 Apply sealing silicone on the axial piston pump flange where it
mates with the gearbox, see section F Technical data.
13 Install the axial piston pump.
Position the axial piston pump so that the pump shaft engages
the gearbox transmission. Install the attaching bolts.
14 Connect the suction hose to the axial piston pump.

15 Fill the pump with oil through the connections on the top.
Axial piston pump 1 (right)

Axial piston pump 2 (Left)

Axial piston pump 1 (right) 16 Connect the hydraulic hoses to the axial piston pump in accord-
NOTE
17 Brush sealing silicone on the gear pump’s sealing surface; see
The illustration shows a separate pump.

18 Fit the gear pump in place.
Fit the gear pump on the axial piston pump and install the attach-
ing bolts. Be careful so that the gear pump’s shaft engages the
axial piston pump’s output shaft.
19 Vent the axial piston pump, see Axial piston pump with variable
displacement, bleeding (hydraulic oil pump alternative Sauer-
Danfoss) page 29.
C AUTION
Vent the axial piston pump before starting the engine.
The illustration shows the gear pump pre-assembled
on hydraulic oil pump 1 The oil in the axial piston pump may cavitate and
cause product damage.


C AUTION

010475

24 Check the pump pressures, see Axial piston pump, checking (hy-
draulic oil pump alternative Sauer-Danfoss) page 19.
NOTE
and filter in the hydraulic system as well.
C AUTION



page
–
bleeding (hydraulic oil pump alternative Rexroth)
NOTE
Safety.
1 Remove the hydraulic oil tank’s breather filter.

2 Connect compressed air at max. pressure max. 10 kPa to the hy-
draulic oil tank’s connection for breather filter.
3 Loosen the hoses to the hydraulic system’s feed from the axial
piston pump one at a time and let oil flow out. Tighten the connec-
tions when oil free of air flows out.
4 Remove the compressed air from the tank and fit the breather fil-
ter.
6 Let the engine idle for at least one minute. Check that all connec-
tions seal tightly.
7 Lower the boom and raise it again very slowly so that the pump
operates under minimum load while air pockets are eliminated.
8 Stop the engine
9 Wash the engine compartment.

page
–
bleeding (hydraulic oil pump alternative Sauer-

Danfoss)
NOTE
Safety.
1 Remove the hydraulic oil tank’s breather filter.

2 Connect compressed air at max. pressure max. 10 kPa to the hy-
draulic oil tank’s connection for breather filter.

30 10 Common hydraulics – 10.4.3 Pipes and hoses

Axial piston pump 1 (right) 3 Loosen the hoses to the hydraulic system’s feed from the axial
piston pump (1 or 2) one at a time and let oil flow out. Tighten the
connections when oil free of air flows out.
4 Remove the compressed air from the tank and fit the breather fil-
ter.
6 Let the engine idle for at least one minute. Check that all connec-
tions seal tightly.
7 Lower the boom and raise it again very slowly so that the pump
operates under minimum load while air pockets are eliminated.
8 Stop the engine
9 Wash the engine compartment.

page
–

10 Common hydraulics – 10.5 Hoses, pipes and valves 31
10.5 Hoses, pipes and valves

page
–
Hoses with ORFS couplings are used almost exclusively. For maxi-
mum service life and function, the following should be observed when
replacing hoses.
1. To avoid stresses in the connection, there should be a length of
straight hose after the connection.
2. The hose may not be twisted. (A twist of 7% reduces service life
by 90%.)
3. Minimise the number of bends by using correct couplings.
4. Avoid sharp bends.
5. Keep the hoses clean internally. Leave the plugs in place as long
as possible when installing.
6. Check the position of the O-rings and tighten to the correct torque,
NOTE
Straight coupling requires a counterhold wrench to prevent
damage to the O-ring.
7. The O-rings must not be oiled when fitted.
Hose length
C/L
Hose length is measured on a laid-out hose between the sealing sur-
faces. On angled connections, measure from the sealing surface's
centre line [C/L] according to the figure.
Cleanliness
The function and service life of hydraulic components depend to a
great extent on how clean the hydraulic oil is. Therefore, it is very im-
portant to prevent dirt from entering the brake and hydraulic system.
Some simple advice to keep the hydraulic system clean.
• Always clean the area around a component before starting to
001015
work.
C/L line for measuring hose length • Plug hose connections immediately after disconnecting. If possi-
ble, use correct plugs for the connection type. If plugs are missing,
use clean plastic bags and cable ties or tape to seal the connec-
tion.
• Never reuse oil that has been drained from the machine.
• If possible, filter the oil before pouring it into the machine. Oil bar-
rels often contain impurities.
When filling hydraulic oil, fill through the caps at the hydraulic oil
filters in the tank so that the oil is filtered.

32 10 Common hydraulics – 10.5.2 Priority valve
10.5.2 Priority valve

Priority valve, description
page
–
See section 5 Steering, group 5.2.2 Priority valve.
10.5.3 Shuttle valve

Shuttle valve, description (hydraulic oil pump
page
–
A shuttle valve chooses between two pressure signals and sends on
the strongest. The shuttle valves are used to sends load signals to the
hydraulic oil pumps. This means that the pumps are controlled by the
function that demands the highest pressure, if several functions are
1 activated at the same time.
Depending on options, there are two to four shuttle valves. The shuttle
2 valves are fitted on a bracket for oil filling between the engine and
transmission.
3 The shuttle valves choose between the following control signals:
1. Chooses between the pressure signal from the control valve for
4
lift, lower and extension and the pressure signal from valve block
top lift hydraulics. The shuttle valve sends the pressure signal on
to hydraulic oil pump 4. See Axial piston pump with variable dis-
placement, description (hydraulic oil pump alternative Rexroth)
page 12.
lift, lower and extension and the pressure signal from the steering
valve. The shuttle valve sends the pressure signal on to control
hydraulic oil pump 2. See Axial piston pump with variable dis-
002203
page 12.
1. Shuttle valve attachment
2. Shuttle valve control 3.
Chooses between the pressure signal from shuttle valve steering
3. Shuttle valve for mini-wheel or joystick control
(position 2) and the pressure signal from the control valve option
4. Shuttle valve option frame frame. The shuttle valve sends the pressure signal on to hydraulic
oil pumps 3 and 4. See Axial piston pump with variable displace-
ment, description (hydraulic oil pump alternative Rexroth) page
12.
This shuttle valve is fitted if the machine is equipped with joystick
control or mini-wheel.
4.
Chooses between the pressure signal from shuttle valve attach-
ment(position 1) and the pressure signal from the control valve
option frame. The shuttle valve sends the pressure signal on to
page 12.
This shuttle valve is fitted if the machine is equipped with support
jacks, hydraulic sliding cab or vertically adjustable cab.

10 Common hydraulics – 10.5.3 Shuttle valve 33
Shuttle valve, description (hydraulic oil pump

page
–
A shuttle valve chooses between two pressure signals and sends on
the strongest. The shuttle valves are used to sends load signals to the
hydraulic oil pumps. This means that the pumps are controlled by the
function that demands the highest pressure, if several functions are
1 activated at the same time.
Depending on options, there are two to four shuttle valves. The shuttle
2 valves are fitted on a bracket for oil filling between the engine and
transmission.
3 The shuttle valves choose between the following pressure signals:
4
lift, lower and extension and the pressure signal from valve block
top lift hydraulics. The shuttle valve sends the pressure signal on
to main pump 1. See Axial piston pump with variable displace-
ment, description (hydraulic oil pump alternative Sauer-Danfoss)
page 13.
lift, lower and extension and the pressure signal from the steering
valve. The shuttle valve sends the pressure signal on to control
placement, description (hydraulic oil pump alternative Sauer-Dan-
002203
foss) page 13.

1. Shuttle valve attachment
3.
2. Shuttle valve control
Chooses between the pressure signal from control valve option
3. Shuttle valve for mini-wheel or joystick control
frame and the pressure signal from the shuttle valve option frame
4. Shuttle valve option frame (position 4). The shuttle valve sends the pressure signal on to hy-
draulic oil pump 2. See Axial piston pump with variable displace-
ment, description (hydraulic oil pump alternative Sauer-Danfoss)
page 13.
This shuttle valve is fitted if the machine is equipped with joystick
control or mini-wheel.
4.
Chooses between the pressure signal from shuttle valve attach-
ment (position 1) and the pressure signal from the control valve
option frame. The shuttle valve sends the pressure signal on to
placement, description (hydraulic oil pump alternative Sauer-Dan-
foss) page 13.
This shuttle valve is fitted if the machine is equipped with support
jacks, hydraulic sliding cab or vertically adjustable cab.

34 10 Common hydraulics – 10.5.4 Collection block, filtered returns
10.5.4 Collection block, filtered returns

Collection block, filtered returns, description
page
–
The block collects several return lines from different components and
1 2 leads these on back to the tank through the tank filters.
The block is fitted on top of the lifting beam in front of the transmission.
003205
1. Collection block, unfiltered returns

2. Collection block, filtered returns
10.5.5 Collection block, unfiltered returns

Collection block, unfiltered return lines, description
page
–
The block collects several return lines from different valves and leads
1 2 these directly back to the tank.
The drain lines are very sensitive to back-pressure, if pressure builds
up in the drain lines the valves will not work properly.
The block is fitted to the side of the lifting beam in front of the transmis-
sion.
003205
1. Collection block, unfiltered returns

2. Collection block, filtered returns

10 Common hydraulics – 10.6 Temperature control, cleaning and hydraulic oil 35
10.6 Temperature control,

cleaning and hydraulic oil
Temperature control, cleaning and hydraulic oil,
page
–
The oil of the hydraulic system is cooled and cleaned through circula-
tion by a separate pump through the radiator and filters. The radiator
˚C
has a temperature-regulated electric fan that prevents overheating.
9 ˚C
D795 Temperature control consists of a hydraulic oil tank, hydraulic oil
pump, hydraulic oil cooler, cooling fan, hydraulic oil filter, fine filter, hy-
D797-R draulic oil temperature sensor and bypass valve.
D3 4 D4 The hydraulic oil pump pumps oil (from the tank) which is cooled in the
hydraulic oil cooler and cleaned by the oil filters in the tank. Some of
5 M the oil is filtered by the fine filter. An electric cooling fan increases the
air flow through the cooler when the temperature needs to be lowered.
2
A bypass valve leads the hydraulic oil past the cooler directly to the
tank if the resistance through the cooler and filters is too high. The
8 temperature sensor controls fan activation and temperature display.
1 6
7
007414
˚C 3
Pos Description Signal value Reference

1 The hydraulic oil pump pumps oil from - Gear pump with fixed displacement, de-
the hydraulic oil tank. scription page 6
2 The hydraulic oil cooler cools the oil. - Hydraulic oil cooler, description page 37
3 The hydraulic oil temperature sensor U = 0.5-4.5 V Sensor hydraulic oil temperature, descrip-
(B776) sends Control unit frame rear tion page 39
(D797-R) a voltage signal proportional to D3: Diagnostic menu, see section 8 Control
the hydraulic oil temperature. system , group 8.4.5.1 HYD, menu 1
4 Control unit frame rear (D797-R) trans- Hydraulic fan active: Section 11 Common electrics, group
mits temperature on the CAN bus and U = 24 V 11.5.3.3 Control unit, frame rear
supplies power to the cooling fan as nec- D4: Diagnostic menu, see section 8 Control
essary. system , group 8.4.5.1 HYD, menu 1
5 The cooling fan (M668) increases air flow - Cooling fan, description page 38
through the radiator.
6 The hydraulic oil filters clean the hydrau- - Hydraulic oil filter, description page 43
lic oil.
7 Some of the oil is pumped through the - Fine filter hydraulic oil, description page 47
hydraulic oil fine-filter for deep cleaning.
8 If resistance through the oil cooler and - Cooler bypass valve, description page 40
hydraulic oil filter becomes too great, the
cooler bypass valve opens and directs
the oil to the tank.

36 10 Common hydraulics – 10.6.1 Tank heater
Pos Description Signal value Reference

9 The KID control unit (D795) shows hy- Checked by control sys- Section 11 Common electrics, group
draulic oil temperature in the display. tem, error shown with 11.5.3.12 KID control unit
error code.
10.6.1 Tank heater

Tank heater, safety
page
–
C AUTION
The tank heater is connected to high voltage. Connec-
tion and reconnection of the tank heater may only be
performed by personnel authorised for work with high
voltage.
Tank heater, description

page
–
The tank can be equipped with a heater. The tank heater is designed
for cold climates.
The tank heater runs off high current. Heater output is adapted through
different connections and adaptation to different operating voltages -
110, 230 or 400 V AC. Higher voltage generates higher heater output.
The heater is mounted in a hole in the connection cover at the bottom
of the short side of the tank.
The tank heater can be equipped with a programmable thermostat
000430
which maintains the temperature at an even level. The thermostat is

fitted directly onto the heating element and can be adjusted with a
knob on the junction box. Recommended temperature setting is 20-
30 °C.

10 Common hydraulics – 10.6.2 Hydraulic oil cooler 37
10.6.2 Hydraulic oil cooler

Hydraulic oil cooler, description
page
–
The working hydraulics use a through-flow cooler with electric cooling

fan (the same type of cooler as used for the brake system). The oil is
cooled when it passes the cooler, which is fitted inside the side panel
on the right-hand side behind the hydraulic oil tank.
001013
Hydraulic oil cooler, change

page
–
NOTE
Safety.

2 Drain the oil from the hydraulic oil tank; see Hydraulic oil, chang-
ing page 47.

38 10 Common hydraulics – 10.6.3 Cooling fan
3 Mark up and disconnect hydraulic hoses from the cooler. Let the
oil in the cooler drain into the collection container.
NOTE
contamination.
4 Disconnect the cabling from the cooling fan.
5 Remove the attaching bolts and lift away the cooler.
6 Transfer the cooling fan to the new cooler.
7 Install the cooler.
8 Connect the cabling to the cooling fan.
9 Connect the hydraulic hoses to the cooler.
1. Cooling fan
2. Connector NOTE
3. Radiator Check that the O-rings are intact and fitted correctly.
C AUTION

10.6.3 Cooling fan

Cooling fan, description
page
–
The electric cooling fan is forcing. The cooling fan is located at the rear
of the cooler. The fan draws air from the machine’s outside through the
cooler. Openings in the side cover allows air to pass through the
cooler.
The radiator is supplied voltage by Control unit frame rear (D797-R)
upon activation when the engine is running. The cooling fan is activat-
ed when oil temperature is 65 °C in the hydraulic oil tank and is deac-
tivated when oil temperature is 55 °C.
The signal can be checked from the diagnostic menu, see tab 8 Con-
trol system , group 8.4.5.1 HYD, menu 1.7
001014

10 Common hydraulics – 10.6.4 Sensor hydraulic oil temperature 39
10.6.4 Sensor hydraulic oil temperature

Sensor hydraulic oil temperature, description
page
–
The hydraulic oil temperature sensor (B776) detects the temperature

of the hydraulic oil. The sensor is located on the hydraulic oil tank’s
rear short end.
The sensor detects the oil temperature in the tank, determining the ac-
cumulated heat in the hydraulic oil. Because of this, the cooling fan
may continue to run after the machine has been parked and switched
off.
The hydraulic oil temperature sensor (B776) is supplied voltage by,
and sends a voltage signal proportional to the oil temperature to, Con-
trol unit frame rear (D797-R).
Control system, group 8.4.5.1 HYD, menu 1.
001092
Hydraulic oil temperature sensor, change

page
–
NOTE
Safety.

ing page 47.
3 Disconnect the cabling from sensor hydraulic oil temperature
(B776).
4 Change sensor hydraulic oil temperature (B776).
NOTE
5 Connect the cabling to the sensor.
008222
Sensor hydraulic oil temperature (B776)

40 10 Common hydraulics – 10.6.5 Radiator bypass valve
C AUTION

7 Use the display, go to the diagnostic menu, see section 8 Control

DIAG HYD 1(6) system, group 8.4.5.1 HYD, menu 1.
HYDRAULIC OIL
TEMP XXX TEMP indicates hydraulic oil temperature in °C. Check that cor-
FAN XY rect temperature is shown.
000141
Diagnostic menu Hyd, menu 1
10.6.5 Radiator bypass valve

Cooler bypass valve, description
page
–
The bypass valve protects the cooler from overpressure. The valve
opens a passage past the cooler directly to the tank if resistance in the
cooler becomes too high.
007426

10 Common hydraulics – 10.6.5 Radiator bypass valve 41
Cooler bypass valve, replacement

page
–
NOTE
Safety.
I M P OR TA NT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
1 Machine in service position, section B Safety.

ing page 47.
4 Disconnect the bypass valve from the tank.
NOTE
Note how the bypass valve faces; the valve is marked with
an arrow.
5 Install the new bypass valve, turning the valve to face the same
way as the old one. Use Loctite when fitting the bypass valve.
007426
Bypass valve
C AUTION

42 10 Common hydraulics – 10.6.6 Breather filter hydraulic oil tank
10.6.6 Breather filter hydraulic oil tank

Breather filter hydraulic oil tank, description
page
–
A breather filter of insert type is mounted on the hydraulic oil tank to

protect the tank from impurities. On top of the filter housing is an indi-
cator that shows when the filter is clogged and should be changed.
001454

10 Common hydraulics – 10.6.7 Oil filter 43
10.6.7 Oil filter

Hydraulic oil filter, description
page
–
The oil in the hydraulic system is cleaned by two return filters located
inside the hydraulic oil tank. The oil is pumped through the cooler and
back through the filters by the cooling pump. Some of the return oil
from the load handling functions also passes through the filters.
001455
Hydraulic oil filter, description (high-pressure filter)

page
–
As an option the machine can be equipped with two additional high-

pressure filters that are fitted directly after the axial piston pumps. The
filters are placed in front of the transmission under the lifting beam.
The filters are used in conjunction with the hydraulic oil filters in the
tank.
003602

44 10 Common hydraulics – 10.6.7 Oil filter
Hydraulic oil filter, replacement

page
–
NOTE
Safety.
I M P OR TA NT

2 Remove the cover plates (position 1) over the hydraulic oil filters.
3 Lift up the filter unit and place it in the receptacle. Let the hydrau-
lic oil drain.
4 Separate the filter unit and remove the filter insert. Handle the fil-
ter insert as environmentally hazardous waste. Note the position
of the parts.
1. Oil filter cover

2. Hydraulic oil filler orifice
5 Clean the filter holder’s parts. Be especially thorough with the
magnetic rod.
6 Fit the new filters and assemble the filter units.
7 Install the filter units and the covers. Tighten the screws
crosswise.
Magnetic rod

10 Common hydraulics – 10.6.7 Oil filter 45
C AUTION

Hydraulic oil filter (high-pressure filter), replacement

page
–
NOTE
Safety.
I M P OR TA NT

2 Depressurise the hydraulic and brake systems; see section B
Safety.
3 Remove the drain plugs in the bottom of the filters.
Let the oil run out. Wait a moment since it runs out slowly.
4 Remove the filter holders.
NOTE
The filter holders are heavy, loosen them carefully.
5 Clean the filter holders.
6 Remove the filter inserts.
NOTE
Note the location of the O-rings.
7 Fit the O-rings on the filter inserts and filter holders. Lubricate the
O-rings with hydraulic oil.
003602
8 Fit the new filter inserts on the filter mounting.
High-pressure filter, under machine 9 Fit the filter holder and drain plug.

46 10 Common hydraulics – 10.6.7 Oil filter
NOTE
C AUTION

010475

13 Check that the filter holders are not leaking.
C AUTION


10 Common hydraulics – 10.6.8 Hydraulic oil 47
10.6.8 Hydraulic oil

Hydraulic oil, changing
page
–
NOTE
Safety.
I M P OR TA NT

2 Remove the filler cap and pump out the hydraulic oil into a recep-
tacle.
3 When as much oil as possible has been pumped out. Place a re-
ceptacle under the hydraulic oil tank’s drain plug and drain the
last of the hydraulic oil.
4 Fit the drain plug when the oil has drained.
1. Oil filter cover NOTE

2. Hydraulic oil filler orifice Make sure that the seal washer is installed as well.
5 If the hydraulic oil filters are to be changed, change them before
filling the tank with oil, see Hydraulic oil filter, replacement page
44 and Hydraulic oil filter (high-pressure filter), replacement page
45.
6 Fill new hydraulic oil through the filler holes on the filters’ covers.
This results in filtering of the oil that is filled and protects the hy-
draulic system from impurities.
Fill oil until the oil level is in the middle of the level glass. For vol-
ume and grade, see section F Technical data.
10.6.9 Hydraulic oil fine-filter

Fine filter hydraulic oil, description
page
–
The fine filter is located on the frame member in the engine compart-
ment. The filter is connected to hydraulic oil pump cooling and filtra-
tion. The filter is connected in parallel to the hydraulic oil filters in the
hydraulic oil tank.
Oil is pumped from the hydraulic oil tank through the fine filter and then
back to the hydraulic oil tank.
The fine filter cleans a smaller amount of oil but with a higher degree
of filtration when the machine is running.

48 10 Common hydraulics – 10.6.10 Pipes and hoses
Hydraulic oil fine filter, replacement

page
–
NOTE
Safety.
I M P OR TA NT
Make sure that the area around the filter is clean when
working.

2 Remove the cover.
3 Lift up the filter insert and place it in the receptacle. Let the hy-
draulic oil drain.
4 Fit the new filter insert and refit the cover over the fine filter.
C AUTION


page
–

10 Common hydraulics – 10.7 Auxiliaries 49
10.7 Auxiliaries
10.7.1 Hydraulic cylinders
page
–
Fault tracing, leakage
C AUTION
All fault tracing should be carried out with as low a
pressure in the system as possible so that the leak-
age can be detected. High pressure causes the seals
to close tighter, which prevents detection of leaks.
1 Carefully check the source of the leakage before taking any ac-
tion. It may be possible to rectify the fault without disassembly.
2 Check for external leakage:
• At cylinder end welds
• At sleeve coupling welds
• Between cylinder barrel and cylinder head
This could be due to a defective O-ring or damaged O-ring
sealing surfaces. Both faults can be rectified with the cylinder
in situ.
• Between cylinder head an piston rod
This could be due to a damaged piston rod or damaged or
worn piston rod seal.
3 Check for internal leakage. Pressurise the cylinder and check
whether the piston sinks back.
1. Piston rod
2. Scraper This could be due to a worn piston seal.
3. Cylinder head
4. Piston rod seal Dismantling of cylinders
5. O-ring with thrust ring
6. Cylinder barrel
7. Sleeve coupling C AUTION
8. Welded cylinder end face
9. Piston
Before dismantling always check that the piston rod
10. Piston seal, double-acting
is clean and free from all residual paint. Also check
11. Example of weld
that connections and couplings are free from burrs
and impact marks. Make sure that the chamfer up to
the chromium surface of the piston rod is free from
burrs and residual paint.
1 Remove the cylinder from its mounting and undo the connec-
tions.
2 Plug the cylinder connections and hoses without delay.

50 10 Common hydraulics – 10.7.1 Hydraulic cylinders
3 If the cylinder is opened - observe the strictest cleanliness!
Inspection of surfaces
1 Inspect the sealing surfaces. Always bearing mind the function of
the seals and the type of sealing surfaces they have. See the fol-
lowing descriptions:
• O-ring groove, internal and external
• piston rod seal in the cylinder head
• sealing groove on the piston
• cylinder barrel surface
• piston rod surface. The piston rod is chromium plated with a
layer thickness of 20-50 my. Slight damage to the chromium
plating may not necessarily be the direct cause of leakage.
• all sliding surfaces (dynamic surfaces), e.g. cylinder barrel
and piston rod. These are always the hardest to seal.
C AUTION
When fitting the cylinder head:
Get it absolutely straight. This is best done by hand.

Under no circumstances hit it with any mallet. If the
cylinder head is fitted crooked, the sealing lip of the
piston rod seal could be damaged, making an improp-
er seal. This applies to all types of piston rod seals.

10 Common hydraulics – 10.7.1 Hydraulic cylinders 51
Function and removal of the seals
2 Piston rod seal

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 greatly subject to
1
wear since it is both a dynamic and a static seal, i.e. it seals against a
moving surface on the piston rod while the sealing surface with the cyl-
inder head is fixed. There are different types of piston rod seals:
• Single V-ring seal
3 • Pre-stressed V-ring seal with thrust ring
• Compressible seal
4 The simple V seal has a V-shaped section with two lips that seal in
6 opposite directions. The hydraulic pressure works in the V-shape,
pressing the sealing lips out towards the sealing surfaces on the piston
rod and in the cylinder barrel. Even minor damage to the sealing lips
can generate large leaks. Examine the sealing lips by carefully using
a fingernail to feel around the seal. To remove, use a screwdriver to
prise the seal outward and bend it up (see illustration). It is extremely
important that the screwdriver is always inserted in the V shape so that
it cannot touch and thereby damage a sealing surface. A mark from a
001497
5 screwdriver on a sealing surface can have a devastating effect and

1. Hydraulic pressure cause major leakage.
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
The pretensioned V seal also has an O-ring in the seal’s V-shaped
2
space. The O-ring creates a strong seal at low hydraulic pressure
1 since the O-ring already presses the sealing lips out toward the sealing
surfaces when unloaded. It is just as sensitive to damage as the V
seal. Examine in the same manner. To remove, use a screwdriver to
prise the seal outward and bend it up (see illustration). It is extremely
important that the screwdriver is always inserted in the V shape so that
3 it cannot touch and thereby damage a sealing surface. A mark from a
7
screwdriver on a sealing surface can have a devastating effect and
6 4 cause major leakage.
001498
5
1. Hydraulic pressure
6. Screwdriver
7. O-ring

The compressible piston rod seal consists of a solid rubber profile

2
and provides a larger sealing surface than the V seals. To remove, use
a screwdriver to prise the seal outward and bend it up (see illustration).
1
With this type of seal with sealing surfaces that cover so much of the
3 seal groove, it is particularly important that marks are not made with
the screwdriver.
6
4
5 001499
5
6. Screwdriver
Thrust ring and O-ring
The thrust ring and O-ring combination is used for sealing between two
fixed surfaces, such as between cylinder barrel and cylinder head.
The purpose of the thrust ring is to lend rigidity to the O-ring so that it
is not deformed. The O-ring is pressed against the thrust ring and the
3
sealing surface by the hydraulic pressure in the cylinder.
4 When the cylinder head is mounted in the barrel: Take extreme care
not to damage the O-ring.
2
001506
1
2. O-ring
3. Thrust ring

Scraper
øD+10
The purpose of the scraper is to scrape the piston rod clean and pre-
1 vent impurities from entering the cylinder barrel.
The scraper is fitted with a special fitting tool, which has a greater outer
diameter than the scraper so that the press force against the scraper
2 ceases right when the scraper is pressed into position. If the scraper
were to be pressed in further, the metal capsule will be deformed (see
lower illustration), which would impair the function of the scraper.
4
To prevent the scraper from bottoming in its recess in the cylinder
3 head, the recess is slightly deeper than the width of the scraper.
øD
6
001496
1. Correct assembly tool

2. Scraper, correctly fitted
3. Cylinder head
4. Clearance between scraper and bottom of cylinder
head cavity
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
2 then prise out the scraper. Polish away any damage to the cylinder
head.
C AUTION
3 No tool must be applied from the inside. This could
give rise to burrs on the cylinder head which could in
turn damage the piston rod. Burrs may also damage
the piston rod seal when fitting the piston.
001551
1. Screwdriver
2. Scraper
3. Cylinder head

On the single-acting V-ring seal it is always the long side that seals
2
against the fixed surface and the short side that seals against the mov-
ing surface.
1 To remove, use a screwdriver to prise the seal outward and bend it up
(see illustration). It is extremely important that the screwdriver is al-
ways inserted in the V shape so that it cannot touch and thereby dam-
age a sealing surface. A mark from a screwdriver on a sealing surface
3 can have a devastating effect and cause major leakage.
6 4
002370
5
2. Seal pressed out toward cylinder barrel
3. Seal pressed in toward piston
4. Sealing surface, cylinder barrel
5. Sealing surface. piston
6. Screwdriver
The seal must always be fitted as an assembly together with the thrust
ring.
Always assemble by hand. No tools should be used as they could eas-
ily damage the surface of the piston.
For easier assembly the seal can be heated in hot water to make it
soft.
Lubricate with hydraulic oil.
002950
Double-acting piston seal

5 4 3 1 6
The double-acting seal functions with pressure from both sides, e.g. in
a steering cylinder.
All of the interior surface of the cylinder barrel is a sealing surface and
it is therefore extremely important that it is completely free from
damage.
Exercise care when fitting the piston in the cylinder barrel, making sure
2
002951
that the seal is not damaged by the cylinder barrel threads.
1. Variable sealing surface to cylinder barrel Dismantling:

2. Fixed sealing surface with piston
1 Remove guide rings and thrust rings.
3. Guide ring
4. Thrust ring 2 Move the seal over to one side of the sealing groove.
5. Piston crown 3 Press it up so that there is a gap between seal and piston.
6. Cylinder barrel

4 Without damaging the surface of the piston - cut off the seal with
a knife.
5 Carefully examine the seal to find any damage that can cause
leakage. This will be easier if you bend the seal sharply bit by bit
and feel over the sealing surface with a fingernail.
Assembly:
1 All double-acting piston seals are of similar design: a middle seal-
ing body. then thrust rings and farthest out guide rings.
2 First fit the sealing body, then the thrust rings and finally the guide
rings - all must be done by hand without tools to avoid damage.
Repairing the piston rod surface

A small impact mark on a piston rod may be sufficient to cause leak-
1 2 3
age. The chromium plating on the piston rod has a thickness of 20-50
micrometres and can be treated to make good minor damage. This
may be a satisfactory alternative to costly disassembly.
1 Locate the damage using your fingertips and fingernails.
4 2 Use a small, highly-polished hammer and work the surrounding

material inwards towards the damage, starting from the outside.
3 Instead of a small sharp mark there will now be a small uniform
concavity in the chromium plating.
4 Polish with emery cloth, progressing from number 240 to 600.
Wrap the emery cloth round a file to give it good support. Note
that there must always be chromium plating present at the
damage.
5 It is important to treat small impact marks before disassembly and
assembly to avoid damaging the cylinder head.
6 Repairing larger damage on a piston rod
002952
• fill the damage with weld metal, use chromium or stainless

1. Piston rod steel electrodes
2. Chromium plating • remove all slag completely
3. Impact mark
• file the weld down to the same level as the chrome
4. Highly-polished hammer
• polish evenly using emery cloth

Dismantling steering cylinders

It can prove extremely difficult to extract the piston rod from the cylin-
der barrel on steering cylinders because the O-ring in the cylinder
head fastens in the retaining ring groove in the cylinder barrel. It is
therefore best to remove the O-ring before trying to withdraw the pis-
ton 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
the like 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 retaining ring from the cylinder barrel.
10 Carefully extract the piston rod from the cylinder barrel.
002953

11 Common electrics 1
11 Common electrics
Table of Contents 11 Common electrics

mm mm mm mm mm mm
11 Common electrics .......................................................................................... 3

11.2 Electric protection ....................................................................................... 3
11.2.1 Battery disconnector .............................................................................. 3
11.2.2 Fuses ..................................................................................................... 3
11.2.3 Safety switch .......................................................................................... 3
11.3 Batteries ..................................................................................................... 4
11.3.1 Start battery ........................................................................................... 4
11.4 Alternator .................................................................................................... 6
11.4.1 Alternator ............................................................................................... 6
11.5 Distribution of electricity ............................................................................. 7
11.5.1 Power supply ......................................................................................... 7
11.5.2 Electronic box ...................................................................................... 16
11.5.3 Control units ......................................................................................... 18
11.5.5 Cables .................................................................................................. 33
11.6 Communication ........................................................................................ 43
11.6.1 CAN-bus .............................................................................................. 43
11.6.2 Redundant CAN bus ............................................................................ 45
11.6.3 CAN bus drivetrain ............................................................................... 48
11.6.4 Communication between PC and machine .......................................... 49
11.6.5 RMI (Remote Machine Interface) ......................................................... 50
11.6.6 Kalmar CAN Customer Gateway ......................................................... 51

2 11 Common electrics

11 Common electrics 3
11 Common electrics
mm mm mm mm mm mm
11.2 Electric protection

11.2.1 Battery disconnector
Battery disconnector, description
page
–
The positive terminals of the batteries connected in series are con-

nected to the machine’s electrical system via the battery disconnect
switch. The battery disconnector cuts off all power from the batteries
to the machine’s electrical system.
I M P OR TA NT
Never turn off the voltage with the battery disconnect
A switch when the engine is running. This could dam-
age the alternator.
The battery disconnect switch must not be used for

emergency stop!
000268
A. Position of battery disconnect switch
11.2.2 Fuses
Fuses, replacement
page
–
When checking and replacing the main fuse:

1. Switch off the main current (battery disconnect switch).
2. Remove the plastic cover.
3. Check that fuses are intact. Replace if necessary.
The fuses are 25 A.
When checking and replacing the fuse:
1. Switch off the main current (battery disconnect switch).
2. Remove the cover of the electronic box.
3. Check and, if necessary, replace fuses.
The fuse chart provides information about each fuse.
11.2.3 Safety switch

Emergency stop, description
page
–
See Emergency stop switch voltage (15E), function description page

11.

4 11 Common electrics – 11.3 Batteries
11.3 Batteries
11.3.1 Start battery
Start battery, description
page
–
The machine’s electrical system is supplied by two 12 V batteries con-

nected in series.
The negative terminal is connected to the frame. The positive terminal
is connected to the battery disconnector.
The batteries are charged by the alternator, see Alternator, description
(engine alternative Volvo) page 6.
WARN IN G
Battery electrolyte contains corrosive sulphuric acid
Risk of corrosive injuries, health hazard!
Immediately remove electrolyte from the skin. Wash

with soap and copious amounts of water. If electrolyte
gets in the eyes, rinse with copious amounts of water
000269
and seek medical help immediately.
WARN IN G
Risk of explosion!
Personal injury!
During charging, hydrogen gas forms around the bat-

teries. Sparks could ignite the hydrogen gas, causing
an explosion. Disconnect the battery with the battery
013022
disconnect switch.
Alternative location for batteries
WARN IN G
Risk of explosion if the battery short circuits (also
causes loss of capacity).
Fire hazard, personal injury!
The battery's terminals may not be connected to each

other or commonly to ground (frame).

11 Common electrics – 11.3.1 Start battery 5
Starter battery, replacement

page
–

2 Disconnect the cables from the battery terminals, starting with the
negative (minus) cable.
3 Replace the batteries.
4 Connect the cables to the battery terminals. Connect the nega-
tive cable last of all.
NOTE
Take great care when reconnecting the cables to prevent
short circuiting.
000269

6 11 Common electrics – 11.4 Alternator
11.4 Alternator
11.4.1 Alternator
Alternator, description (engine alternative Volvo)
page
–
The alternator generates current during operation and supplies this to

the batteries. The alternator produces AC current and has an integrat-
ed charge regulator.
The alternator is driven by the engine via a belt. Faults are indicated
by the warning lamp for low battery charging.
The signal can be checked from the diagnostic menu, section 8 Con-
trol system , section 8.4.6.4 ENGINE, menu 4.
001905
The illustration shows engine alternative Volvo

TWD1240VE
Alternator, description (engine alternative Cummins

page
–
QSM11)
The alternator generates current during operation and supplies this to
the batteries. The alternator produces AC current and has an integrat-
ed charge regulator.
The alternator is driven by the engine via a belt. Faults are indicated
by the warning lamp for low battery charging.
The signal can be checked from the diagnostic menu, section 8 Con-
trol system , section 8.4.6.4 ENGINE, menu 4.
007444
Alternator, replacement
page
–

11 Common electrics – 11.5 Distribution of electricity 7
11.5 Distribution of electricity

11.5.1 Power supply
11.5.1.2 Redundant voltage feed of control
units
Redundant voltage feed for control units, description of
page
–
operation
1 2 3 4
D1 D2 D3 D4
- +
D8 D7 D9
D11
D795 D790-1 D797-R D797-F D797-O D793

11 5, 6 8 7 9
10 12 13 14
D790-2 D791-1 D791-2 D791-3 D791-4 D794
007420
D10 D12 D13 D14
Pos Explanation Signal de- Reference

scription
1 The NC switch, operator’s door (S 266-LE) U = 24 V Section 9 Frame, body, cab and accessories, group
or the NC switch, passenger door (S 266- 9.10.2 Doors
RI) sends a voltage signal to the cab control D1: Diagnostic menu, see section 8 Control system,
unit (D790-1) when the door is opened. group 8.4.2.12 LIGHTS, menu 12 or 8.4.11.2 SLID-
ING CAB, menu 1
2 The interior lighting switch of the cab control - Section 9 Frame, body, cab and accessories, group
unit (D790-2) sends a voltage signal to the 9.6.12 Interior lighting
cab control unit (D790-1). D2: Diagnostic menu, see section 8 Control system,
group 8.4.2.12 LIGHTS, menu 12
3 The switch for warning lights (S109) sends U = 24 V Section 9 Frame, body, cab and accessories, group
a voltage signal to the cab control unit 9.6.7 Warning lights
(D790-1). D3: Diagnostic menu, see section 8 Control system,
4 When the ignition (S150) is turned to posi- U = 24 V Section 9 Frame, body, cab and accessories, group
tion I, it sends a voltage signal to the cab 9.1 Controls and instruments
control unit (D790-1). D4: Diagnostics menu, see section 8 Control sys-
tem, group 8.4.1.4 CAN/POWER, menu 4
5 The cab control unit (D790-1) activates a - Cab control unit, description page 19
hold circuit, which activates the control
unit’s control logic.

8 11 Common electrics – 11.5.1.2 Redundant voltage feed of control units
Pos Explanation Signal de- Reference

scription
6 The cab control unit (D790-1) activates a UK11:7 = 24 V Cab control unit, description page 19
redundant voltage feed to other control
UK11:8 = 24 V
units.
UK11:9 = 24 V
The cab control unit (D790-1) has 4 outputs
for redundant voltage feed while other con- UK11:10 = 24 V
trol units have two inputs for redundant volt-
age feed. In case of a malfunction of one
voltage feed the control unit is supplied by
the other feed.
7 The cab control unit (D790-1) supplies volt- UK2:7 = 24 V Control unit, frame front, description page 20
age to the control logic of the other control D7: Diagnostics menu, see section 8 Control sys-
UK2:8 = 24 V
units via the redundant voltage feed. tem, group 8.4.1.8 CAN/POWER, menu 8
8 UK2:7 = 24 V Control unit, frame rear, description page 21

UK2:8 = 24 V D8: Diagnostics menu, see section 8 Control sys-
9 UK2:7 = 24 V Control unit, frame option, description page 22

10 UK2:7 = 24 V Attachment control unit, description page 23

tem , group 8.4.1.16 CAN/POWER, menu 16
11 UK2:7 = 24 V KID control unit, description page 31

12 UK2:7 = 24 V Attachment control unit, option, description page 24

13 UK2:7 = 24 V Control unit, attachment left jack pair, description

page 25
UK2:8 = 24 V
D13: Diagnostics menu, see section 8 Control sys-
14 UK2:7 = 24 V Control unit, attachment right jack pair, description

page 26
UK2:8 = 24 V
D14: Diagnostics menu, see section 8 Control sys-

11 Common electrics – 11.5.1.3 Ignition voltage (15) 9
11.5.1.3 Ignition voltage (15)

Ignition voltage (15), description of operation
page
–

Battery disconnector In position 1 Battery disconnector, description page 3
Redundant voltage feed Activated Redundant voltage feed for control units, description of op-
eration page 7
Redundant CAN bus Communication estab- Redundant CAN bus, description page 45
lished
- +
D4
1 2
D1 D2 D3 3 6
4, 5
D8 D9 D10 D11 D12
D795 D790-1 D797-R D797-F D797-O D793

2, 8 9 10 11 12
7
D790-2 D791-1 D791-2 D791-3 D791-4 D794
007421
Pos Explanation Signal Reference
description
1 Warning light comes on and sends a U = 24 V Section 9 Frame, body, cab and accessories, group
voltage signal to the cab control unit 9.6.7 Warning lights
(D790-1). D1: Diagnostic menu, see section 8 Control system ,
2 When the start key is turned to posi- U = 24 V Section 9 Frame, body, cab and accessories, group
tion I, it sends a voltage signal to the 9.1 Controls and instruments
cab control unit (D790-1). D2: Diagnostics menu, see section 8 Control system,
group 8.4.1.4 CAN/POWER, menu 4
3 The cab control unit (D790-1) sup- U = 24 V Cab control unit, description page 19
plies voltage to ignition voltage relay D3: Diagnostics menu, see section 8 Control system,
K315-1 in the frame electronic box group 8.4.1.4 CAN/POWER, menu 4
and ignition voltage relay K315-2.
4 Ignition voltage relay K315-1 supplies U = 24 V -

voltage to fuse holder in the cab elec-
tronic box and in the frame electronic
box.

10 11 Common electrics – 11.5.1.3 Ignition voltage (15)
Pos Explanation Signal Reference

description
5 The fuses feed voltage to control U = 24 V -
units, relays, solenoid valves and oth-
er electronic components.
6 Ignition voltage relay K315-2 supplies U = 24 V Control unit, engine, description (engine alternative
voltage to the engine control unit Volvo TWD1240VE) page 28
(D794).
7 Drivetrain’s CAN-bus establishes Checked by control Drivetrain CAN bus, description page 48
communication. system, error
shown with error
code.
8 Ignition voltage to the cab control unit UK1:2 = 24 V Cab control unit, description page 19
(D790-1). D8: Diagnostics menu, see section 8 Control system,
UK1:3 = 24 V
UK1:4 = 24 V
9 Ignition voltage to Control unit, frame UK2:1 = 24 V Control unit, frame rear, description page 21
rear (D797-R). D9: Diagnostics menu, see section 8 Control system,
UK2:9 = 24 V
10 Ignition voltage to Control unit, frame UK2:1 = 24 V Control unit, frame front, description page 20
front (D797-F). D10: Diagnostics menu, see section 8 Control sys-
UK2:9 = 24 V
UK2:10 = 24 V
11 Ignition voltage to Control unit, frame UK2:10 = 24 V Control unit, frame option, description page 22
option (D797-O). D11: Diagnostics menu, see section 8 Control sys-
12 Ignition voltage to the transmission UA1 = 24 V Transmission control unit, description page 27
control unit (D793). D12: Diagnostics menu, see section 8 Control sys-

11 Common electrics – 11.5.1.4 Emergency stop switch voltage 11
11.5.1.4 Emergency stop switch voltage

Emergency stop switch voltage (15E), function description
page
–

value
Redundant volt- Activated Redundant voltage feed for control units, description of operation page 7
age feed
Ignition voltage Activated Ignition voltage (15), description of operation page 9
Safety switch Not activated Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments
3, 4 6
- +
D4 D5
D2
D7 D8
D795 D790-1 D797-R D797-F D797-O D793

1, 2, 5 7 8
12 11 10 9
D790-2 D791-1 D791-2 D791-3 D791-4 D794
007422
D12 D11 D10 D9

1 Ignition voltage is activated by the cab Checked by control sys- Ignition voltage (15), description of opera-
control unit (D790-1). tem, error shown with tion page 9
error code.
2 The cab control unit (D790-1) supplies UK3009-1/86 = 24 V Cab control unit, description page 19
voltage to the emergency stop switch volt- D2: Diagnostics menu, see section 8 Con-
age relay (K3009-1) in the frame electron- trol system , group 8.4.1.5 CAN/POWER,
ic box. menu 5
3 The emergency stop switch voltage relay UK3009-2/87 = 24 V Electronic box frame, description page 17
(K3009-1) supplies voltage to the emer- D3: Diagnostics menu, see section 8 Con-
gency stop switch voltage relay (K3009-2) trol system , group 8.4.1.5 CAN/POWER,
in the frame electrical distribution box. menu 5

12 11 Common electrics – 11.5.1.4 Emergency stop switch voltage

(K3009-1) also sends a voltage signal to D4: Diagnostics menu, see section 8 Con-
UK3009-2/87 = 0 V
the cab control unit (D790-1), which veri- trol system , group 8.4.1.5 CAN/POWER,
fies that emergency stop switch voltage menu 5
relay K3009-1 is active but emergency
stop switch voltage relay K3009-2 is
inactive.
This verifies that the operation breaker is
working.
5 The cab control unit (D790-1) activates UK3009-2/86 = 24 V Cab control unit, description page 19
the emergency stop switch voltage relay D5: Diagnostics menu, see section 8 Con-
(K3009-2) in the electronic box. trol system , group 8.4.1.5 CAN/POWER,
menu 5
K3009-2 supplies voltage to emergency
stop switch circuit.

11 Common electrics – 11.5.1.4 Emergency stop switch voltage 13

7 The control units are supplied with emer- Emergency stop switch Control unit, frame front, description page
gency stop switch voltage as long as in home position: UK2:6 20
emergency stop switch is not pressed in. = 24 V D7: Diagnostics menu, see section 8 Con-
The control units on the attachment are trol system , group 8.4.1.8 CAN/POWER,
only supplied emergency stop switch volt- menu 8
age, thus all attachment functions stop if
8 Emergency stop switch Control unit, frame option, description page
the emergency stop switch is activated.
in home position: UK2:6 22
If the emergency stop switch is pressed, = 24 V D8: Diagnostics menu, see section 8 Con-
ignition voltage to the cab control unit
trol system , group 8.4.1.12 CAN/POWER,
(D790-1) is cut off, thereby cutting off con-
menu 12
trol current to emergency stop switch volt-
9 age relay (K3009-1) and emergency stop Emergency stop switch Control unit, attachment right jack pair, de-
switch voltage relay (K3009-2). The power in home position: UK2:1 scription page 26
supply to the control units is cut off and the = 24 V D9: Diagnostics menu, see section 8 Con-
functions cease. trol system , group 8.4.1.19 CAN/POWER,
Emergency stop switch
As an extra safety measure, the cab con- in home position: UK2:11 menu 19
trol unit (D790-1) also transmits the status = 24 V
of the emergency stop switch the CAN
10 bus. Thus, functions are also cut off at the Emergency stop switch Control unit, attachment left jack pair, de-
signal level. in home position: UK2:1 scription page 25
= 24 V D10: Diagnostics menu, see section 8 Con-
Emergency stop switch trol system , group 8.4.1.18 CAN/POWER,
in home position: UK2:11 menu 18
= 24 V
11 Emergency stop switch Attachment control unit, option, description

in home position: UK2:1 page 24
= 24 V
12 Emergency stop switch Attachment control unit, description page

in home position: UK2:1 23
= 24 V
in home position: UK2:10
= 24 V
in home position: UK2:11
= 24 V

14 11 Common electrics – 11.5.1.5 Voltage converter
Emergency stop switch, checking

page
–
1 Start the machine and active any load handling function.

2 Activate lift.
3 Press in the emergency stop switch and check that the lifting
movement stops.
4 Reset the emergency stop switch (turn in the arrows’ direction)
and check that the lift function works again.
000039
Safety switch
11.5.1.5 Voltage converter

Voltage converter, description
page
–
The voltage converter is located under a protective casing to the left

behind the operator’s seat.
The voltage converter converts 24 Volt to 12 Volt. 12 V voltage is avail-
able for accessories by means of a connector X067 in the cab’s elec-
tronic box. (Contains both 15, 30-voltage, ground and 12V.)

11 Common electrics – 11.5.1.5 Voltage converter 15
Voltage converter, replacement

page
–

2 Remove the covers behind the driver’s seat.
3 Detach the electrical cables from the converter.
4 Remove the voltage converter.
The voltage converter is located behind the operator’s

seat.

16 11 Common electrics – 11.5.2 Electronic box
11.5.2 Electronic box

11.5.2.1 Electronic box cab
Electronic box cab, description
page
–
The electronic box is mounted on the rear wall of the cab, on the left.
Located there are:
• Control unit cab (D790-1)
• Circuit fuses
6 • Buzzer for alarm if, for example, the operator leaves the machine
without the parking brake being applied
• Connectors
• Relays
•
Voltage converter 24 V to 12 V
• Connector customer accessory. Output voltage 24 V, max. 10 A.
1
Connector 2-pin Universal mate-n-lock. For part number see
Spare parts catalogue.
2
3 NOTE
This connector is not on the machine if the machine is
4 equipped with voltage converter.
5
008230
1. Control unit cab (D790-1)

2. Outlet for control unit programming
3. Outlet for drivetrain CAN bus
4. Fuse holder
5. Voltage converter
6. Customer accessory connector 24V / 10A

11 Common electrics – 11.5.2.2 Electronic box frame 17
11.5.2.2 Electronic box frame

Electronic box frame, description
page
–
The electrical distribution box is mounted on the side of the machine.

3 4
2 Also located there are:
1 5
4
• Circuit fuses
F5
6
D7
9 3
• Socket for programming transmission control unit (D793)
F5
9 7
F5
68
8-1
X1
F5
K1
8-2
• Main fuses
8-3
K3 K4
K2
• Transmission control unit (D793)
8 • Power relays for voltage feed to the machine’s functions.
004923
1. Circuit fuses
2. Socket for programming transmission control unit
(D793)
3. Power relay (K315-1)
4. Main fuses
5. Transmission control unit (D793)
6. Main fuse
7. Relay (K315-2)

18 11 Common electrics – 11.5.3 Control units
11.5.3 Control units

Control units, position
page
–
1 2 3 4 5
15
7
14
010503
13 12 11 10 9 8
1. Control unit cab (D790-1) 10. Transmission control unit (D793)

2. Control unit KID (D795) 11. Engine control unit (D794)
3. Control unit KIT (D790-2) 12. Control unit, frame rear (D797-R)
4. Control unit, frame front (D797-F) 13.
Control unit cab, option (D790-3)
5. .
Frame option control unit (D797-O) Only on machines with both the combi attachment and
6. Attachment control unit (D791-1) mini-wheel or combi attachment and joystick control
7. 14.
Attachment control unit, option (D791-2) Control unit CAN gateway RMI (D795-2)
8. 15.
Control unit, attachment left jack pair (D791-3) Control unit, Kalmar CAN customer gateway (D795-2)
9.
Control unit, attachment right jack pair (D791-4)

11 Common electrics – 11.5.3.1 Control unit cab 19
11.5.3.1 Control unit cab

Cab control unit, description
page
–
The cab control unit (D790-1) is the central control unit of the control
2 1
system. The cab control unit (D790-1) sends activation signals to other
units and controls and monitors their functions. It administrates work
in the control unit network. The control unit controls the redundant volt-
age feed and handles communication via a redundant CAN bus and
gateway for the drivetrain CAN bus. The cab control unit (D790-1) also
processes all input signals from cab controls and transmits these sig-
5 6 nals on the CAN bus.
4
3
000041
2 The cab control unit has four indicator lights that indicate the control
1. Connection terminals - fan, work lights, windscreen unit’s function (see illustration).
wiper
2. Connection terminals, other Light 1 Green light on when there is battery voltage to the unit.
3. Light 1, battery voltage The light is physically controlled by voltage feed to the
4. Light 2, redundant voltage feed, redundant CAN control unit.
bus and power supply Light 2 Flashes green when the redundant voltage feed to the
5. Light 3, communication control units and redundant CAN bus communication
6. Light 4, error indication are active. No power in the system.
Shines with a steady green when power electronics
and 15-voltage are supplied voltage.
Light 3 Long single flash yellow during communication with the

control unit display (D795). This is a basic condition of
fault tracing.
Short single flash yellow during communication with
the engine control unit (D794) and transmission control
unit (D793).
Double flash yellow (short and long flash) during com-
munication with the display and engine or transmis-
sion.
Light 4 Red light on at active error.
Control unit cab, replacement

page
–

2 Remove the cover from the electronic box.
3 Unplug the cab control unit (D790-1) connectors.
4 Change control unit.
5 Check that the new control unit matches the machine’s forklift
number (Z-number).
6 Calibrate the new control unit; see section 8 Control system,
group 8.5.2.3 Calibrate DRIVETRAIN.
7 Set the fresh air damper at fully closed and fully open, wait a few
seconds in each position so that the damper has time to go to the
end position.

20 11 Common electrics – 11.5.3.2 Control unit, frame front
11.5.3.2 Control unit, frame front

Control unit, frame front, description
page
–
Control unit, frame front (D797-F) processes input data from sensors
1 and sends control signals to relays and solenoid valves in the ma-
chine’s front half.
2
The control unit has four indicator lights that indicate the control unit’s
3 function (see illustration).
4 Light 1 Green light on when there is battery voltage to the unit.

The light is physically controlled by voltage feed to the
control unit.
Light 2 Flashes green when one or more of the following is

missing: redundant voltage feed left, redundant volt-
000043
6 5 age feed right or 15-voltage.

1. Light 1, battery voltage Shines green when redundant voltage feed left, redun-
2. Light 2, redundant voltage feed and power supply dant voltage feed right and 15-voltage are supplied
3. Light 3, communication voltage.
4. Light 4, error indication
Light 3 Single yellow flash during communication with display
5. Control signals (inputs and outputs)
(KID) or cab control unit (D790-1).
6. Power supply (redundant voltage feed for control
units, redundant CAN bus) and input data Double yellow flash during communication with display
and cab control unit (D790-1).
Control unit, frame front, replacement

page
–

2 Detach the cables from the control unit, frame front (D797-F).
number (Z-number).
group 8.5.2.1 Calibrate SCALE (pressure sensor).
6 Verify lowering speed, see section 7 Load handling, group 7.2
Lifting/lowering. In the event of deviations contact Cargotec.
D ANGER


11 Common electrics – 11.5.3.3 Control unit, frame rear 21
11.5.3.3 Control unit, frame rear

Control unit, frame rear, description
page
–
Control unit, frame rear (D797-R) processes input data from sensors
1 and sends control signals to relays and solenoid valves for functions
in the machine’s rear half.
2

control unit.

000043
Control unit, frame rear, replacement

page
–

2 Detach the cables from the control unit, frame rear (D797-R).
number (Z-number).
group 8.5.2.1 Calibrate SCALE (length sensor, angle sensor).

22 11 Common electrics – 11.5.3.4 Frame option control unit
11.5.3.4 Frame option control unit

Control unit, frame option, description
page
–
1
Control unit, frame option (D797-O) is a unit that processes input data
2 from sensors and sends control signals to relays and solenoid valves
for the optional functions in the machine’s front half.
3
Light 1 Green light on when there is battery voltage to the unit.

000043
control unit.

6 5
1. Light 1, battery voltage
age feed right or 15-voltage.
2. Light 2, redundant voltage feed and power supply
3. Light 3, communication Shines green when redundant voltage feed left, redun-
4. Light 4, error indication dant voltage feed right and 15-voltage are supplied
5. Control signals (inputs and outputs) voltage.
6. Power supply (redundant voltage feed for control Light 3 Single yellow flash during communication with display
units, redundant CAN bus) and input data (KID) or cab control unit (D790-1).
Double yellow flash during communication with display
Control unit, frame option, replacement

page
–

2 Disconnect the cable harness from the control unit.
number (Z-number).
5 The control unit is not calibrated.

11 Common electrics – 11.5.3.5 Control unit, attachment 23
11.5.3.5 Control unit, attachment

Attachment control unit, description
page
–
The attachment control unit (D791) processes input data from sensors
1 and sends control signals to relays and solenoid valves for functions
for the top lift attachment.
2

control unit.

000043
Attachment control unit, replacement

page
–

number (Z-number).

24 11 Common electrics – 11.5.3.6 Attachment control unit, option
11.5.3.6 Attachment control unit, option

Attachment control unit, option, description
page
–
1
The attachment control unit, option (D791-2) processes input data
for optional functions on the top lift attachment.
3

000043
control unit.

6 5
3. Light 3, communication Shines green when redundant voltage feed left, redun-
4. Light 4, error indication dant voltage feed right and 15-voltage are supplied
5. Control signals (inputs and outputs) voltage.
6. Power supply (redundant voltage feed for control Light 3 Single yellow flash during communication with display
units, redundant CAN bus) and input data (KID) or cab control unit (D790-1).
Attachment control unit, option, replacement

page
–

number (Z-number).

11 Common electrics – 11.5.3.7 Control unit, attachment left jack pair 25
11.5.3.7 Control unit, attachment left jack pair

Control unit, attachment left jack pair, description
page
–
1
Control unit, attachment left jack pair (D791-3) processes input data
to control the left jack pair on the attachment with lifting jacks. See sec-
3 tion 7 Load handling , group 7.9.2 Twistlock and lifting jacks.
4 The control unit has four indicator lights that indicate the control unit’s
function (see illustration).

000043 control unit.
6 5
3. Light 3, communication
4. Light 4, error indication Shines green when redundant voltage feed left, redun-
5. Control signals (inputs and outputs) dant voltage feed right and 15-voltage are supplied
6. Power supply (redundant voltage feed for control voltage.
units, redundant CAN bus) and input data Light 3 Single yellow flash during communication with display
Control unit, attachment left jack pair, replacement

page
–

number (Z-number).
6 Start the machine and drive to a free space. Operate the folding
DIAG COMBI 14(17) sequence for lifting jacks up and down. Use the diagnostic menu
SEQUENCE MODE Combi, menu 14 and check that the lifting jacks go through all the
LE RI sequence modes from 1-5.
FRONT X X
000227
REAR X X
Diagnostic menu Combi, menu 14

26 11 Common electrics – 11.5.3.8 Control unit, attachment right jack pair
11.5.3.8 Control unit, attachment right jack pair

Control unit, attachment right jack pair, description
page
–
1
Control unit, attachment right jack pair (D791-4) processes input data
to control the right jack pair on the attachment with lifting jacks. See
3 section 7 Load handling , group 7.9.2 Twistlock and lifting jacks.

control unit.
000043
6 5
4. Light 4, error indication Shines green when redundant voltage feed left, redun-
5. Control signals (inputs and outputs) dant voltage feed right and 15-voltage are supplied
6. Power supply (redundant voltage feed for control voltage.
units, redundant CAN bus) and input data Light 3 Single yellow flash during communication with display
Control unit, attachment right jack pair, replacement

page
–

number (Z-number).
6 Start the machine and drive to a free space. Operate the folding
DIAG COMBI 14(17) sequence for lifting jacks up and down. Use the diagnostic menu
SEQUENCE MODE Combi, menu 14 and check that the lifting jacks go through all the
LE RI sequence modes from 1-5.
FRONT X X
000227
REAR X X
Diagnostic menu Combi, menu 14

11 Common electrics – 11.5.3.9 Control unit transmission 27
11.5.3.9 Control unit transmission

Transmission control unit, description
page
–
The transmission control unit TCU (D793) is part of drivetrain control

1 2 3
and handles the transmission’s function, selection of gear at load and
engine speed, etc.
The transmission control unit TCU (D793) is connected via separate
D
M CAN bus communication to the engine, which is connected to the cab
E
F S control unit (D790-1). The cab control unit (D790-1) sends drivetrain
information on to other units.
The control unit has two function keys and three status lights (see
illustration).
000045
Function button M Select display group.
1. Display
Function button S Select display group mode.
2. Status lights
3. Function keys Status light D Yellow light indicates test mode.
Status light E Yellow light indicates fault in unit.
Status light F Red light during reset.
Control units can show information in the display in three display

groups with various status information. The M and S function keys are
used to navigate in the display and select display group and status in-
formation.
The following status information can be shown in the display:
Display group I
• GPOS - shows transmission’s direction of rotation
• VSPD - shows speed in km/h
• dist - shows distance driven in km or miles
Display group II
• CPOS - shows gear position
• Tspd - shows measured turbine speed in km/h or mph
• Espd - shows measured engine speed in rpm
• Ospd - shows measured speed out from the transmission in rpm
• Srat - shows the turbine speed ratio (Tspd)/engine speed (Espd)
• TQ I - shows measured torque (Nm) of transmission in
• Ttmp - shows measured temperature in the oil sump (Celsius or
Fahrenheit)
• Ctmp - shows measured temperature in the converter (Celsius or
Fahrenheit)
Display group III
• Err - shows error codes (current and history)

28 11 Common electrics – 11.5.3.10 Control unit, engine
Transmission control unit, replacement

page
–

2 Disconnect the cable harness from the TCU control unit.
number (Z-number).
group 8.5.2.3 Calibrate DRIVETRAIN and section 2 Transmis-
sion, group 2.8 Control system, transmission.
11.5.3.10 Control unit, engine

Control unit, engine, description (engine alternative Volvo
page
–
TWD1240VE)
The engine control unit (D794) is part of drivetrain control and handles
engine function, fuel injection, etc.
1 The engine control unit (D794) is connected via separate CAN bus
communication to the transmission, which is connected to the cab
control unit (D790-1). The cab control unit (D790-1) sends drivetrain
2 The control unit is located on the engine has no function keys or dis-
play. All functions are controlled via the CAN bus and an external con-
trol system.
007427
3
The control unit monitors the following values to optimise engine
Control unit, engine performance.
1. Connector 1 (black)
• engine rpm
2. Connector 2 (red)
3. Cooling duct for control unit (fuel) • camshaft’s position
• boost pressure
• charge-air temperature
• coolant temperature
• oil pressure
• oil temperature
• water in fuel
• fuel pressure
• coolant level
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the cor-
rect fuel volume and to check the condition of the engine.

11 Common electrics – 11.5.3.10 Control unit, engine 29
Control unit, engine, description (engine alternative Volvo

page
–
TAD1250VE)
1 engine function, fuel injection, etc.
The engine control unit (D794) is connected via separate CAN bus
2 communication to the transmission, which is connected to the cab
3 information on to other units.
The control unit is located on the engine has no function keys or dis-
trol system.
007424
The control unit monitors the following values to optimise engine
Control unit, engine performance.
1. Cooling duct for control unit (fuel) • engine rpm
2. Connector A (black)
• camshaft’s position
3. Connector B (grey)
• boost pressure
• oil pressure
• oil temperature
• oil level
• crankcase pressure
• water in fuel
• fuel pressure
• coolant level

30 11 Common electrics – 11.5.3.11 Control unit KIT
Control unit, engine, description (engine alternative

page
–
Cummins)
1 2 3
engine function, fuel injection, etc.
The engine control unit (D794) is connected via separate CAN bus
communication to the transmission, which is connected to the cab
The control unit is located on the engine has no function keys or dis-
007423 trol system.
The control unit monitors the following values to optimise engine per-
formance.
1. Connector OEM
2. Connector, Actuator • engine rpm
3. Connector, Sensor • boost pressure
• oil pressure
• oil temperature
• coolant level
• water in fuel
• air pressure
Engine control unit, replacement

page
–
11.5.3.11 Control unit KIT

KIT control unit, description
page
–
The KIT control unit (D790-2) handles functions for the gear selector
1 2
and multi-function lever, the direction indicator switch and start key po-
sitions II and III. It also handles the key panel (B) for the control system
and its panel for warning and indicator lights (A).
The KIT control unit (D790-2) has several individual function keys and
indicator lights (see illustration).
See the operator’s manual for detailed information on warning and in-
dicator lights and function keys.
000049
1. Panel for warning and indicator lights

2. Panel for keys

11 Common electrics – 11.5.3.12 Control unit KID 31
Control unit KIT, replacement

page
–

3 Detach KIT from the steering wheel panel.
4 Detach the connector sockets.
5 Remove the warning panel for warning and indicator lights.
7 KIT is not calibrated.
11.5.3.12 Control unit KID

KID control unit, description
page
–
The KID control unit (D795) displays to the operator information sent
1 2 by the control unit, such as speed, in the form of messages, status, er-
ror indications, etc.
There is an indicator light to the right of the display that is activated
with a red light when there is a serious malfunction in the control sys-
tem. The error code and information are shown on the display.
See the operator’s manual for detailed information on the display.
000051
1. LCD display
2. Series of diodes that serve as an indicator light for
major error.
Control unit KID, replacement

page
–

3 Detach the connector from KID.
4 Detach KID from the steering wheel panel.
6 KID is not calibrated.

32 11 Common electrics – 11.5.3.13 Control unit cab, option
11.5.3.13 Control unit cab, option

Control unit cab, option, description
page
–
1
Control unit, cab option (D790-3) is only available on machines with
2 both combi attachment and joystick control or combi attachment and
mini-wheel. The control unit handles the signals to and from the joy-
3 stick or mini-wheel and sends the information further on the CAN bus.

control unit.
000043
6 5
4. Light 4, error indication Shines green when redundant voltage feed left and
5. Control signals (inputs and outputs) right and 15-voltage are supplied voltage.
6. Power supply (redundant voltage feed for control Light 3 Single yellow flash during communication with either
units, redundant CAN bus) and input data KID control unit (D795) or cab control unit (D790-1).
Double yellow flash during communication with both
KID control unit (D795) and cab control unit (D790-1).
Control unit cab, option, replacement

page
–

number (Z-number).

11 Common electrics – 11.5.5 Cables 33
11.5.5 Cables
Connectors, overview
page
–
The list includes all connectors on the machine with a brief description
of their locations and to which functions the signals in them are related.
Con- Location Function

nector
X001 Control unit cab (D790-1) Power supply and earth connection Control unit cab (D790-1)
X002 Control unit cab (D790-1) Windscreen wipers

Cooling fan
Actuator motor, recirculation
X004 Control unit cab (D790-1) Air conditioning system
X005 Control unit cab (D790-1) Switch option

Switch warning light (Hazard)
Air conditioning system
Extra sensors
Accelerator pedal
X006 Control unit cab (D790-1) Instrument lighting dimmer

Switch work lights
Switch option
Seat heater
Accelerator pedal
Brake pedal
X007 Control unit cab (D790-1) Control lever

Indicator light support jacks down
X008 Control unit cab (D790-1) Control lever

Switch, bypass
Switch, parking brake
Switch sliding cab
Switch support jacks
Switch 30-35 stop
Switch option
Switch twistlocks
X009 Control unit cab (D790-1) Combi attachment

Overheight
Lever steering or mini-wheel
X009A Extension X009A Lever steering or mini-wheel

34 11 Common electrics – 11.5.5 Cables

nector
X010 Control unit cab (D790-1) Sensor, end position cab
Water valve
Seat heating
Relay, work lighting
Hour counter
Relay, Compressor
Power supply relays K315-1, K3009-1, K3009-2 and K315-2
Windscreen washing
Windscreen wiper, roof
X011 Control unit cab (D790-1) Ignition

Lighting, control unit KID (D795)
Switches, cab doors
Buzzer
Interior lighting
Power supply, Control unit cab (D790-1)
Horn
NC switch, seat
Feedback relay K3009-1
Seat heating
X012 Control unit cab (D790-1) Windscreen wiper, rear

Windscreen wiper, roof
X013 Control unit cab (D790-1) CAN-bus

RS232
X015 Control unit KIT (D790-2) CAN-bus

Power supply and earth connection, Control unit KIT (D790-2)
X016 Control unit KIT (D790-2) Ignition switch
X017 Control unit KIT (D790-2) Control, windscreen wipers

Control, gear
Control, main and dipped beams
X018 Control unit KIT (D790-2) Steering angle sensor

Switch, direction indicators
X018A Extension X018 Steering angle sensor
X020 Control unit KID (D795) CAN-bus

RS232 Printer
Power supply and earth connection, Control unit KID (D795)
X021 Control unit cab, option (D790-3) Lever steering or mini-wheel


nector
X022 Control unit cab, option (D790-3) Power supply and earth connection Control unit cab, option (D790-3)
CAN bus, Control unit, cab option (D790-3)
X033 Air conditioning system Control, fan

Control, temperature
Control, air distribution
X034 Air conditioning system Heater fan

Water valve
X035 Air conditioning system Valve, air distribution

Sensor, air temperature
X036 Air conditioning system Actuator motor, recirculation

Sensor, air temperature
X038 Instrument panel, cab Accelerator pedal

Clutch-release pedal
X039 Electronic box cab Hour counter

Relay, Compressor, seat with air suspension
Switch, cab door
Actuator motor, recirculation
Fan motor, heating
Water valve, ECC
X048 Electronic box cab Termination resistor
X049 Electronic box cab CAN-bus
X050 Electronic box cab D-sub

RS232 Control unit cab (D790-1)
X051 Electronic box cab Power supply, Control unit cab (D790-1)
CAN-bus

Control relays K315-1, K3009-1, K3009-2 and K315-2
X054 Electronic box cab Interior lighting

Working lights
Flashing hazard lights
X055 Electronic box cab Windscreen wiper, roof

Current, CD player
Current, COM radio


nector
X056 Electronic box cab Flashing hazard lights
Working lights, boom
Working lights, cab
X057 Electronic box cab Windscreen wiper, rear

Power supply, reversing camera
X058 Electronic box cab Motor, windscreen washers

Engine heater start inhibitor
X059 Electronic box cab CAN-bus,

Power supply, Control unit cab, option (D790-3)

Interior lighting
X060A Extension X060 CAN-bus

Interior lighting
X061 Electronic box cab Earth connection, Control unit KID (D795)
Power supply, Control unit KIT (D790-2)
Windscreen wiper front
Actuator, recirculation
X061A Extension X061 Earth connection, Control unit KID (D795)

Power supply, Control unit KIT (D790-2)
X062 Electronic box cab Horn

Map lighting
Cigarette lighter 12V
X063 Electronic box cab Seat heater

Compressed-air damped seat
X064 Electronic box cab Sensor, end position cab
X071-1 Electronic box cab Power supply, cab
X071-2 Electronic box cab Earth connection, cab
X072 To Right Behind Seat Power outlet
X073 Right side of instrument panel Cigarette socket 12V
X080 Instrument panel, cab Switch work lights

Switch, main beams
Switch, warning lights
Switch, seat heater
Switch, option


nector
X081 Instrument panel, cab Switch, option
Extra sensors
Hour counter
X082 Instrument panel, cab NC switch, cab door left side
X168 Electronic box frame Power supply, boom and attachment
X200 Boom mounting CAN-bus

Redundant power supply, control units
X201 Electronic box frame Earth connection and power supply, Control unit transmission (D793)
X202 Boom mounting Sensor, boom length

Sensor, boom angle
Sensor, damping boom out
Sensor, damping boom in
Sensor, damping boom up
Sensor, damping boom down
Earth connection and power supply, boom sensor
Solenoid valve regeneration extension
Solenoid valve blocking extension
X203 Electronic box frame Termination resistor
X205 Electronic box frame CAN-bus

Transmission control unit (D793)
X206 Boom mounting Revolving beacon boom

X210 Between engine and transmission Power supply and earth connection, Control unit engine (D794)
CAN bus, Control unit engine (D794)
X211 Control unit, frame front (D797-F) 42-pin connector to Control unit, frame front (D797-F)
X212 Control unit, frame front (D797-F) Power supply and earth connection, Control unit, frame front (D797-F)
CAN bus, Control unit, frame front (D797-F)
Temperature brake fluid
Safety switch
X221 Control unit, frame rear (D797-R) 42-pin connector to Control unit, frame rear (D797-R)


nector
X222 Control unit, frame rear (D797-R) Power supply and earth connection, Control unit, frame rear (D797-R)
CAN bus, Control unit, frame rear (D797-R)
Temperature hydraulic oil
Fuel gauge
Safety switch
D+ alternator
X231 Frame option control unit (D797-O) 42-pin connector to Control unit, frame option (D797-O)
X232 Frame option control unit (D797-O) Power supply and earth connection, Control unit, frame option (D797-O)
CAN bus, Control unit, frame option (D797-O)
Safety switch
X233 Frame option control unit (D797-O) Sensor support jacks

Solenoid valve support jacks up and down
X235 Frame option control unit (D797-O) Solenoid valve steering left and right (joystick control or mini-wheel)
X246 AC compressor Power supply sensor pressure refrigerant
X251 Control unit transmission (D793), 30-pin connector for Transmission control unit (D793)
electronic box frame
X252 Control unit transmission (D793), 18-pin connector for Transmission control unit (D793)
electronic box frame
X253 Transmission Solenoid valves, transmission

Pressure sensor, transmission
X254 Electronic box frame Power supply and earth connection Control unit transmission (D793)
X259 Transmission Temperature sensor, transmission oil for radiator
X260 Electronic box frame CAN bus, Control unit transmission (D793)
X261 Electronic box frame RS232 Control unit transmission (D793)
X264 Electronic box frame Solenoid valve brake transmission
X265 Cab Reversing camera
X270 Lamp bracket left frame Main and dipped beams

Driving direction indicator
Side marker lights
X271 Lamp bracket front Main and dipped beams

Side marker lights


nector
X272 Lamp bracket left rear Reversing light
Tail light
Brake light
Side marker lights
X273 Lamp bracket right rear Reversing light

Tail light
Brake light
Side marker lights
X278 Between engine and transmission Electromagnetic clutch compressor

Solenoid valve, engagement of hydraulics for top lift
Sensor pressure refrigerant
Solenoid valve deactivation of hydraulics
X279 Engine Power supply and earth connection, Control unit engine (D794)
CAN-bus Drivetrain
X282 Cable connected to printer RS232 Printer
X301 Boom mounting Fuse holder power supply and earth connection to boom and attachment
X400 Boom nose Fuse holder power supply and earth connection to boom and attachment
X401 Boom nose CAN bus control units on boom nose and attachment
Redundant power supply control units on boom nose and attachment
X403A Attachment, right side Sensor, abutment right side

Sensor, twistlocks right side
X403B Attachment, right side Sensor, abutment right side

Sensor, twistlocks right side
X404 Attachment left side Sensor, abutment left side

Sensor, twistlocks left side
X405 Boom nose Indicator light locked twistlocks

Indicator light unlocked twistlocks
Indicator light alignment
X406 Attachment centre section Extra working lights combi attachment
X408 Boom nose Indicator light overheight jacks raised
X411 Attachment control unit (D791-1) 42-pin connector for attachment control unit (D791-1)


nector
X412 Attachment control unit (D791-1) Power supply and earth connection, attachment control unit (D791-1)
CAN bus, Control unit attachment (D791-1)
Safety switch
X414 Boom nose CAN bus and power supply control unit attachment right jack pair
(D791-4)
X415 Boom nose Combi attachment
X416 Attachment centre section Rotation stop
X421 Attachment control unit, option 42-pin connector for Control unit, attachment option (D791-2)
(D791-2)
X422 Attachment control unit, option Power supply and earth connection, Control unit, attachment option
(D791-2) (D791-2)
CAN bus attachment option control unit (D791-2)
Safety switch
X428 Boom Revolving beacon
X431 Control unit, attachment left jack 42-pin connector for Control unit, attachment left jack pair (D791-3)
pair (D791-3)
X432 Control unit, attachment left jack Power supply and earth connection, Control unit, attachment left jack pair
pair (D791-3) (D791-3)
CAN bus, Control unit, attachment left jack pair (D791-3)
Safety switch
X433 Control unit, attachment left jack Levelling

pair (D791-3) Indicator lights, alignment combi attachment
X434 Combi attachment, left side front Sensor, clamping position left front jack
Sensor, alignment left front jack
X435 Combi attachment, left side rear Sensor, clamping position left rear jack
Sensor, alignment left rear jack
X441 Control unit, attachment right jack 42-pin connector for Control unit, attachment right jack pair (D791-4)
pair (D791-4)
X442 Control unit, attachment right jack Power supply and earth connection, Control unit, attachment right jack
pair (D791-4) pair (D791-4)
CAN bus, Control unit, attachment right jack pair (D791-4)
Safety switch
X443 Control unit, attachment right jack Solenoid valve, tilt in and out
pair (D791-4) Indicator lights: Front jacks up and down
Indicator lights: Clamping position front and rear jacks
X444 Combi attachment, right side front Sensor, clamping position right front jack
Sensor, alignment right front jack


nector
X445 Combi attachment, right side rear Sensor, clamping position right rear jack
Sensor, alignment right front jack
X489 Attachment centre section Sensor, overheight jacks up and down

Indicator light, overheight jacks up and down
Solenoid valve overheight jacks up and down
X901 Voltage converter, cab Voltage converters 24V/12V or only joint
X905 Cab panel 12V socket for Com radio
Signal types, general

page
–
The machine’s control units use a number of different types of signals

to receive signals from sensors and switches and control solenoid
valves, lights, etc. The table below describes the different signal types.
Signal type Explanation Usage area
Analogue inputs
Rheostat Resistance input 0–200 Ω. Linear work range with accuracy of 3%. E.g. fuel level sensor.
Temperature Rheostat input with non-linear work area. The resistance value is equiva- E.g. hydraulic oil temper-
lent to temperature and the work range of approx. -40 to 150 °C. ature sensor and climate
There are two different resistance curves - one for the cab control unit control system tempera-
(D790-1) and one for the frame and attachment control units. ture sensor.
Accuracy is ±0.5 °C in the interval 0 –100 °C (sensor’s measurement in-

accuracy not included). Outside of the interval 0 –100 °C, accuracy is
±2 °C.
Voltage An analogue signal 0–5 V. The work range is 0.5 to 4.5 V. E.g. accelerator pedal
and analogue cab con-
trols (operating lever and
heater controls).
Analogue outputs
Current feedback A modulated signal between 0 V and system voltage, i.e. 24 V. The work Hydraulics, e.g. lifting/
voltage out, PWM range is 0 to 2 A. lowering of the boom.
A modulated signal is a digital signal translated to an analogue (continu- Used when the output
ous) signal adapted for a purpose, such as solenoid valve control. signal actuates propor-
When the slide in a solenoid valve gets hot, resistance drops. This gener- tional solenoid valves.
ates a lower current through the valve slide, which can cause the valve’s
servo pressure to remain constant. An internal ampermeter measures
current in the circuit and regulates the voltage level in order to maintain
the desired current value in the valve slide.
Voltage out, PNP A modulated signal between 0 V and system voltage, i.e. 24 V. Requires E.g. interior lighting and
PWM a grounding point as reference. background illumination
in switches.

Signal type Explanation Usage area
Voltage out, re- A modulated signal between 0 V and system voltage, i.e. 24 V. Requires E.g. cab fan.
versed polarity, 24 V as reference.
NPN PWM
Digital inputs
Digital input signal Signal in, U < 5 V generates logic zero (0) E.g. input signal from a
with pull down and Signal in, U > 16 V generates logic one (1) breaker with search light-
search lighting ing.
If there is no signal in, the input is grounded.
Digital input signal Signal in, U < 5 V generates logic zero (0) E.g. position sensors (in-
with pull down Signal in, U > 12 V generates logic one (1) ductive sensors) and
brake pressure (pressure
If there is no signal in, the input is grounded. switches).
Bandwidth 300 Hz, i.e. designed for slow sensors.
Digital outputs
High side driver, Logic one (1) generates voltage out, U >= 22.5 V E.g. side marker lights,
1.5 A Max. load 1.5 A solenoid valves.
Open load 0.15 A

Max. instantaneous current load, 8 A
High side driver, 5 Logic one (1) generates voltage out, U >= 22.5 V E.g. work lighting and
A Max. load 5 A wiper motors.
Open load 0.9 A

High side driver, Logic one (1) generates voltage out, U >= 22.5 V E.g. cooling fan.
10 A Max. load 10 A This output is only found
Open load 1.9 A on the frame and attach-
ment control units.
H-bridge Logic one (1) generates voltage out, U >= 22.5 V or grounded output, E.g. climate control sys-
U=0V tem water valve (works in
Max. load 0.5 A both directions).
Open load 0.15 A

The H-bridge works with two outputs in a pair. At logic one (1), one output
gives voltage while the other output is grounded. At logic zero (0), the out-
puts switch voltage levels.

11 Common electrics – 11.6 Communication 43
11.6 Communication
11.6.1 CAN-bus
CAN bus, description
page
–
Communication between the control units takes place using so-called

1 2
"CAN buses" (Controller Area Network) based on the ISO 11898
standard and CAN specification 2.0B.
The CAN bus is a fast control bus with logical hardware circuits. A sim-
120 ohm 120 ohm
ple technology that is highly reliable (low error frequency), which is a
requirement for control signals to be able to regulate systems based
on varying conditions and requirements.
CAN specifies:
5 5
• that the signal traffic is carried by "twisted pair" cables
3
4 • that termination resistors (position 1) are necessary (adapted to
2 cables’ impedance) so that the pulse train (position 4) can obtain
U [V]
a sharp signal.
• that the signal valve is given as the potential difference between
3 the cables, CAN + and CAN - (position 2 and 3).
000026
t [S]
• form of signal messages.
Messages are sequential and signal is high (voltage
high) or low (voltage low).
1. Termination resistor (120 ohm)
2. CAN + (voltage high)
3. CAN - (voltage low)
4. Pulse
5. Control unit
Message
There are two types of messages:
A
• CAN Standard, has identity field of 11 bits
• CAN Extended, has identity field of 29 bits
B C D E F G CAN works in messages sent in frames of 8 bytes (64 bits). A com-

000027
plete message is approx. 100 bits long. The illustration depicts how a
t [S]
message is structured.
Messages are sequential and signal is high (voltage
high) or low (voltage low). Start bit (B)
A. Length message Indicates that the transmission of a frame, i.e. a message, is now be-
B. Start bit ginning.
C. Identity field/Priority Identity field (C)
D. Check field (length of data segment)
E. Data segment Indicates what kind of information the message contains, e.g. meas-
F. Checksum for error detection urement information on engine speed.
G. Acknowledgement bit Does not indicate address to control unit. CAN does not work with ad-
dressing. All control units receive messages and send them on.
Control field (D)
Indicates how the length of the data segment that follows.

44 11 Common electrics – 11.6.1 CAN-bus
Data segment (E)

Contains the information to be conveyed to control units in the net-
work.
Checksum for error detection (F)
Calculates a checksum for the message. This makes it possible for the
receiving control unit to detect errors in the sent message.
Acknowledge (G)
The transmitting control unit sets a bit to logic one (1) when the mes-
sage is sent. The first control unit to receive the message sends it on
and sets the bit to logic zero (0).
Communication
The CAN network consists of control units and segment. The segment
(bus) is a twisted pair cable that leads CAN + and CAN - signal levels
from control unit to control unit.
Each control unit measures the potential difference of its two inputs.
3,5 V The potential difference generates logic zero and logic one. The illus-
tration depicts an approved interval according to the standard for po-
tential levels. CAN + has a recommended value of 3.5 V and CAN -
U [V]
has 1.5 V. As a worst case scenario, the potential difference can be

0,5 V 0.5 V and still be approved. In practice, a potential difference of 2 V is
recommended for reliable communication.
Pulse train can only be observed using an oscilloscope, NOT with a
1,5 V digital multimeter.
When a message is sent, all control units in the network listen. Mes-
sages are saved in the control unit and relevant information is proc-
essed. The control unit that receives the message first confirms
000028
t [S] receipt (sets an acknowledge bit). The transmitting control unit then
knows that the message has been received by at least one control
Potential levels CAN + and CAN -
unit.
One control unit at a time sends the message. Other control units lis-
ten and wait until the bus is available. If two messages are to be sent
simultaneously then the sending of the message with the lowest prior-
ity (highest value in identity field) is concluded. This means that mes-
sages do not need to be re-sent in the event of a communication
conflict but only in the event of a bus error (erroneous message).
The CAN bus exchanges around 100 messages per second in the net-
work.
Different bus systems can be used e.g. random sending or primary
(master) / secondary (slave),
HLP High Layer Protocol
CAN only specifies messages and how communication shall take
place, i.e. one protocol. In order to manage the network the CAN pro-
tocol needs to be supplemented by a HLP which specifies:
• flow control
• transport of data above a length of 8 bits in 8 bit messages (divi-
sion)
• how control units are addressed in the network
• how bits in the message's data field shall be interpreted

11 Common electrics – 11.6.2 Redundant CAN bus 45
11.6.2 Redundant CAN bus

Redundant CAN bus, description
page
–
The redundant CAN bus handles communication between all of the

D791-4 D791-3 D791-2 D791-1 machine’s control units except the transmission control unit (D793)
CAN R CAN L CAN R CAN L CAN R CAN L CAN R CAN L
and the engine control unit (D794). These have a separate CAN bus;
see Drivetrain CAN bus, description page 48.
Redundant CAN bus means that the control units are connected to a
D790-1 D790-2 D795
CAN R CAN L CAN R CAN L network that communicates via a CAN bus (see CAN bus, description
page 43) and that there are double communication routes on the net-
work. The network is divided into control units and segments (seg-
CAN L CAN R CAN L CAN R CAN L CAN R
003170
D797-R D797-O D797-F ments are cables between the control units). The number of active
segments depends on the number of control units the machine has,
Principle illustration, redundant CAN bus which depends on the machine’s equipment level (options).
The network is built on the CAN kingdom principle, which means that
one control unit is central and is the master unit. In this case, it is the
cab control unit (D790-1). Other control units in the network are sec-
ondary (slaves) and handle special areas, e.g. cab components.
The control units have two CAN bus connections - CAN L (left) and
CAN R (right). The control units are connected to one another in series
in a loop.
The redundant CAN bus can handle the loss of a segment. The link is
analysed upon start-up. If a segment is faulty, messages are sent via
another route.
If several segments are lost, one or more control units lose communi-
cation and work independently, often with significantly limited function-
ality.
CAN bus faults are indicated with an error code and a warning in the
display. If several CAN bus segments are faulty, the system only
shows an error code for the first faulty out segment.

46 11 Common electrics – 11.6.2 Redundant CAN bus
Connection of redundant CAN bus
Condition Refer- Reference

ence val-
ue
Battery disconnector In position Battery disconnector, description page 3
1
Redundant voltage feed Activated. Redundant voltage feed for control units, description of operation page 7
S5
S2
D791-1 S2
D791-2
22 3
10 D790-2 S3
S9 S8
S1 D790-1 S5
D795 S4
1, 11 9
S3
D791-3 S4 D791-4
D797-R D797-F
4 5
6 S6 D797-O S7 8
7
013023
The illustration shows two alternatives for how the segment numbering
is changed depending on the number of control units on the machine:
Solid lines show the CAN-bus with a minimal number of control units.
Dotted lines show the CAN-bus with a maximal number of control
units.

1 The cab control unit (D790-1) establish- Checked by control Cab control unit, description page 19
es redundant CAN bus communication system, error shown Diagnostic menu, see section 8 Control sys-
by sending a request on the CAN bus with error code. tem, group 8.4.1.1 CAN/POWER, menu 1 and
via CAN R. 8.4.1.2 CAN/POWER, menu 2
2 The attachment control unit (D791-1) A clicking sound is Attachment control unit, description page 23
sends a response back on the CAN bus audible when then Diagnostic menu, see section 8 Control sys-
via CAN L and sends the request on via termination resistor is tem, group 8.4.1.1 CAN/POWER, menu 1 and
CAN R. activated. 8.4.1.2 CAN/POWER, menu 2
Termination resistors in the control
nodes ensure communication segment
by segment.

11 Common electrics – 11.6.2 Redundant CAN bus 47

3 Control unit, attachment option (D791- A clicking sound is Attachment control unit, option, description
2) sends a response back on the CAN audible when then page 24
bus via CAN L and sends the request on termination resistor is Diagnostic menu, see section 8 Control sys-
via CAN R. activated. tem, group 8.4.1.1 CAN/POWER, menu 1 and
Termination resistors in the control 8.4.1.2 CAN/POWER, menu 2
by segment.
4 Control unit, attachment left jack pair A clicking sound is Control unit, attachment left jack pair, descrip-
(D791-3) sends a response back on the audible when then tion page 25
CAN bus via CAN L and sends the re- termination resistor is Diagnostic menu, see section 8 Control sys-
quest on via CAN R. activated. tem, group 8.4.1.1 CAN/POWER, menu 1 and
by segment.
5 Control unit, attachment right jack pair A clicking sound is Control unit, attachment right jack pair, descrip-
(D791-4) sends a response back on the audible when then tion page 26
CAN bus via CAN L and sends the re- termination resistor is Diagnostic menu, see section 8 Control sys-
quest on via CAN R. activated. tem, group 8.4.1.1 CAN/POWER, menu 1 and
by segment.
6 Control unit, frame rear (D797-R) sends A clicking sound is Control unit, frame rear, description page 21
a response back on the CAN bus via audible when then Diagnostic menu, see section 8 Control sys-
CAN L and sends the request on via termination resistor is tem, group 8.4.1.1 CAN/POWER, menu 1 and
by segment.
7 Control unit, frame option (D797-O) A clicking sound is Control unit, frame option, description page 22
sends a response back on the CAN bus audible when then Diagnostic menu, see section 8 Control sys-
via CAN L and sends the request on via termination resistor is tem, group 8.4.1.1 CAN/POWER, menu 1 and
by segment.
8 Control unit, frame front (D797-F) sends A clicking sound is Control unit, frame front, description page 20
a response back on the CAN bus via audible when then Diagnostic menu, see section 8 Control sys-
CAN L and sends the request on via termination resistor is tem, group 8.4.1.1 CAN/POWER, menu 1 and
by segment.

48 11 Common electrics – 11.6.3 CAN bus drivetrain

9 The KID control unit (D795) sends a re- A clicking sound is KID control unit, description page 31
sponse back on the CAN bus via CAN L audible when then Diagnostic menu, see section 8 Control sys-
and sends the request on via CAN R. termination resistor is tem, group 8.4.1.1 CAN/POWER, menu 1 and
Termination resistors in the control activated. 8.4.1.2 CAN/POWER, menu 2
by segment.
10 The KIT control unit (D790-2) is not con- A clicking sound is KIT control unit, description page 30
nected to the redundant CAN bus. The audible when then
KIT control unit (D790-2) does not com- termination resistor is
municate until ignition voltage (15) is ac- activated.
tivated.
11 If all control units have responded, the Checked by control Diagnostic menu, see section 8 Control sys-
cab control unit (D790-1) deactivates system, error shown tem, group 8.4.1.1 CAN/POWER, menu 1 and
the segment to the attachment control with error code. 8.4.1.2 CAN/POWER, menu 2
unit (D791-1).
If a control unit has not responded, the
cab control unit (D790-1) uses both
CAN L and CAN R to keep communica-
tion open and analyses which segment
is faulty.
11.6.3 CAN bus drivetrain

Drivetrain CAN bus, description
page
–
The drivetrain CAN bus is based on the SAE J1939 standard where
4 6
selected messages are used to control engine and transmission.
SAE J1939 is a standard from SAE (Society of Automotive Engineers)
for data communication in vehicles. The standard regulates hardware
interface, bit times and message composition.
D790-1 3 5
Control units for engine and transmission come from the respective
transmission and engine supplier. The control units use the same
standard of communication and therefore the messages for each en-
gine are constructed using the same structure.
Communication with engine control unit (D794) and transmission con-
trol unit (D793) are separate from the redundant CAN bus.
The signals can be checked from the diagnostic menu, see section 8
Control system , group 8.4.1.3 CAN/POWER, menu 3.
000033
1 2
1. Redundant CAN bus
2. CAN bus drivetrain
3. Control unit, engine
4. Engine
5. Control unit transmission
6. Transmission

11 Common electrics – 11.6.4 Communication between PC and machine 49
11.6.4 Communication between PC and

machine
Communication between PC and machine,
page
–
description
The machine has three or four sockets for communication between
control units and PC. Two are located in electronic box cab and one or
1 two in electronic box cab frame. It is the socket for communication with
engine alternative Volvo that varies.
2 Sockets for programming control units in the cab electrical distribution
box (position 1) are used for programming the control units in the cab,
on the frame, and on the attachment.
The socket for CAN bus drivetrain in the cab electronic box (position
2) is used for communicating with the engine and transmission via
CAN bus.
The VODIA socket in the frame electronic box (position 3) (Volvo en-
gine only) is used to connect the Volvo’s diagnostic tool - VODIA.
The socket for transmission control unit (D793) programming in the
frame electronic box (position 4) is used to program the transmission
control unit (D793).
For further details on communication between computer and machine,
contact Cargotec.
3
4
006887
1. Diagnostic socket, machine

2. Diagnostic socket engine, CAN bus drivetrain
(engine alternative Cummins QSM11)
3. Diagnostic socket, engine VODIA (Volvo engine)
4. Diagnostic socket, transmission

50 11 Common electrics – 11.6.5 RMI (Remote Machine Interface)
11.6.5 RMI (Remote Machine Interface)

RMI (Remote Machine Interface), description
page
–
Remote Machine Interface is a tool for reading data from the machine
at a distance. The RMI consists of a control unit which is connected to
007443
the machine, antenna for communication and GPS-antenna ( ) for
positioning.
RMI interface (A911)
RMI interface (A911) records communication on the CAN bus and
sends the information to a central RMI server. In the event of a fault in
the machine the control unit can send the information via GSM, GPRS,
WLAN, radio modem, SMS or e-mail.
From the RMI-server, data from the machine can be analysed and
processed for reading out different values. For example, when it is
time for service or if there are error codes stored in the machine.
As an option, there is a GPS-antenna, making it possible to read

off the machine’s position.
Control unit CAN gateway RMI (D795-2) sends some information from
the machine’s CAN bus on to the RMI interface (A911), which sends it
on via the RMI server.
NOTE
RMI only sends data from the machine, but no data can be sent
010504
to the machine. RMI cannot be used to control the machine.
Control unit CAN gateway RMI (D795-2)

11 Common electrics – 11.6.6 Kalmar CAN Customer Gateway 51
11.6.6 Kalmar CAN Customer Gateway

Kalmar CAN Customer Gateway
page
–
Kalmar CAN Customer Gateway is an interface to connect an external

equipment in order to store machine data.
The Kalmar CAN Customer Gateway control unit (D795-2) translates
communication on the machine’s CAN bus to RS232 and CAN for con-
010504
nection to external devices according to a predetermined protocol.
Control unit, Kalmar CAN Customer Gateway NOTE

(D795-2) Kalmar CAN Customer Gateway only sends data from the ma-
chine, no data can be sent to the machine. Kalmar CAN Custom-
er Gateway cannot be used to control the machine.
The following data are examples of data available to the customer via
Kalmar CAN Customer Gateway:
• Operating time
• Temperature values
• Fuel consumption
• Current speed
• Current weight of load
• Operating time remaining until next service
• Number of lifted containers, different counters for different sizes
• Position of twistlock (locked/open)
• Boom position

52 11 Common electrics – 11.6.6 Kalmar CAN Customer Gateway

D Error codes 1
D Error codes
Table of Contents D Error codes

mm mm mm mm mm mm
D Error codes ..................................................................................................... 3

Error codes, explanation ........................................................................................ 3
Error code menu, description ................................................................................. 4
Reading out error code ........................................................................................... 7
1 Engine ............................................................................................................. 9
Error codes engine, general ................................................................................... 9
Error codes engine (engine alternative Volvo) ..................................................... 10
Engine error codes (engine alternative Cummins QSM11) .................................. 27
2 Transmission................................................................................................ 39
Error codes, transmission .................................................................................... 39
8 Control system ............................................................................................. 91
Error codes machine ............................................................................................ 91

2 D Error codes

D Error codes – D Error codes 3
D Error codes
mm mm mm mm mm mm
Error codes, explanation

page
–
The error codes are explained in table form for Engine, Transmission
as well as Control system. They are sorted according to error code
number.
The error code table has the following information:
• Code, error code's number, shown in field C on display.
C
• Description, explanation of the error code and when it's
D E generated.
• Limitation, in case of certain error codes certain functions are im-
B
000389
paired or limited to protect the machine and operator.

• Action, information of what should be checked to find the cause of
B. Error code level (symbol)
the error code.
C. Error code number
D. Error cause (symbol) • Diagnostic menu, reference to suitable diagnostic menu to fix the
E. Function (symbol) problem, read signal value or check the function.
In addition to the explanation of the display figure, the description
of the diagnostic menus contains reference to circuit diagrams
that are found in section E Schematics and reference to function
group for further information about functions and components.
• Function group is a reference to which function group the error
code is connected. This field is used to search for more informa-
tion as necessary. The function group can be used to find different
types of information.
Sections 0-12 contain a description of the function and its compo-
nents, component position and work instructions for different
work.

4 D Error codes – D Error codes
Error code menu, description

page
–
The control system’s display is divided into four fields that show infor-
C mation (see figure to the left).
D E • Field B: Error code level shown with a symbol.

• Field C: Indicates error code.
B
000389
• Field D: Indicates type of error.
• Field E: Indicates which function is affected by error code.
• The book symbol means that there's information in the operator's
manual.
Field B: Error code level

The control system gives error code information in three levels which
are indicated with a symbol in the lower left corner (B) on the display
unit.
• Stop
C Indicates a serious malfunction that may affect operator safety or
cause machine breakdown. The error code must be taken care of
D E
immediately. Stop working with the machine and contact service
immediately.
000350
• Warning
C Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine, con-
D E
tact service as soon as possible.
000351
• Information
C Information to the operator that something should be fixed, e.g.,
broken bulb. Fix the cause of the error code as soon as possible.
D E See section 6 Inspection and maintenance in the Operator’s
manual.
000352
The error code is stored in the error code list under operating
menu for service.

Field C: Error code number

The control system gives error codes from three sub-systems:
• Machine:
C
Shown with error code number XXX on display.
D E
000389
• Engine:
XX/YY Shown with error code number XXX/YY on display.
D
NOTE
B If several error codes come from the engine, the error code
001343
level is shown for the most serious error code.
• Transmission:
XXX/YY Shown with error code number XX/YY on display.
B
001344
Field D: Type of error

1. Too high/too low temperature.
1 2 3
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
4 5 6 5. Incorrect signal from control.

6. Incorrect signal to bulb.
7. Incorrect signal, for example, open circuit.
7
000396

Field E: Affected function

1. Attachment
1 2 3
2. Rotation of attachment
3. Side shift of attachment
4. Length adjustment attachment
4 5 6 5. Levelling attachment
6. Twistlocks
7. Tilt attachment
7 8 9 8. Bottom lift-attachment
9. Bottom lift-attachment, clamping position
10. Bottom lift-attachment, jacks up/down
10 11 12 11. Boom up/down

12. Boom in/out
13. Pressure sensor lift cylinder (overload system, OP)
14. No overload system
13 14 15
15. Support jacks up/down
16. Hydraulic functions
17. Brake system
16 17 18
18. Steering
19. Engine
20. Transmission
19 20 21 21. Central lubrication
22. Control unit
23. Hardware-related error
22 23 24 24. Cab
25. Air conditioning system
26. Fuel system
25 26 27 27. Headlights
28. Windscreen wipers
29. Battery voltage
28 29 30 30. Bulb for lighting

000397

Reading out error code

page
–
NOTE
In case of an error code, perform the actions recommended in the
error code table to find the problem.
Error codes are stored as active and inactive. Active errors are
shown in the error code menu.
Always use error code menus for reading out error codes, other-
wise there is a risk of missing error codes.
1 Turn the start key to position I.
WARN IN G
Risk of machine damage.
In case of error codes of level “WARNING” and

“STOP”, serious machine damage may result if the
engine is started.
Do not start the engine until the cause of the error

code has been identified or repaired.
2 Navigate to the service menu and press Enter.

000056
3 Safety menu is shown. Hold Enter depressed for at least two

seconds.
1 23
4 5
000060
4 The error code list is shown on the display. Active error code is
shown on display where field C shows error code number togeth-
er with X(Y). X shows sequence number for shown error code
and (Y) shows number of active error codes.
Scroll between error codes with key 1 and 2 (arrow function).
001998
Error codes disappear from the list when the cause has been
remedied.

5 Note error code number (field C) to not forget.

C
• Error code level is shown with a symbol in field B
D E • Error code is shown in field C
B • Error cause is shown with a symbol in field D
000389
• Function affected by the error is shown with a symbol in
field E
The book symbol is an instruction for the operator to read the
operator’s manual.
6 Use the error code tables to find more information about the error
code.
7 After action, check that no active error codes remain for the func-
tion in question.

D Error codes – 1 Engine 9
1 Engine
mm mm mm mm mm mm
Error codes engine, general

page
–
When contacting engine suppliers, use Volvo/Cummins codes.

• Display indicates error code according to SAE J1939
SPN/FMI
• J1587 indicates error code according to SAE J1587 (for Volvo:
Vodia).
PID, PPID, SID, PSID/FMI
Table 1. Specification FMI
FMI Description SAE-text

0 Too high value. Valid data, but higher than normal operating range.
1 Too low value. Valid data, but lower than normal operating range.
2 Incorrect data. Intermittent or incorrect data.
3 Electrical problem. Abnormally high voltage or short-circuiting to higher voltage.
4 Electrical problem. Abnormally low voltage or short-circuiting to lower voltage.
5 Electrical problem. Abnormally low current or open circuit.
6 Electrical problem. Abnormally high current or short-circuiting to frame ground.
7 Mechanical problem. Incorrect response from mechanical system.
8 Mechanical problem or electrical problem. Abnormal frequency.
9 Communication error. Abnormal update rate.
10 Mechanical problem or electrical problem. Abnormally wide variations.
11 Unknown malfunction. Non-identifiable error.
12 Component error. Defective unit or component.
13 Incorrect calibration. Values outside calibration values.
14 Unknown malfunction. Special instructions.
15 Unknown malfunction. Reserved for future use.

10 D Error codes – 1 Engine
Error codes engine (engine

page
–
alternative Volvo)
Description Limitation Action Connec- Diagnos-
tions and tic menu
components
Code J1587
94/FMI PID94/ Fuel pressure No limitation. Check cabling between Volvo -
FMI sensor, short control unit and compo- TWD1240VE:
circuited to volt- nent. D794/2:3
age, ground, or Check the sensor. Volvo
open circuit. TAD1250VE:
D794/B:16
94/FMI PID94/ Low fuel pressure No limitation. Change fuel filter. - -

FMI (feed). Change fuel pre-filter.
Check if pressure can be
built up with the hand
pump.
97/1 PID97/1 Water in fuel. No limitation. Drain water separator. - -

Clean metal filter in the
fuel feed’s hose connec-
tion on the engine.
Check fuel filter and fuel
pre-filter.
97/3 PID97/3 Water-in-fuel sen- No limitation. Check cabling between Volvo -

sor short circuited control unit and compo- TWD1240VE:
to ground or open nent. D794/2:4
circuit. Check the sensor. Volvo
TAD1250VE:
D794/B:8
98/FMI PID98/ Low oil level. No limitation. Check oil level. - ENGINE,
FMI menu 6
98/FMI PID98/ Oil level sensor, No limitation. Check cabling between Volvo ENGINE,
FMI short circuited to control unit and compo- TAD1250VE: menu 6
voltage, ground, nent. D794/B:3, B:4,
or open circuit. Check the sensor. A:31
100/1 PID100/1 Low engine oil Engine will shut Check oil level. - ENGINE,
pressure. down. Change oil filter. menu 6
Check the system pres-

sure valves and the safe-
ty valve in the lubrication
system.
Check the sensor.


tions and tic menu
components
Code J1587
100/3 PID100/3 Sensor oil pres- No limitation. Check cabling between Volvo ENGINE,
sure, cable short control unit and TWD1240VE: menu 6
circuited to supply component. D794/1:14
voltage. Check the sensor. Volvo
TAD1250VE:
D794/B:11
100/4 PID100/4 Oil pressure sen- No limitation. Check cabling between Volvo ENGINE,
sor, open circuit control unit and TWD1240VE: menu 6
or short circuit to component. D794/1:14
ground. Check the sensor. Volvo
TAD1250VE:
D794/B:11
102/0 PID102/0 Boost pressure No limitation. Check the turbocharger. - ENGINE,

high. Check the sensor. menu 6
Check fuel quality and

injectors.
102/1 PID102/1 Boost pressure Reduced en- Check the air filter. - ENGINE,
low. gine power. Check the turbocharger. menu 6
Check the sensor.

Check the fuel feed
pressure.
102/3 PID102/3 Sensor boost The engine jerks Check cabling between Volvo ENGINE,
pressure, cable more than nor- control unit and compo- TWD1240VE: menu 7
short-circuited to mal during ac- nent. D794/1:3
voltage. celeration or Check the sensor. Volvo
under load. TAD1250VE:
D794/A:22
102/4 PID102/4 Boost pressure The engine jerks Check cabling between Volvo ENGINE,
sensor, cable more than nor- control unit and compo- TWD1240VE: menu 7
short circuited to mal during ac- nent. D794/1:3
ground or open celeration or Check the sensor. Volvo
circuit. under load. TAD1250VE:
D794/A:22
105/0 PID105/0 High charge-air Engine will shut Check coolant level. - ENGINE,
temperature. down. Check that the charge-air menu 7
cooler is clean.
Check thermostat.
Check the sensor.


tions and tic menu
components
Code J1587
105/3 PID105/3 Charge air tem- No limitation. Check cabling between Volvo ENGINE,
perature sensor, control unit and compo- TWD1240VE: menu 7
cable short nent. D794/1:2
circuited to supply Check the sensor. Volvo
voltage or open TAD1250VE:
circuit. D794/A:47
105/4 PID105/4 Charge air tem- No limitation. Check cabling between Volvo ENGINE,
perature sensor, control unit and compo- TWD1240VE: menu 7
cable short nent. D794/1:2
circuited to Check the sensor. Volvo
ground or open TAD1250VE:
circuit. D794/A:47
106/FMI PID106/ Boost pressure The engine jerks Check cabling between Volvo ENGINE,
FMI sensor, short cir- more than nor- control unit and compo- TWD1240VE: menu 6
cuit to voltage, mal during ac- nent. D794/1:3
ground or open celeration or Check the sensor. Volvo
circuit. under load. TAD1250VE:
D794/A:22
106/FMI PID106/ Boost pressure No limitation. Check cabling between - ENGINE,

FMI too high. control unit and compo- menu 6
nent.
Check the sensor.
110/0 PID110/0 High coolant tem- Volvo Check coolant level. - ENGINE,
perature. TWD1240VE: Check that radiator is menu 7
Engine will shut clean.
down.
Check thermostat.
Volvo
TAD1250VE: No Check the cap on the ex-
pansion tank.
limitation.
Check if there’s air in
coolant system.
Check the sensor.
110/3 PID110/3 Coolant tempera- Preheating is ac- Check cabling between Volvo ENGINE,
ture sensor, cable tivated even if control unit and compo- TWD1240VE: menu 7
short circuited to engine is warm. nent. D794/1:25
supply voltage or Check the sensor. Volvo
D794/B:27


tions and tic menu
components
Code J1587
110/4 PID110/4 Coolant tempera- Preheating is ac- Check cabling between Volvo ENGINE,
ture sensor, cable tivated even if control unit and compo- TWD1240VE: menu 7
short circuited to engine is warm. nent. D794/1:25
TAD1250VE:
D794/B:27
111/1 PID111/1 Low coolant level. Volvo Check the coolant level, - -
TAD1250VE: top up if needed.
Engine will shut Check the sensor.
down.
Volvo
TAD1250VE: No
limitation.
111/FMI PID111/ Coolant level sen- Volvo Check cabling between Volvo -
FMI sor, short TWD1240VE: control unit and compo- TWD1240VE:
circuited to Engine will shut nent. D794/2:7
voltage. down. Check the sensor. Volvo
Volvo TAD1250VE:
TAD1250VE: No D794/B:23
limitation.
153/FMI PID153/ Crankcase venti- No limitation. Clean the crankcase - -

FMI lation pressure ventilation.
too high. Check for wear on the
cylinder liner, piston and
piston rings.
153/FMI PID153/ Crankcase venti- No limitation. Check cabling between Volvo -

FMI lation pressure control unit and compo- TAD1250VE:
sensor, short cir- nent. D794/B:28
cuit to voltage, Check the sensor.
ground or open
circuit.
158/FMI PID158/ Low battery Engine may be Check and charge the - -
FMI voltage. difficult to start. batteries.
Check the alternator.
Check the battery ca-
bles.


tions and tic menu
components
Code J1587
172/FMI PID172/ Intake air temper- No limitation. Check cabling between Volvo ENGINE,
FMI ature sensor, control unit and compo- TWD1240VE: menu 7
short circuit to nent. D794/1:2
voltage, ground, Check the sensor. Volvo
or open circuit. TAD1250VE:
D794/A:47
175/0 PID175/0 High engine oil Reduced en- Check oil level. - ENGINE,
temperature. gine power. Check the lubrication menu 7
system’s thermostat.
Check the sensor.
175/3 PID175/3 Oil temperature No limitation. Check cabling between Volvo ENGINE,
sensor, cable control unit and compo- TWD1240VE: menu 7
short circuited to nent. D794/1:1
supply voltage or Check the sensor. Volvo
D794/A:31,
B:3, B:4
175/4 PID175/4 Oil temperature No limitation. Check cabling between Volvo ENGINE,
sensor, cable control unit and compo- TWD1240VE: menu 7
short circuited to nent. D794/1:1
TAD1250VE:
D794/A:31,
B:3, B:4
190/FMI PID190/ Engine rpm too No limitation. Ease off throttle or select - -
FMI high. higher gear.
608/FMI PPID98/ Signal error for No limitation. Check the CAN bus driv- - CAN/
FMI start and stop. etrain. POWER,
menu 3
620/3 SID232/3 Voltage feed to Several error Check cabling between Volvo -
1079/2 sensor, cable codes for sensor control unit and compo- TWD1240VE:
short circuited to error. nent. D794/1:5
voltage. Reduced en- Volvo
gine power. TAD1250VE:
Incorrect instru- D794/B:17
ment values.


tions and tic menu
components
Code J1587
620/4 SID232/4 Voltage feed to Several error Check cabling between Volvo -
1079/3 sensor, cable codes for sensor control unit and compo- TWD1240VE:
short circuited to error. nent. D794/1:4
ground. Reduced en- Volvo
gine power. TAD1250VE.
Incorrect instru- D794/B:17
ment values.
626/3 PID45/3 Preheating relay, Preheating can- Check cabling between Volvo ENGINE,
cable short not be activated. control unit and compo- TWD1240VE: menu 5
circuited to volt- nent. D794/2:36
age. Check the relay. Volvo
TAD1250VE:
D794/B:25
626/4 PID45/4 Preheating relay, Preheating is Check cabling between Volvo ENGINE,
cable short continually acti- control unit and compo- TWD1240VE: menu 5
circuited to vated. nent. D794/2:36
ground. Check the relay. Volvo
TAD1250VE:
D794/B:25
626/5 PID45/5 Preheating relay, Preheating can- Check cabling between Volvo ENGINE,
open circuit on ca- not be activated. control unit and compo- TWD1240VE: menu 5
ble or defective nent. D794/2:36
component. Check the relay. Volvo
TAD1250VE:
D794/B:25
629/FMI SID254/ Engine control The engine will Change the control unit. - -
FMI unit (D794), inter- not start.
nal fault. Engine runs
roughly.
630/FMI SID253/ Engine control The engine will Re-program the control - -
FMI unit (D794), mem- not start. unit.
ory error.
636/3 SID21/3 Sensor rpm cam- Engine takes Check cabling between Volvo -
shaft, no signal. longer time to control unit and compo- TWD1240VE:
start than nor- nent. D794/1:7, 1:18
mal. Engine runs Check the sensor. Volvo
normally when it TAD1250VE:
has started. D794/B:45,
B:46


tions and tic menu
components
Code J1587
636/8 SID21/8 Sensor engine Engine takes Check cabling between Volvo -
rpm, camshaft, longer time to control unit and compo- TWD1240VE:
abnormal fre- start than nor- nent. D794/1:7, 1:18
quency. mal. Engine runs Check the sensor. Volvo
normally when it TAD1250VE:
has started. D794/B:45,
B:46
637/2 SID22/2 Engine speed Engine is ex- Check cabling between Volvo ENGINE,
sensor, flywheel, tremely difficult control unit and compo- TWD1240VE: menu 2
irregular signal. to start and runs nent. D794/1:30,
rough, if it starts. Check the sensor. 1:31
Volvo
TAD1250VE:
D794/B:37,
B:38
637/3 SID22/3 Sensor engine Engine is ex- Check cabling between Volvo ENGINE,
rpm, flywheel, ab- tremely difficult control unit and compo- TWD1240VE: menu 2
normal frequency. to start and runs nent. D794/1:30,
rough, if it starts. Check the sensor. 1:31
Volvo
TAD1250VE:
D794/B:37,
B:38
637/8 SID22/8 Sensor engine Engine is ex- Check cabling between Volvo ENGINE,
rpm, flywheel, ab- tremely difficult control unit and compo- TWD1240VE: menu 2
normal frequency. to start and runs nent. D794/1:30,
rough, if it starts. Check that the sensor is 1:31
connected correctly. Volvo
TAD1250VE:
D794/B:37,
B:38
639/FMI SID231/ Communication Engine off: en- Use diagnostic menu to Volvo CAN/
FMI error with Engine gine cannot be find incorrect segment. TWD1240VE: POWER,
control unit started. Check cabling between D794/2:1, 2:2 menu 3
(D794), configu- Engine on: en- control unit and compo- Volvo
ration error. gine goes to idle nent. TAD1250VE:
and can only be Check the control unit. D794/B:51,
stopped by us- B:55
ing the emer-
gency stop.


tions and tic menu
components
Code J1587
639/FMI SID231/ Communication Instruments and Use diagnostic menu to - CAN/
FMI error with Engine controls do not find incorrect segment. POWER,
control unit work. Check cabling between menu 3
(D794), configu- control unit and compo-
ration error. nent.
Check the control unit.
639/FMI SID240/ Engine control It may not be Re-program the control - -

FMI unit, memory er- possible to start unit.
ror. the engine.
651/2 SID1/2 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 1. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:11,
and has reduced Check the injector. 1:12
power. Volvo
TAD1250VE:
D794/A:20,
A:24
power. Volvo
TAD1250VE:
D794/A:20,
A:24
power. Volvo
TAD1250VE:
D794/A:20,
A:24
power. Volvo
TAD1250VE:
D794/A:20,
A:24


tions and tic menu
components
Code J1587
651/7 SID1/7 Incorrect com- Runs rough at Check fuel pressure. Volvo -
pression or defec- low rpm and low Check valve clearance. TWD1240VE:
tive injector load. D794/1:11,
cylinder 1. Check cabling between 1:12
control unit and compo-
nent. Volvo
TAD1250VE:
Check the injector.
D794/A:20,
Perform compression A:24
test and check cylinder 1.
power. Volvo
TAD1250VE:
D794/A:20,
A:24
power. Volvo
TAD1250VE:
D794/A:20,
A:24
power. Volvo
TAD1250VE:
D794/A:12,
A:16
power. Volvo
TAD1250VE:
D794/A:12,
A:16


tions and tic menu
components
Code J1587
power. Volvo
TAD1250VE:
D794/A:12,
A:16
Check cabling between
cylinder 2. 1:12
nent. Volvo
TAD1250VE:
Check the injector.
D794/A:12,
power. Volvo
TAD1250VE:
D794/A:12,
A:16
power. Volvo
TAD1250VE:
D794/A:28,
A:32
jector cylinder 3. cylinders, control unit and compo- TWD1240VE.
power. Volvo
TAD1250VE:
D794/A:28,
A:32


tions and tic menu
components
Code J1587
power. Volvo
TAD1250VE:
D794/A:28,
A:32
power. Volvo
TAD1250VE:
D794/A:28,
A:32
cylinder 3. 1:12
nent. Volvo
TAD1250VE:
Check the injector.
D794/A:28,
power. Volvo
TAD1250VE:
D794/A:28,
A:32
power. Volvo
TAD1250VE:
D794/A:52,
A:56


tions and tic menu
components
Code J1587
power. Volvo
TAD1250VE:
D794/A:52,
A:56
power. Volvo
TAD1250VE:
D794/A:52,
A:56
power. Volvo
TAD1250VE:
D794/A:52,
A:56
cylinder 4. 1:24
nent. Volvo
TAD1250VE:
Check the injector.
D794/A:52,
power. Volvo
TAD1250VE:
D794/A:52,
A:56


tions and tic menu
components
Code J1587
power. Volvo
TAD1250VE:
D794/A:44,
A:48
power. Volvo
TAD1250VE:
D794/A:44,
A:48
power. Volvo
TAD1250VE:
D794/A:44,
A:48
power. Volvo
TAD1250VE:
D794/A:44,
A:48
655/7 SID5/7 Incorrect com- Engine runs on 5 Check that cabling to the Volvo -
pression or defec- cylinders, injectors is not damaged. TWD1240VE:
tive injector sounds rough Check cabling between D794/1:35,
cylinder 5. and has reduced control unit and compo- 1:24
power. nent. Volvo
Check the injector. TAD1250VE:
D794/A:44,
Perform compression
A:48


tions and tic menu
components
Code J1587
power. Volvo
TAD1250VE:
D794/A:44,
A:48
and has reduced Check the component. 1:24
power. Volvo
TAD1250VE:
D794/A:36,
A:40
power. Volvo
TAD1250VE:
D794/A:36,
A:40
power. Volvo
TAD1250VE:
D794/A:36,
A:40
power. Volvo
TAD1250VE:
D794/A:36,
A:40


tions and tic menu
components
Code J1587
cylinder 6. Check cabling between 1:24
nent. Volvo
TAD1250VE:
Check the injector.
D794/A:36,
power. Volvo
TAD1250VE
D794/A:36,
A:40
677/FMI PPID3/ Starter motor re- The engine will Check cabling between Volvo ENGINE,
FMI lay, short circuit to not start. control unit and compo- TWD1240VE: menu 5
SID39/ voltage/ground. Engine starts im- nent. D794/2:31
FMI mediately when Check the motor. Volvo
ignition is turned TAD1250VE
on. D794/B:29
1485/3 PPID5/3 Main relay, cable The instrument Check cabling between Volvo -
short circuited to panel loses volt- control unit and compo- TWD1240VE:
voltage. age when the ig- nent. D794/1:32
nition key is Check the relay. Volvo
turned to the TAD1250VE:
start position. D794/A:8
The engine will
not start.
2017/ PSID201 Communication Engine off: en- Use diagnostic menu to Volvo CAN/
FMI /FMI error with Engine gine cannot be find incorrect segment. TWD1240VE: POWER,
control unit started. Check cabling between D794/2:1, 2:2 menu 3
(D794), configu- Engine on: en- control unit and compo- Volvo
ration error. gine goes to idle nent. TAD1250VE:
and can only be Check the control unit. D794/B:51,
stopped by us- B:55
ing the emer-
gency stop.


tions and tic menu
components
Code J1587
2047/xx Undetectable er- - Contact the engine sup- D794 -
ror code from the plier for further informa-
engine. tion.
Error codes
above 2047 can-
not be shown in
the display.
Possible error
codes: 2791,
520192, 520194,
520195.
2791/3 PPID19 Internal EGR: The engine con- Check the wiring (boost Volvo -
Wiring error trol unit limits en- pressure sensor). TAD1250VE:
(boost pressure gine output. Contact an authorised D794/B:30
sensor). IEGR cannot be Volvo Penta workshop.
Mechanical error activated. Check the component
on IEGR. (IEGR).
on IEGR. (IEGR).
on IEGR. (IEGR).
2791/7 PPID19 Internal EGR: Could damage Check the wiring (boost Volvo -
Mechanical error the turbine pressure sensor). TAD1250VE:
on IEGR. wheel of the tur- Contact an authorised D794/B:30
bocharger and Volvo Penta workshop.
increase force
Check the component
and emissions.
(IEGR).
520192/ PPID8 Piston cooling No limitation. Check cabling between Volvo -

1 pressure sensor, control unit and compo- TAD1250VE:
short circuited to nent. D794/B:14
voltage, ground, Check the sensor.
or open circuit.


tions and tic menu
components
Code J1587
520192/ PPID8 Low piston cool- No limitation. Check that engine oil - -
3 ing pressure. pressure is over 175 kPa.
520194/ PPID4 Start input CIU: Engine cannot Check that start key con- D794 -
3 Short circuited to be started. nections are not dam-
minus (-). Engine starts im- aged.
Activated too mediately when Check that the start key

long. the ignition is wiring is not damaged.
switched on.
520194/ PPID4 Start input CIU: Engine cannot Check that start key con- D794 -
4 Short circuited to be started. nections are not dam-
minus (-). Engine starts im- aged.
Activated too mediately when Check that the start key

long. the ignition is wiring is not damaged.
switched on.
520195/ PPID6 Stop input on con- The engine can Check that the connec- Volvo -
4 trol unit: only be stopped tions and wiring are not TAD1250VE:
Short circuited to with the auxiliary damaged. D794/B:27
minus (-). stop. Volvo
Activated too TWD1240VE:
long. D794/2:6

Engine error codes (engine

page
–
alternative Cummins QSM11)

tions and tic menu
compo-
nents
Code J1587
84/2 PID084/2 Electrical error, Engine speed is Check cabling between - -
speed sensor, invalid limited to maxi- control unit and compo-
data. mum rpm without nent.
gear. Check the sensor.
84/10 PID084/ Electrical error, Engine speed is Check cabling between - -

10 speed sensor, signal limited to maxi- control unit and compo-
manipulation detect- mum rpm without nent.
ed. gear. Check the sensor.
91/3 PID091/3 Electrical error, ac- Engine does not Check cabling between - -
celerator pedal, ca- respond to throt- control unit and compo-
ble short circuited to tle. nent.
supply voltage. Check the component.
celerator pedal, ca- respond to throt- control unit and compo-
ble short circuited to tle. nent.
ground. Check the component.
celerator pedal, low respond to throt- control unit and compo-
frequency. tle. nent.
Check the component.
celerator pedal, high respond to throt- control unit and compo-
frequency. tle. nent.
91/19 SID091/2 Communication er- Engine will only Use diagnostic menu to - CAN/
ror with cab control idle. find incorrect segment. POWER,
unit (D790-1), electri- menu 3
cal error, accelerator
pedal.
97/3 PID097/3 Electrical error, wa- No limitation. Check cabling between D794/Sen- -
ter-in-fuel sensor, control unit and compo- sor:09
cable short circuited nent.
to supply voltage. Check the component.


tions and tic menu
compo-
nents
Code J1587
97/4 PID097/4 Electrical error, wa- No limitation. Check cabling between D794/Sen- -
ter-in-fuel sensor, control unit and compo- sor:09
to ground. Check the component.
97/15 PID097/ Water in fuel. Risk of white ex- Drain water from the fuel - -
15 haust smoke and filter.
reduced engine
output.
100/1 PID100/1 Low engine oil pres- Engine output is Check the engine oil lev- - ENGINE,
sure. reduced gradually. el; fill as necessary. menu 6
The engine is
switched off after
30 seconds.
100/2 PID100/2 Oil pressure sensor, No warning of low Check the sensor. D794/Sen- ENGINE,
data error. engine oil pressor:44 menu 6
sure.
100/3 PID100/3 Sensor oil pressure, No warning of low Check cabling between D794/Sen- ENGINE,
cable short circuited engine oil pres- control unit and compo- sor:44 menu 6
to supply voltage. sure. nent.
Check the sensor.
100/4 PID100/4 Oil pressure sensor, No warning of low Check cabling between D794/ ENGINE,
open circuit or short engine oil pres- control unit and compo- Black:14 menu 6
circuit to ground. sure. nent.
Check the sensor.
100/18 PID100/1 Low engine oil pres- No limitation. Check oil level in the en- - ENGINE,
sure. gine, top up as needed. menu 6
Check the sensor.
102/2 PID102/2 Boost pressure sen- Reduced engine Check cabling between D794/Sen- ENGINE,
sor indicates high power. control unit and compo- sor:39 menu 7
boost pressure but nent.
other engine data in- Check the sensor.
dicates that pressure
should be normal.
102/3 PID102/3 Sensor boost pres- Reduced engine Check cabling between D794/Sen- ENGINE,
sure, cable short- power. control unit and compo- sor:39 menu 7
circuited to voltage. nent.
Check the sensor.


tions and tic menu
compo-
nents
Code J1587
102/4 PID102/4 Boost pressure sen- Reduced engine Check cabling between D794/ ENGINE,
sor, cable short power. control unit and compo- Black:3 menu 7
circuited to ground or nent.
open circuit. Check the boost pres-
sure sensor.
103/16 PID103/0 Over-rev protection, Reduced engine Check the component. - -

turbo. power.
105/0 PID105/0 Intake air too hot. Engine output is Check the coolant level in - ENGINE,
reduced gradually. the engine, top up as menu 7
The engine is needed.
switched off after Check that the charge-air
30 seconds. cooler is clean, clean as
needed.
Check that the fan belts
are intact. Check the in-
take air temperature sen-
sor.
105/3 PID105/3 Charge air tempera- Risk of white ex- Check cabling between D794/Sen- ENGINE,
ture sensor, cable haust smoke. No control unit and compo- sor:38 menu 7
short circuited to warning of high nent.
supply voltage or coolant tempera- Check that the charge air
open circuit. ture. temperature sensor is
correctly installed and
connected.
Check the charge air
temperature sensor.
105/4 PID105/4 Charge air tempera- Risk of white ex- Check cabling between D794/Sen- ENGINE,
ture sensor, cable haust smoke. No control unit and compo- sor:38 menu 7
short circuited to warning of high nent.
ground or open cir- coolant tempera- Check that the sensor is
cuit. ture. correctly installed and
connected.
Check the sensor.
108/2 PID108/2 Electrical error, air Reduced engine Check the sensor. - -
pressure sensor, power.
data error.
108/3 PID108/3 Electrical error, air Reduced engine Check cabling between D794/Sen- -
pressure sensor, ca- power. control unit and compo- sor:06
ble short circuited to nent.
supply voltage. Check the sensor.


tions and tic menu
compo-
nents
Code J1587
108/4 PID108/4 Electrical error, air Reduced engine Check cabling between D794/Sen- -
pressure sensor, ca- power. control unit and compo- sor:06
ble short circuited to nent.
ground. Check the sensor.
110/0 PID110/0 High coolant temper- Engine output is Check coolant level. - ENGINE,
ature. reduced gradually. Check that radiator is menu 7
The engine is clean.
switched off after
30 seconds. Check if there’s air in
coolant system.
Check the cap on the ex-
pansion tank.
Check the sensor.
Check thermostat.
110/3 PID110/3 Coolant temperature No indication of Check cabling between D794/Sen- ENGINE,
sensor, cable short engine tempera- control unit and sor:02 menu 7
circuited to supply ture. component.
voltage or open
circuit.
110/4 PID110/4 Coolant temperature No indication of Check cabling between D794/Sen- ENGINE,
sensor, cable short engine tempera- control unit and compo- sor:02 menu 7
circuited to ground. ture. nent.
Check that the sensor is
connected correctly.
Check the sensor.
111/1 PID111/1 Low coolant level. Engine output is Check the coolant level, - -
reduced gradually. top up if needed.
The engine is Check the sensor.
switched off after
30 seconds.
111/2 PID111/2 Electrical error, cool- No warning of low Check cabling between D794/Sen- -
ant level sensor, coolant level. control unit and compo- sor:09
data error. nent.
Check the sensor.
166/2 PID116/2 Output imbalance Uneven idling. Check the fuel quality. - -
between cylinders. The error code could be
generated if the fuel sys-
tem is opened, allowing
air to enter the system.
Troubleshoot the engine.


tions and tic menu
compo-
nents
Code J1587
167/1 PID167/1 Low battery voltage. Warning active Check batteries and al- D794/ -
until voltage is cor- ternator. OEM:7, 8,
rect. 17, 18, 28
167/16 PID167/0 Low battery voltage. Warning active Check fuses. Check bat- D794/ -
until voltage is cor- teries and alternator. OEM:7, 8,
rect. 17, 18, 28
167/18 PID167/1 High battery voltage. Warning active Check batteries and al- D794/ -
until voltage is cor- ternator. OEM:7, 8,
rect. The engine 17, 18, 28
runs at increased
idle to increase
voltage.
168/16 PID168/0 High voltage supply No limitation. Check fuses. Check bat- D794/ -
to control unit. teries and alternator. OEM:7, 8,
17, 18, 28
168/18 PID168/1 Low voltage supply Uneven idling. Check fuses. Check bat- D794/ -
to control unit. teries and alternator. OEM:7, 8,
17, 18, 28
175/0 PID175/0 High engine oil tem- Engine output is Check the engine coolant - ENGINE,
perature. reduced gradually. and oil level. Top up as menu 7
The engine is necessary.
switched off after Check that the oil cooler
30 seconds. is clean; clean as need-
ed.
Check that the fan belts
are intact.
Check the sensor.
175/3 PID175/3 Oil temperature sen- No indication of Check cabling between D794/Sen- ENGINE,
sor, cable short engine oil temper- control unit and compo- sor:42 menu 7
circuited to supply ature. nent.
voltage or open cir- Check that the sensor is
cuit. connected correctly.
175/4 PID175/4 Oil temperature sen- No indication of Check cabling between D794/Sen- ENGINE,
sor, cable short engine oil temper- control unit and compo- sor:42 menu 7
circuited to ground. ature. nent.
Check the sensor.


tions and tic menu
compo-
nents
Code J1587
188/4 SID032/4 Electrical error, Reduced engine Check cabling between D794/Ac-
wastegate solenoid power. control unit and compo- tuator: 24
valve 1 short nent.
circuited to ground. Check the solenoid
valve.
190/0 PID190/0 Engine rpm too high. Fuel supply re- Ease off throttle or select - -
stricted until en- higher gear.
gine speed is
below permitted
value.
190/2 PID190/2 Electrical error, rpm/ Engine stops and Check cabling between D794/Sen- -
ignition mode sen- cannot be restart- control unit and compo- sor:47, 50
sor; no signal from ed. nent.
any sensors. Check the sensor.
190/10 PID190/ Electrical error, rpm/ No limitation. Check cabling between D794/Sen- -
10 ignition mode sen- control unit and compo- sor: 47, 50
sor, one of two sig- nent.
nals missing. Check the sensor.
191/16 PID191/0 Speed limitation acti- Speed is reduced. Reduce throttle applica- - -
vated. tion.
191/18 PID191/1 Speed warning for Engine will only Increase throttle applica- - -
low speed. idle. tion.
251/2 PID251/2 Internal error, Con- - - - -

trol unit, engine.
441/3 PID441/3 Auxiliary tempera- No warning of high Check cabling between D794/Sen-
ture sensor short temperature, Con- control unit and compo- sor: 12
circuited to ground. trol unit, engine nent.
(D794). Check the sensor.
441/4 PID441/4 Auxiliary tempera- No warning of high Check cabling between D794/Sen-
ture sensor short temperature, Con- control unit and compo- sor: 12
circuited to supply trol unit, engine nent.
voltage. (D794). Check the sensor.
558/2 SID230/2 Electrical error, ac- No limitation. Check cable between D794/ -
celerator pedal sen- control unit and compo- OEM: 03,
sor, idling contact, nent. 13
data error. Check component.


tions and tic menu
compo-
nents
Code J1587
558/4 SID230/4 Electrical error, ac- Engine does not Check cable between D794/ -
celerator pedal sen- respond to throt- control unit and compo- OEM: 03,
sor, idling contact tle. nent. 13
cable short circuited Check component.
to ground.
558/13 SID230/ Electrical error, ac- Engine will only Check cable between D794/ -
13 celerator pedal sen- idle. control unit and compo- OEM: 13
sor, idling contact, nent.
calibration error. Check component.
608/2 SID250/2 Communication er- No limitation. Check the control unit. D794/
ror with Control unit OEM: 26,
engine (D794). 27, 36, 37,
46
608/9 SID250/9 Communication er- No limitation. Check the control unit. D794/
ror with Control unit OEM: 26,
engine (D794). 27, 36, 37,
46
620/3 SID232/3 Electrical error, refer- Reduced engine Check cabling between D794/Sen- -
1080/3 ence voltage to sen- output. No warn- control unit and compo- sor: 18, 25,
sor short circuited to ing of low oil pres- nent. 45
supply voltage. sure or low Check the control unit.
coolant level.
1081/4 ence voltage to sen- output. No warn- control unit and compo- sor: 18, 25,
sor short circuited to ing of low oil pres- nent. 45
ground. sure or low Check the component.
coolant level.
626/11 SID237/ Electrical error to Preheating not Check cabling between D794/Ac- ENGINE,
11 control of preheating working. Risk of control unit and compo- tuator: 34 menu 5
relay. white smoke. nent.
627/2 SID251/2 Voltage supply to Reduced engine Check the fuses. D794/ -
control unit disap- output. Engine dif- Check batteries and al- OEM:7, 8,
pears but ignition not ficult to start or ternator. 17, 18, 28
off. dies.
629/12 SID254/ Internal error, Con- The engine will not Check the control unit. - -
12 trol unit, engine. start.
629/12 SID254/ Internal error, Con- No limitation. Check the control unit. - -
12 trol unit, engine.


tions and tic menu
compo-
nents
Code J1587
630/2 SID253/2 Software error, Con- Reduced engine Re-program the software - -
trol unit, engine output. Engine dif- in Control unit, engine
(D794). ficult to start or (D794).
dies.
632/3 SID017/3 Electrical error, fuel No limitation. Check cabling between D794/Ac- -
cut-off solenoid control unit and compo- tuator: 33
valve, cable short nent.
circuited to supply Check the solenoid
voltage. valve.
632/4 SID017/4 Electrical error, fuel Engine will shut Check cabling between D794/Ac- -
cut-off solenoid down. control unit and compo- tuator: 33
valve, cable short nent.
valve.
639/2 SID231/2 Communication er- Functions via CAN Use diagnostic menu to - CAN/
ror with Control unit bus not working. find incorrect segment. POWER,
engine (D794). menu 2
ror with Control unit bus not working. find incorrect segment. POWER,
engine (D794). menu 2
ror with Control unit, bus not working. find incorrect segment. POWER,
engine (D794), time- menu 2
out error.
639/13 SID231/ Communication er- Functions via CAN Use diagnostic menu to - CAN/
13 ror with Engine con- bus not working. find incorrect segment. POWER,
trol unit (D794), menu 2
configuration error.
644/2 SID030/2 Electrical error, ac- Engine will shut Check cabling between - -
celerator pedal, sig- down. control unit and compo-
nal not within valid nent.
interval. Check the component.
647/4 SID033/4 Electrical error, fan Cooling fan runs Check cabling between D794/Ac- -
connection, cable constantly. control unit and compo- tuator:10,
short circuited to nent. Actuator: 9
ground. Check the component.
651/5 SID001/5 Electrical error, cylin- Engine runs on 5 Check cabling between D794/Ac- -
der 1 injector, open cylinders, sounds control unit and compo- tuator:10,
circuit on cable. rough and has re- nent. Actuator: 9
duced power. Check the injector.


tions and tic menu
compo-
nents
Code J1587
der 1 injector, cable cylinders, sounds control unit and compo- tuator:10,
short circuited to rough and has re- nent. Actuator: 9
ground. duced power. Check the injector.
der 2 injector, open cylinders, sounds control unit and compo- tuator: 7, 8
circuit on cable. rough and has re- nent.
der 2 injector, cable cylinders, sounds control unit and compo- tuator:7, 8
short circuited to rough and has re- nent.
circuit on cable. rough and has re- nent. 16
653/6 SID003/6 Electrical error, cylin- Engine runs on 5 Check cable between D794/Ac- -
short circuited to rough and has re- nent. 16
ground. duced power. Check component.
circuit on cable. rough and has re- nent. 36
short circuited to rough and has re- nent. 36
der 5 injector, cable cylinders, sounds control unit and compo- tuator: 3, 4
ground. duced power. Check component.


tions and tic menu
compo-
nents
Code J1587
duced power. Check component.
der 6 injector, cable cylinders, sounds control unit and compo- tuator: 1, 2
702/3 SID040/3 Electrical error, auxil- No limitation. Check cabling between D794/Ac- -
PID154/3 iary output 2, cable control unit and compo- tuator: 14
short circuited to nent.
703/3 SID051/3 Electrical error, auxil- No limitation. Check cabling between D794/Ac- -
iary output 2, cable control unit and compo- tuator: 45
short circuited to nent.
974/3 SID029/3 Electrical error, auxil- Engine does not Check cabling between D794/ -
iary accelerator ped- respond to throt- control unit and compo- OEM: 21
al, cable short tle. nent.
circuited to supply Check the component.
voltage.
974/4 SID029/4 Electrical error, auxil- Engine does not Check cabling between D794/ -
iary accelerator ped- respond to throt- control unit and compo- OEM: 21
al, cable short tle. nent.
circuited to ground. Check the component.
974/19 SID029/2 Communication er- Engine does not Use diagnostic menu to - CAN/
ror with cab control respond to throt- find incorrect segment. POWER,
unit (D790-1), electri- tle. menu 2
cal error, accelerator
pedal.
1043/3 PID221/3 Electrical error, ac- Engine will only Check cabling between D794/ -
celerator pedal refer- idle. control unit and compo- OEM: 48
ence voltage, cable nent.
short circuited to Check the component.
supply voltage.
1043/4 PID221/4 Electrical error, ac- Engine will only Check cabling between D794/ -
celerator pedal refer- idle. control unit and compo- OEM: 48
ence voltage, cable nent.
short circuited to Check the component.
ground.


tions and tic menu
compo-
nents
Code J1587
1072/11 SID070/ Electrical error, sole- Engine brake 1 Check cabling between D794/Ac- -
11 noid valve engine cannot be activat- control unit and compo- tuator: 44
brake 2. ed. nent.
Check the solenoid
valve.
1073/11 SID029/ Electrical error, sole- Engine brake 2 Check cabling between D794/Ac- -
11 noid valve engine cannot be activat- control unit and compo- tuator: 44
brake 2. ed. nent.
Check the solenoid
valve.
ence voltage to sen- power. control unit and compo- sor: 17, 37
sor short circuited to nent.
supply voltage. Check the sensor.
ence voltage to sen- power. control unit and compo- sor: 17, 37
sor short circuited to nent.
ground. Check the sensor.
1188/3 SID032/3 Electrical error, Reduced engine Check cabling between D794/Ac- -
valve 1 short nent.
voltage. valve.
valve 2 short nent.
voltage. valve.
valve 2 short nent.
valve.
1265/4 SID085/4 Electrical error, oil- No limitation. Check cabling between - -

burn solenoid valve, control unit and compo-
to ground. Check the solenoid
valve.


tions and tic menu
compo-
nents
Code J1587
1319/2 PID102/2 Electrical error, Reduced engine Check cabling between D794/Sen- -
boost pressure sen- power. control unit and compo- sor: 9
sor. nent.
Check the sensor.
1380/1 PID017/1 Low engine oil level. No limitation. Check the engine oil lev- - -
el; fill as necessary.
1383/31 SID151/ Engine shut off other No limitation. Switch of the engine with - -
11 than with start key, the start key.
causing load.
1384/31 SID029/ Engine shut off other No limitation. Switch of the engine with - -
14 than with start key, the start key.
causing load.
1387/3 PID223/3 Electrical error, auxil- No pressure guard Check cabling between D794/Sen- -
iary pressure sensor, (customer-specif- control unit and compo- sor: 19
cable short circuited ic option). nent.
to supply voltage. Check the sensor.
1387/4 PID223/4 Electrical error, auxil- No pressure guard Check cabling between D794/Sen- -
iary pressure sensor, (customer-specif- control unit and compo- sor: 19
cable short circuited ic option). nent.
to ground. Check the sensor.
1484/31 SID216/ Error codes in other No limitation. Check error codes for - -
11 control units. other machine control
units, particularly the cab
control unit (D790-1) and
transmission control unit
(D793).

D Error codes – 2 Transmission 39
2 Transmission
mm mm mm mm mm mm
Error codes, transmission

page
–
The machine is available with two transmission alternatives, transmis-

sion alternative Dana and transmission alternative Dana full flow. Both
alternatives use the same error codes, but some error codes are relat-
ed to different components depending on the transmission alternative.
In this case there are two different descriptions marked "Dana" and
"Dana full flow" respectively.
Control unit transmission can generate two modes with reduced func-
tionality to protect the transmission in case of serious malfunctions:
• "Limp-home".
In this mode only 1-2 gear in both directions can be used. If the
malfunction occurs in a higher gear then downshifting has to be
performed manually to 1st gear or 2nd.
• "Shut-down"
In this mode, the transmission is in permanent neutral position as
there is no oil pressure to enable selection of a gear.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
00/50 7F09D/C Memory error in control Transmission - - -
unit transmission. locked in neutral
(Shut-down).

(Shut-down).

(Shut-down).

(Shut-down).

40 D Error codes – 2 Transmission
Connec- Diag-
components menu
Code SPN/FM1
20/60 7F065/1 Dana Transmission Check cabling Dana TRANSM,
Sensor oil pressure indi- locked in neutral between control D793/A2 - menu 10
cates low oil pressure (Shut-down). unit and sensor. X253
when there should be Check the
pressure. sensor.
Dana full flow Dana full flow

Sensor gear 1/3 D793/A2 -
(B6067) indicates low oil B6067
pressure when there
should be pressure.

Sensor oil pressure indi- locked in neutral between control D793/A2 - menu 10
cates oil pressure when (Shut-down). unit and sensor. X253
there should not be Check the
pressure. sensor.

(B6067) indicates oil B6067
pressure when there
should not be oil pres-
sure.
21/00 7F069/1 Oil pressure sensor (1) Transmission Check the feed - -
has too low oil pressure. locked in neutral pressure to the
(Shut-down). transmission.
Save informa-
tion about actual
pressure when
the problem oc-
curred.
21/01 7F069/0 Oil pressure sensor (1) Transmission Check the feed - -
has too high oil pres- locked in neutral pressure to the
sure. (Shut-down). transmission.
Save informa-
tion about actual
pressure when
the problem oc-
curred.

Connec- Diag-
components menu
Code SPN/FM1
22/00 7F06A/1 Oil pressure sensor (2) Transmission Check the feed - -
Save informa-
tion about actual
pressure when
the problem oc-
curred.
22/01 7F06A/0 Oil pressure sensor (2) Transmission Check the feed - -
Save informa-
tion about actual
pressure when
the problem oc-
curred.
23/00 7F06B/1 Oil pressure sensor (3) Transmission Check the feed - -
Save informa-
tion about actual
pressure when
the problem oc-
curred.
23/01 7F06B/0 Oil pressure sensor (3) Transmission Check the feed - -
Save informa-
tion about actual
pressure when
the problem oc-
curred.
24/00 7F06C/1 Oil pressure sensor (4) Transmission Check the feed - -
Save informa-
tion about actual
pressure when
the problem oc-
curred.

Connec- Diag-
components menu
Code SPN/FM1
24/01 7F06C/0 Oil pressure sensor (4) Transmission Check the feed - -
Save informa-
tion about actual
pressure when
the problem oc-
curred.
30/04 7F090/1 Low battery voltage. Control unit saves Check cabling - CAN/
stored information to control unit. POWER,
to flash memory Check alterna- menu 15
and restarts to clear tor, battery and
memory. cabling between
battery and al-
ternator.
30/05 7F090/0 High battery voltage. Control unit re- Check voltage - CAN/
ceives reduced pro- feed. POWER,
portional control If auxiliary start menu 15
precision depend- equipment is
ing on reduced connected, dis-
PWM work cycle. connect it.
31/00 7F093/1 Reference voltage sen- Control unit re- Check voltage - CAN/
sor 8 V, too low. ceives reduced sen- feed. POWER,
sor signals. Check the con- menu 15
trol unit.
31/01 7F093/0 Reference voltage sen- Control unit re- Check voltage - CAN/
sor 8 V, too high. ceives reduced sen- feed. POWER,
sor signals. Check the con- menu 15
trol unit.
34/00 7F0BB/1F Sensor, drum rpm Transmission Check cabling - TRANSM,

(B752) incorrect. locked in gear 1 and between gear menu 6
2 (Limp-home). control and sen-
sor.
Check the sen-
sor.

Connec- Diag-
components menu
Code SPN/FM1
34/01 7F0BC/1 Measured turbine speed Transmission Check cabling - -
during start-up is too locked in neutral between gear
low. (Shut-down). control and sen-
sor.
Check the
sensor.
Check the feed
pressure to the
transmission.
34/02 7F0BD/0 Measured turbine speed Transmission Check cabling - -

during start-up is too locked in neutral between the
high. (Shut-down). gear control and
drum rpm
sensor.
Check the
sensor.
34/03 7F0BE/1 Transmission indicates Transmission Check drum - -

that system pressure is locked in neutral rpm sensor.
absent when it should (Shut-down). Check Solenoid
be present. valve RSP Drive
(Y6066).
Feed pressure
to transmission
too low.
34/04 7F0BE/0 Transmission indicates Transmission Check cabling - -

that system pressure is locked in neutral between the
present when it should (Shut-down). gear control and
be absent. drum rpm
sensor.
Check the
sensor.
Check Solenoid
valve RSP Drive
(Y6066).
40/06 7F05E/2 Incorrect direction from Control unit locks Check cabling - TRANSM,
gear selector. transmission in to gear selector menu 2
neutral. with regards to
forward and re-
verse signal.

Connec- Diag-
components menu
Code SPN/FM1
40/08 7F041/1F Seat direction was Transmission Check seat di- - -
changed when the park- locked in neutral rection or show
ing brake was not acti- (Shut-down). the driver how
vated and/or the gear the seat is
control was not in neu- turned as per
tral position, and/or the the correct pro-
machine was not sta- cedure.
tionary.
41/06 7F05F/2 Incorrect gear selection Control unit doesn’t Check cabling - TRANSM,
from gear selector. allow change of to gear selector menu 2
range, however, op- with regards to
eration of machine signal range.
is possible.
42/04 7F080/1 Actual gear ratio too Control unit indi- Check transmis- - TRANSM,
low. cates that one or sion with pur- menu 6
several clutches are pose to
slipping. understand if
and, if that is the
case, which
clutch is slip-
ping.
Check the set
gear ratio for the
control unit.
42/05 7F080/0 Actual gear ratio too Control unit indi- Check transmis- - TRANSM,
high. cates that one or sion with pur- menu 6
several clutches are pose to
slipping. understand if
and, if that is the
case, which
clutch is slip-
ping.
Check the set
gear ratio for the
control unit.

Connec- Diag-
components menu
Code SPN/FM1
43/03 7F063/0 Dana Control unit indi- Check cabling Dana TRANSM,
Signal from Sensor en- cates the error. between control D793/H3 - menu 10
gine rpm and oil temper- unit and compo- B758/766
ature transmission nent.
(B758/766) outside valid Check the sen-
interval. sor.

The signal from Sensor D793/H3 -
oil temperature (B7660) B7660
outside valid interval.
43/07 7F063/10 Torque converter tem- Control unit indi- Check transmis- Dana TRANSM,
perature exceeds cates the error to sion oil cooler, D793/H3 - menu 10
100 °C. make operator clean as need- B758/766
aware of the warned.
ing’s level. Dana full flow
Check the ther-
mostat in the D793/H3 -
transmission oil B7660
cooler.
43/08 7F063/0 Torque converter tem- The control unit pro- Check transmis- Dana TRANSM,
perature exceeds tects the transmission oil cooler, D793/H3 - menu 10
120 °C. sion and does not clean as need- B758/766
allow the tempera- ed.
ture in the torque Dana full flow
Check the ther-
converter to exceed mostat in the D793/H3 -
the limit value. transmission oil B7660
The control unit cooler.
locks the transmis-
sion in neutral posi-
tion, the engine is
restricted to 50% of
max. rpm.
44/10 7F0C6/9 Faulty signal for acceler- - Use diagnostic - CAN/

ator pedal position from menu to find in- POWER,
engine control unit correct seg- menu 3
(D794). ment.
45/06 7F048/2 Invalid combination for The control unit lim- Check the - -
redundant digital speed its machine speed speed sensors.
inputs. to the reduced
speed.
46/05 7F036/F Max. torque for inching - - - -

has been exceeded.

Connec- Diag-
components menu
Code SPN/FM1
47/01 7F07B/10 The transmission has Control unit indi- Release the ac- - -
exceeded the limit value cates the error. celerator pedal
for top speed. and slow down
the machine.
48/00 7F0B3/0 Disengaged 4WD/2WD Control unit indi- Check the 4WD/ - -
selector stuck in en- cates the error. 2WD selector.
gaged mode, or the Check whether
feedback signal is incor- digital feedback
rect. is switched on
and connected
to the control
unit.
48/01 7F0B3/1 Engaged 4WD/2WD se- Control unit indi- Check the 4WD/ - -
lector stuck in engaged cates the error. 2WD selector.
mode, or the return sig- Check whether
nal is incorrect. digital feedback
is switched on
and connected
to the control
unit.
49/00 7F0B4/0 Disengaged Low/High Control unit indi- Check the Low/ - -
selector stuck in en- cates the error. High gear selec-
gaged mode, or the tor.
feedback signal is incor- Check whether
rect. digital feedback
is switched on
and connected
to the control
unit.
49/01 7F0B4/1 Engaged Low/High se- Control unit indi- Check the Low/ - -
lector stuck in engaged cates the error. High gear
mode, or the return sig- selector.
nal is incorrect. Check whether
digital feedback
is switched on
and connected
to the control
unit.

Connec- Diag-
components menu
Code SPN/FM1
Sensor oil pressure, locked in gear 1 and between control D793/A2 - menu 10
short circuited to 2 (Limp-home). unit and sensor. X253
ground. Check the sen-
sor.
(B6067), short circuited B6067
to ground.

Sensor oil pressure, not locked in gear 1 and between control D793/A2 - menu 10
connected or open cir- 2 (Limp-home). unit and compo- X253
cuit. nent.
Check the sen-
sor.
(B6067), not connected B6067
or open circuit.
50/04 7F010/11 Sensor gear 1/3 The control unit Check cabling D793/A2 - TRANSM,
(B6067), the value is be- identifies the error between control B6067 menu 10
low the lowest calibrated and use the lowest unit and compo-
value. value in its settings. nent.
Check the sen-
sor.
50/05 7F010/F Sensor gear 1/3 The control unit Check cabling D793/A2 -
(B6067), the value is identifies the error between control B6067
above the highest cali- and use the highest unit and compo-
brated value. value in its settings. nent.
Check the sen-
sor.
51/00 7F011/4 Dana The control unit lim- Check cabling Dana TRANSM,
Sensor engine rpm and its the transmis- between control D793/H3 - menu 10
oil temperature trans- sion’s temperature unit and sensor. B758/766
mission (B758/766) measurement to the Check the sen-
short-circuited to lowest value in its sor.
ground. settings, which re-
sults in poor tem-
Dana full flow perature Dana full flow
Oil temperature sensor compensation. D793/H3 -
(B7660) short circuited B7660
to ground.

Connec- Diag-
components menu
Code SPN/FM1
Sensor engine rpm and its the transmis- between control D793/H3 - menu 10
oil temperature trans- sion’s temperature unit and sensor. B758/766
mission (B758/766) not measurement to the Check the sen-
connected or open cir- highest value in its sor.
cuit. settings, which re-
sults in poor tem-
Dana full flow perature Dana full flow
Sensor oil temperature compensation. D793/H3 -
(7660), not connected or B7660
open circuit.
51/04 7F011/11 Sensor oil temperature The control unit lim- Check cabling D793/H3 - TRANSM,
(B7660), the value is be- its the transmis- between control B7660 menu 10
low the lowest calibrated sion’s temperature unit and compo-
value. measurement to the nent.
lowest value in its Check the sen-
settings. sor.
51/05 7F011/F Sensor oil temperature The control unit lim- Check cabling D793/H3 - TRANSM,
(B7660), the value is its the transmis- between control B7660 menu 10
above the highest cali- sion’s temperature unit and compo-
brated value. measurement to the nent.
highest value in its Check the sen-
settings. sor.
Sensor oil temperature its the transmis- between control D793/J3 - S221 menu 10
(S221) short-circuited to sion’s temperature unit and sensor.
ground. measurement to the Check the sen-
highest value in its sor.
Dana full flow settings, which re- Dana full flow
Temperature switch sults in poor tem- D793/J3 -
torque converter perature S2210
(S2210) short circuited compensation.
to ground.
Sensor oil temperature its the transmis- between control D793/J3 - S221 menu 10
(S221) open circuit. sion’s temperature unit and sensor.
measurement to the Check the sen-
Dana full flow highest value in its Dana full flow
sor.
Temperature switch settings, which re- D793/J3 -
torque converter sults in poor tem- S2210
(S2210) is not perature
connected. compensation.

Connec- Diag-
components menu
Code SPN/FM1
52/04 7F012/11 Temperature switch The control unit lim- Check cabling D793/J3B - TRANSM,
torque converter its the transmis- between control S2210 menu 10
(S2210), the value is be- sion’s temperature unit and compo-
low the lowest calibrated measurement to the nent.
value. lowest value in its Check the sen-
settings, which re- sor.
sults in poor tem-
perature
compensation.
52/05 7F012/F Temperature switch The control unit lim- Check cabling D793/J3B - TRANSM,
torque converter its the transmis- between control S2210 menu 10
(S2210), the value is sion’s temperature unit and compo-
above the highest cali- measurement to the nent.
brated value. highest value in its Check the sen-
settings, which re- sor.
sults in poor tem-
perature
compensation.
53/00 7F013/4 Analogue input signal 3, Depending on the Check cabling - -

short circuited to function that is as- between control
ground. signed to the pin: unit and compo-
Pressure feedback: nent.
Transmission Check the com-
locked in gear 1 and ponent.
2 (Limp-home).
Oil pressure sensor:
The control unit
locks the transmis-
sion in neutral
position.
Other: The control
unit uses the lowest
value in its settings.

Connec- Diag-
components menu
Code SPN/FM1
53/01 7F013/3 Analogue input signal 3, Depending on func- Check cabling - -
is not connected. tion assigned to the between control
pin: unit and compo-
2 (Limp-home).
The control unit
locks the transmis-
sion in neutral
position.
Other: The control
53/04 7F013/11 Analogue input signal 3, The control unit Check cabling - -
the value is below the identifies the error between control
lowest calibrated value. and use the lowest unit and compo-
value in its settings. nent.
Check the com-
ponent.
53/05 7F013/F Analogue input signal 3, The control unit Check cabling - -
the value is above the identifies the error between control
highest calibrated value. and use the highest unit and compo-
Check the com-
ponent.
54/00 7F014/4 Reference voltage sen- - Check cabling D793/M1 - CAN/

sor 5 V short-circuiting between control S2210, B7667, POWER,
to frame ground. unit and compo- B6069 menu 15
nent.
Check the
sensor.
54/01 7F014/3 Reference voltage sen- - Check cabling D793/M1 - CAN/

sor 5 V short circuited to between control S2210, B7667, POWER,
voltage. unit and compo- B6069 menu 15
nent.
Check the sen-
sor.

Connec- Diag-
components menu
Code SPN/FM1
2 (Limp-home).
The control unit
locks the transmis-
tion.
Other: The control

is not connected. function that is as- between control
signed to the pin: unit and compo-
2 (Limp-home).
The control unit
locks the transmis-
tion.
Other: The control
Check the com-
ponent.
Check the com-
ponent.

Connec- Diag-
components menu
Code SPN/FM1
56/00 7F016/4 Pressure sensor gear 2/ Depending on the Check cabling D793/S1 - TRANSM,
4 (B6069), short function that is as- between control B6069 menu 10
circuited to ground. signed to the pin: unit and compo-
2 (Limp-home).
The control unit
locks the transmis-
tion.
Other: The control
56/01 7F016/3 Pressure sensor gear 2/ Depending on the Check cabling D793/S1 - TRANSM,
4 (B6069), is not con- function that is as- between control B6069 menu 10
nected. signed to the pin: unit and compo-
2 (Limp-home).
The control unit
locks the transmis-
tion.
Other: The control
56/04 7F016/11 Pressure sensor gear 2/ The control unit Check cabling D793/S1 - TRANSM,
4 (B6069), the value is identifies the error between control B6069 menu 10
below the lowest cali- and use the lowest unit and compo-
Check the com-
ponent.
56/05 7F016/F Pressure sensor gear 2/ The control unit Check cabling D793/S1 - TRANSM,
4 (B6069), the value is identifies the error between control B6069 menu 10
above the highest cali- and use the highest unit and compo-
Check the com-
ponent.

Connec- Diag-
components menu
Code SPN/FM1
2 (Limp-home).
The control unit
locks the transmis-
tion.
Other: The control

2 (Limp-home).
The control unit
locks the transmis-
tion.
Other: The control
Check the com-
ponent.
Check the com-
ponent.

Connec- Diag-
components menu
Code SPN/FM1
2 (Limp-home).
The control unit
locks the transmis-
tion.
Other: The control

2 (Limp-home).
The control unit
locks the transmis-
tion.
Other: The control
Check the com-
ponent.
Check the com-
ponent.

Connec- Diag-
components menu
Code SPN/FM1
60/00 7F01A/6 Dana When only one rpm Check cable be- Dana TRANSM,
Sensor rpm drum signal that is not the tween control D793/C3 - menu 6
(B752) short-circuited to engine rpm signal is unit and sensor. B752
ground. incorrect, the con- Check the sen-
trol unit calculates sor.
Dana full flow the missing rpm. Dana full flow
Sensor rpm drum If several rpm sig- D793/C3 -
(B7520) short-circuited nals or if the engine B7520
to ground. speed signal are
defective, the con-
trol unit locks the
transmission control
unit to gear 1-2
(Limp-home).
60/01 7F01A/5 Dana When only one rpm Check cable be- Dana TRANSM,
Sensor rpm drum signal that is not the tween control D793/C3 - menu 6
(B752) not connected. engine rpm signal is unit and sensor. B752
incorrect, the con- Check the sen-
Dana full flow trol unit calculates Dana full flow
sor.
Sensor rpm drum the missing rpm. D793/C3 -
(B7520) not connected. If several rpm sig- B7520
nals or if the engine
speed signal are
defective, the con-
trol unit locks the
unit to gear 1-2
(Limp-home).
60/03 7F01A/A Sensor rpm drum Control unit indi- Check cable be- D793/C3 - TRANSM,
(B7520), value outside cates the error. tween control B7520 menu 6
limit values. unit and compo-
nent.
Check compo-
nent.

Connec- Diag-
components menu
Code SPN/FM1
60/04 7F01A/1 Sensor rpm drum This message is Check the trans- D793/C3 - TRANSM,
(B7520), pulse count too provided as supple- mission to find B7520 menu 6
low. mentary information out if, and
for errors in the which, clutch is
transmission. slipping.
Check the trans-
mission’s set-
tings for the ratio
in the control
unit.
60/05 7F01A/0 Sensor rpm drum This message is Check the trans- D793/C3 - TRANSM,
high. mentary information out if, and
Check the trans-
mission’s set-
tings for the ratio
in the control
unit.
61/00 7F01B/6 Dana When only one rpm Check cable be- Dana TRANSM,
Sensor rpm output shaft signal that is not the tween control D793/E3 - menu 6
Sensor rpm output shaft If several rpm sig- D793/E3 -
defective, the con-
trol unit locks the
unit to gear 1-2
(Limp-home).

Connec- Diag-
components menu
Code SPN/FM1
61/01 7F01B/5 Dana When only one rpm Check cable be- Dana TRANSM,
Sensor rpm output shaft signal that is not the tween control D793/E3 - menu 6
sor.
Sensor rpm output shaft the missing rpm. D793/E3 -
speed signal are
defective, the con-
trol unit locks the
unit to gear 1-2
(Limp-home).
61/03 7F01B/A Sensor rpm output shaft Control unit indi- Check cable be- D793/E3 - TRANSM,
nent.
Check the sen-
sor.
61/04 7F01B/1 Sensor rpm output shaft This message is Check the trans- D793/E3 - TRANSM,
Check the trans-
mission’s set-
tings for the ratio
in the control
unit.
61/05 7F01B/0 Sensor rpm output shaft This message is Check the trans- D793/E3 - TRANSM,
Check the trans-
mission’s set-
tings for the ratio
in the control
unit.

Connec- Diag-
components menu
Code SPN/FM1
62/00 7F01C/6 Dana When only one rpm Check cable be- Dana TRANSM,
Sensor engine rpm signal that is not the tween control D793/F3 - menu 6
(B758/766), short- engine rpm signal is unit and sensor. B758/766
circuited to ground. incorrect, the con- Check the sen-
Sensor engine speed If several rpm sig- D793/F3 -
(B7530), short circuited nals or if the engine B7530
defective, the con-
trol unit locks the
unit to gear 1-2
(Limp-home).
62/01 7F01C/5 Dana When only one rpm Check cable be- Dana TRANSM,
Sensor engine rpm signal that is not the tween control D793/F3 - menu 6
(B758/766), not con- engine rpm signal is unit and sensor. B758/766
nected or has open cir- incorrect, the con- Check the sen-
cuit. trol unit calculates sor.
the missing rpm.
If several rpm sig-
Sensor engine speed nals or if the engine D793/F3 -
(B7530), not connected speed signal are B7530
or has open circuit. defective, the con-
trol unit locks the
unit to gear 1-2
(Limp-home).
62/03 7F01C/A Engine speed informa- Transmission in Use diagnostic - -

tion is not available. Limp-home. menu to find in-
correct seg-
ment.
62/04 7F01C/1 Sensor engine speed This message is Check the trans- D793//F3 - TRANSM,
(B7530), pulse count is provided as supple- mission to find B7530 menu 6
too low. mentary information out if, and
Check the trans-
mission’s set-
tings for the ratio
in the control
unit.

Connec- Diag-
components menu
Code SPN/FM1
62/05 7F01C/0 Sensor engine speed This message is Check the trans- D793/F3 - TRANSM,
(B7530), pulse count is provided as supple- mission to find B7530 menu 6
too high. mentary information out if, and
Check the trans-
mission’s set-
tings for the ratio
in the control
unit.
62/06 7F07A/1 Incorrect engine speed Transmission in Check sensor D793/F3 - TRANSM,
information when tur- Limp-home. for engine rpm B7530 menu 6
bine speed is calculated speed.
Check the com-
ponent’s posi-
tion.
63/00 7F01D/6 Dana When only one rpm Check cable be- Dana TRANSM,
Sensor rpm turbine signal that is not the tween control D793/R2 - menu 6
Sensor rpm turbine If several rpm sig- D793/G3 -
defective, the con-
trol unit locks the
unit to gear 1-2
(Limp-home).

Connec- Diag-
components menu
Code SPN/FM1
63/01 7F01D/5 Dana When only one rpm Check cable be- Dana TRANSM,
Sensor rpm turbine signal that is not the tween control D793/R2 - menu 6
sor.
Sensor rpm turbine the missing rpm. D793/G3 -
speed signal are
defective, the con-
trol unit locks the
unit to gear 1-2
(Limp-home).
63/03 7F01D/A Sensor rpm turbine Control unit indi- Check cable be- D793/G3 - TRANSM,
nent.
Check compo-
nent.
63/04 7F01D/1 Sensor rpm turbine This message is Check the trans- D793/G3 - TRANSM,
Check the trans-
mission’s set-
tings for the ratio
in the control
unit.
63/05 7F01D/0 Sensor rpm turbine This message is Check the trans- D793/G3 - TRANSM,
Check the trans-
mission’s set-
tings for the ratio
in the control
unit.

Connec- Diag-
components menu
Code SPN/FM1
Solenoid valve VFS locked in gear 1 and between control D793/B1 - menu 8
front (Y630), short- 2 (Limp-home). unit and sole- Y630, D793/C1
circuited to each other, noid valve. - Y630
signal cable short- Check the sole-
circuited to voltage, or noid valve.
plus-cable short-
circuited to frame
ground.
Dana full flow Dana full flow TRANSM,

Servo valve gear for- D793/B1 - menu 8
ward and reverse Y6300, D793/
(Y6300), short-circuited C1 - Y6300
to each other, signal ca-
ble short-circuited to
voltage, or plus-cable
short-circuited to frame
ground.

Solenoid valve VFS for- locked in gear 1 and between control D793/B1 - menu 8
ward (Y630) open circuit 2 (Limp-home). unit and sole- Y630, D793/C1
or short-circuited volt- noid valve. - Y630
age. Check the sole-
noid valve.
Servo valve gear for- D793/B1 -
(Y6300) open circuit or C1 - Y6300
short-circuited voltage.

ward (Y630), control 2 (Limp-home). unit and sole- Y630, C1 -
current higher than 1400 noid valve. Y630
mA. Check the sole-
noid valve.
Servo valve gear for- D793/B1 -
(Y6300), control current C1 - Y6300
over 1400 mA.

Connec- Diag-
components menu
Code SPN/FM1
ward (Y630), control 2 (Limp-home). unit and sole- Y630, D793/C1
current outside ap- noid valve. - Y630
proved interval. Incor- Check the sole-
rect impedance. noid valve.
Dana full flow Transmission Dana full flow

Servo valve gear for- locked in neutral D793/B1 -
ward and reverse (Shut-down). Y6300, D793/
(Y6300), control current C1 - Y6300
outside the approved in-
terval. Incorrect imped-
ance.
70/09 7F020/5 Servo valve gear for- Transmission Check cabling D793/B1 - TRANSM,
ward and reverse locked in gear 1 and between control Y6300, D793/ menu 9
(Y6300), not connected. 2 (Limp-home). unit and compo- C1 - Y6300
nent.
Check the sole-
noid valve.

Solenoid valve VFS 2/4 locked in gear 1 and between control D793/D1 - menu 8
(Y6069), short-circuited 2 (Limp-home). unit and sole- Y6069, D793/
to each other, signal ca- noid valve. E1 - Y6069
ble short-circuited to Check the sole-
voltage, or plus-cable noid valve.
ground.

Solenoid valve gear se- D793/D1 -
lection 1/3 (Y6067), Y6067, D793/
short-circuited to each E1 - Y6067
other, signal cable
short-circuited to volt-
age, or plus-cable short-
circuited to frame
ground.

Connec- Diag-
components menu
Code SPN/FM1
(Y6069) open circuit or 2 (Limp-home). unit and sole- Y6069, D793/
short-circuited voltage. noid valve. E1 - Y6069
Check the sole-
noid valve.
lection 1/3 (Y6067), Y6067, D793/
open circuit or short- E1 - Y6067
circuited voltage.

(Y6069), control current 2 (Limp-home). unit and sole- Y6069, D793/
higher than 1400 mA. noid valve. E1 - Y6069
Check the sole-
noid valve.
lection 1/3 (Y6067), con- Y6067, D793/
trol current higher than E1 - Y6067
1400 mA.

(Y6069), control current 2 (Limp-home). unit and sole- Y6069, D793/
outside approved inter- noid valve. E1 - Y6069
val (incorrect imped- Check the sole-
ance). noid valve.

lection 1/3 (Y6067), con- Y6067, D793/
trol current outside E1 - Y6067
approved interval (incor-
rect impedance).
71/09 7F021/5 Solenoid valve gear se- Transmission Check cabling D793/D1 - TRANSM,
lection 1/3 (Y6067), not locked in gear 1 and between control Y6067, D793/ menu 9
connected. 2 (Limp-home). unit and compo- E1 - Y6067
nent.
Check the sole-
noid valve.

Connec- Diag-
components menu
Code SPN/FM1
Solenoid valve VFS re- locked in gear 1 and between control D793/F1 - menu 8
verse (Y631), cables 2 (Limp-home). unit and sole- Y631, D793/G1
short-circuited to each noid valve. - Y631
other, signal cable Check the sole-
short-circuited to volt- noid valve.
circuited to frame
ground.
Dana full flow Dana full flow -

Solenoid valve gear se- D793/F1 -
lection 2/4 (Y6069), Y6069, D793/
short-circuited to each G1 - Y6069
other, signal cable
short-circuited to volt-
circuited to frame
ground.

verse (Y631) open cir- 2 (Limp-home). unit and sole- Y631, D793/G1
cuit or short-circuited noid valve. - Y631
voltage. Check the sole-
noid valve.
lection 2/4 (Y6069), Y6069, D793/
open circuit or short- G1 - Y6069
circuited voltage.

verse (Y631), control 2 (Limp-home). unit and sole- Y631, D793/G1
current higher than 1400 noid valve. - Y631
mA. Check the sole-
noid valve.
lection 2/4 (Y6069), con- Y6069, D793/
trol current higher than G1 - Y6069
1400 mA.

Connec- Diag-
components menu
Code SPN/FM1
verse (Y631), control 2 (Limp-home). unit and sole- Y631, G1 -
current outside ap- noid valve. Y631
proved interval (incor- Check the sole-
rect impedance). noid valve.

lection 2/4 (Y6069), con- Y6069, D793/
trol current outside G1 - Y6069
approved interval (incor-
rect impedance).
72/09 7F022/5 Solenoid valve gear se- Transmission Check cabling Dana full flow -
lection 2/4 (Y6069), not locked in gear 1 and between control D793/F1 -
connected. 2 (Limp-home). unit and compo- Y6069, D793/
nent. G1 - Y6069
Check the com-
ponent.

Solenoid valve VFS 1/3 locked in gear 1 and between control D793/H1 - menu 8
(Y6067), cables short- 2 (Limp-home). unit and sole- Y6067, D793/
circuited to each other, noid valve. J1 - Y6067
signal cable short- Check the sole-
circuited to voltage, or noid valve.
plus-cable short-
circuited to frame
ground.
73/00 Dana full flow Dana full flow

Analogue output signal -
3, cables short-circuited
to each other, signal ca-
voltage or plus-cable
ground.

Connec- Diag-
components menu
Code SPN/FM1
(Y6067) open circuit or 2 (Limp-home). unit and sole- Y6067, J1 -
short-circuited voltage. noid valve. Y6067
Check the sole-
noid valve.
3, open circuit or short-
circuited voltage.

(Y6067), control current 2 (Limp-home). unit and sole- Y6067, J1 -
higher than 1400 mA. noid valve. Y6067
Check the sole-
noid valve.
3, control current over
1400 mA.

(Y6067), control current 2 (Limp-home). unit and sole- Y6067, J1 -
outside approved inter- noid valve. Y6067
val (incorrect imped- Check the sole-
ance). noid valve.

3, control current out-
side the approved inter-
val (incorrect
impedance).
73/09 7F023/5 Analogue output signal Transmission Check cabling - -

3, not connected. locked in gear 1 and between control
2 (Limp-home). unit and compo-
nent.
Check the sole-
noid valve.
74/00 7F024/4 Analogue output signal Control unit indi- Check cabling - -
4, short circuited to cates the error. between control
ground. unit and compo-
nent.
Check the com-
ponent.

Connec- Diag-
components menu
Code SPN/FM1
4 not connected or cates the error. between control
short-circuited voltage. unit and compo-
nent.
Check the com-
ponent.
nent.
Check the com-
ponent.
5 not connected or cates the error. between control
nent.
Check the com-
ponent.
nent.
Check the com-
ponent.
6, not connected or cates the error. between control
nent.
Check the com-
ponent.
6, control current over cates the error. between control
1400 mA. unit and compo-
nent.
Check the com-
ponent.

Connec- Diag-
components menu
Code SPN/FM1
6, output signal outside cates the error. between control
the approved interval unit and compo-
(incorrect impedance). nent.
Check the com-
ponent.
3, not connected. cates the error. between control
unit and compo-
nent.
Check the com-
ponent.
77/02 7F02F/1F All gear packs disen- Transmission - - -

gaged. locked in neutral
(Shut-down).
80/00 7F027/4 Dana Transmission Check cabling Dana Dana

Solenoid valve RSP locked in gear 1 and between control D793/K1 - TRANSM,
Drive (Y6066), cable 2 (Limp-home). unit and compo- Y6066 menu 7
short-circuited to frame nent.
ground. Check the sole-
noid valve.
Solenoid valve drive for- D793/K1 -
ward (Y6066F), cable Y6066F
ground.
80/01 7F027/3 Dana Transmission Check cabling Dana Dana

Solenoid valve RSP locked in gear 1 and between control D793/K1 - TRANSM,
Drive (Y6066), cable is 2 (Limp-home). unit and compo- Y6066 menu 7
not connected or short- nent.
circuited to voltage. Check the sole-
noid valve.
Solenoid valve drive for- D793/K1 -
ward (Y6066F), cable is Y6066F
not connected or short-
circuited to voltage.

Connec- Diag-
components menu
Code SPN/FM1
80/09 7F027/5 Solenoid valve drive for- Transmission Check cabling D793/K1 - TRANSM,
ward (Y6066F), not con- locked in gear 1 and between control Y6066F menu 7
nected. 2 (Limp-home). unit and compo-
nent.
Check the sole-
noid valve.

Solenoid valve VFS 2/4 locked in gear 1 and between control D793/E2 - menu 7
(Y6074), cable short- 2 (Limp-home). unit and sole- Y6074
circuited to frame noid valve.
noid valve.
Solenoid valve drive re- D793/E2 -
verse (Y6066R), cable Y6066R
ground.

Solenoid valve VFS 2/4 locked in gear 1 and between control D793/E2 - menu 7
(Y6074), cable is not 2 (Limp-home). unit and sole- Y6074
connected or short- noid valve.
noid valve.
Solenoid valve drive re- D793/E2 -
verse (Y6066R), cable Y6066R
short-circuited to
voltage.
81/09 7F027/5 Solenoid valve drive re- Transmission Check cabling D793/E2 - TRANSM,
verse (Y6066R), not locked in gear 1 and between control Y6066R menu 7
connected. 2 (Limp-home). unit and compo-
nent.
Check the sole-
noid valve.

Connec- Diag-
components menu
Code SPN/FM1
Solenoid valve VFS 1/3 locked in gear 1 and between control D793/F2 - menu 7
(Y6075), cable short- 2 (Limp-home). unit and sole- Y6075
circuited to frame noid valve.
noid valve.
lection 1/3 (Y6075), ca- Y6075
frame ground.

Solenoid valve VFS 1/3 locked in gear 1 and between control D793/F2 - menu 7
(Y6075), cable is not 2 (Limp-home). unit and sole- Y6075
connected or short- noid valve.
noid valve.
lection 1/3 (Y6075), ca- Y6075
voltage.
82/09 7F029/5 Solenoid valve gear se- Transmission Check cabling D793/F2 - TRANSM,
lection 1/3 (Y6075), not locked in gear 1 and between control Y6075 menu 7
connected. 2 (Limp-home). unit and sole-
noid valve.
Check the sole-
noid valve.
83/00 7F02A/3 Dana Transmission Check cabling Dana Dana

Solenoid valve RSP locked in neutral between control D793/K2 - TRANSM,
Drive (Y6066), cable (Shut-down). unit and compo- Y6066 menu 7
short-circuited to frame nent.
ground. Check the com-
ponent.
Solenoid valve gear se- D793/K2 -
lection 2/4 (Y6074), ca- Y6074
frame ground.

Connec- Diag-
components menu
Code SPN/FM1
83/01 7F02A/4 Dana Transmission Check cabling Dana Dana
Solenoid valve RSP locked in neutral between control D793/K2 - TRANSM,
Drive (Y6066), cable is (Shut-down). unit and compo- Y6066 menu 7
not connected or short- nent.
circuited to voltage. Check the com-
ponent.
Dana full flow Transmission Dana full flow
Solenoid valve gear se- locked in neutral D793/K2 -
lection 2/4 (Y6074), ca- (Shut-down). Y6074
voltage.
90/01 7F0F0/1 Software error Control - - - -

unit, transmission
(D793).

unit, transmission
(D793).

unit, transmission
(D793).

unit, transmission
(D793).

unit, transmission
(D793).

unit, transmission
(D793).

unit, transmission
(D793).

unit, transmission
(D793).

unit, transmission
(D793).
90/11 7F0F0/B Software error Control - - - -

unit, transmission
(D793).

Connec- Diag-
components menu
Code SPN/FM1
90/12 7F0F0/C Software error Control - - - -
unit, transmission
(D793).
90/13 7F0F0/D Software error Control - - - -

unit, transmission
(D793).
90/14 7F0F0/E Software error Control - - - -

unit, transmission
(D793).
90/15 7F0F0/F Software error Control - - - -

unit, transmission
(D793).

unit, transmission
(D793).

unit, transmission
(D793).

unit, transmission
(D793).

unit, transmission
(D793).
90/90 7F0A0/1F Incorrect software in Transmission - - -

Control unit, transmis- locked in neutral
sion (D793). (Shut-down).
90/xx - 7F000/0 System error. Transmission - D793/A:20 -

99/xx locked in neutral
(Shut-down).

unit, transmission
(D793).

unit, transmission
(D793).

unit, transmission
(D793).

Connec- Diag-
components menu
Code SPN/FM1
unit, transmission
(D793).

unit, transmission
(D793).

unit, transmission
(D793).
91/50 7F0F7/A Software error Control - - - -

unit, transmission
(D793).
91/51 7F0F7/B Software error Control - - - -

unit, transmission
(D793).
91/52 7F0F7/C Software error Control - - - -

unit, transmission
(D793).
91/53 7F0F7/D Software error Control - - - -

unit, transmission
(D793).
91/54 7F0F7/E Software error Control - - - -

unit, transmission
(D793).
91/55 7F0F7/F Software error Control - - - -

unit, transmission
(D793).

unit, transmission
(D793).

unit, transmission
(D793).

unit, transmission
(D793).

unit, transmission
(D793).

Connec- Diag-
components menu
Code SPN/FM1
unit, transmission
(D793).
91/70 7F0F7/1E Software error Control - - - -

unit, transmission
(D793).

unit, transmission
(D793).
92/01 7F0F2/1 The gear has no direc- Transmission - - -

tion. locked in neutral
(Shut-down).
92/02 7F0F2/2 Duplicated direction. Transmission Note the time - -

locked in neutral and contact
(Shut-down). Cargotec sup-
port.
92/03 7F0F2/3 Duplicated gear. Transmission Note the time - -

port.
92/04 7F0F2/4 Duplicated shock pat- Transmission Note the time - -

tern. locked in neutral and contact
port.
92/06 7F0F2/6 Incorrect digital input Transmission Note the time - -

signal. locked in neutral and contact
port.
92/07 7F0F2/7 Digital input signal in Transmission Note the time - -

conflict with gear control locked in neutral and contact
position. (Shut-down). Cargotec sup-
port.
92/08 7F0F2/8 Digital input signal Transmission Note the time - -

"Transmission locked in locked in neutral and contact
neutral position" incor- (Shut-down). Cargotec sup-
rect. port.
92/09 7F0F2/9 Digital input signal dupli- Transmission Note the time - -
cated assignment. locked in neutral and contact
port.

Connec- Diag-
components menu
Code SPN/FM1
92/10 7F0F2/A Digital output signal du- Transmission Note the time - -
plicated assignment. locked in neutral and contact
port.
92/11 7F0F2/B Digital output signal se- Transmission Note the time - -
lected on unconfigured locked in neutral and contact
output. (Shut-down). Cargotec sup-
port.
92/12 7F0F2/C Digital output signal in- Transmission Note the time - -
correct. locked in neutral and contact
port.
92/13 7F0F2/D Digital output signal se- Transmission Note the time - -
lected on transmission locked in neutral and contact
cable. (Shut-down). Cargotec sup-
port.
92/14 7F0F2/E Incorrect assignment in Transmission Note the time - -

speed sensors 1-2. locked in neutral and contact
port.
92/15 7F0F2/F Incorrect assignment in Transmission Note the time - -

speed sensor 3. locked in neutral and contact
port.
92/16 7F0F2/10 Duplicated assignment Transmission Note the time - -

in speed sensors. locked in neutral and contact
port.
92/17 7F0F2/11 Incorrect feed voltage Transmission Note the time - -

selected. locked in neutral and contact
port.
92/18 7F0F2/12 Duplicated input signal. Transmission Note the time - -

port.
92/19 7F0F2/13 Cabling sensor pressure Transmission Note the time - -

in conflict with cabling locked in neutral and contact
analogue input signal. (Shut-down). Cargotec sup-
port.

Connec- Diag-
components menu
Code SPN/FM1
92/20 7F0F2/14 Incorrect configuration Transmission Note the time - -
regarding servo motor locked in neutral and contact
or brake valve (ana- (Shut-down). Cargotec sup-
logue output signal 4-5- port.
6).
92/30 7F0F2/1E Incorrect configuration Transmission Note the time - -

regarding full flow selec- locked in neutral and contact
tion and earlier digital (Shut-down). Cargotec sup-
troubleshooting. port.

unit, transmission
(D793).

unit, transmission
(D793).

unit, transmission
(D793).
93/00 7F0F3/0 Failed initialisation of Transmission Switch off the - -

the necessary control locked in neutral machine and
unit data in flash memo- (Shut-down). the main electri-
ry, caused by a memory cal power.
conflict.

conflict.

conflict.

conflict.

Connec- Diag-
components menu
Code SPN/FM1
conflict.

conflict.

conflict.
93/10 7F0F3/A Initiation of statistical Control unit indi- Switch off the - -
data in flash memory, cates the error. machine and
caused by firmware up- the main electri-
date or a memory con- cal power.
flict.
93/11 7F0F3/B Initiation of stored incor- Control unit indi- Switch off the - -
rect data in flash memo- cates the error. machine and
ry, caused by firmware the main electri-
update or a memory cal power.
conflict.
94/00 7F0F4/0 Failed initialisation of Transmission Note the time - -

the necessary control locked in neutral and contact
unit data in flash memo- (Shut-down). Cargotec sup-
ry, caused by a memory port.
conflict.

conflict.

conflict.

Connec- Diag-
components menu
Code SPN/FM1
conflict.

conflict.

conflict.

conflict.
95/00 7F0F5/0 - - - - -
95/70 7F0F5/14 Software error Control Transmission

unit, transmission locked in neutral
(D793). (Shut-down).
95/71 7F09B/1F Control unit cannot in- Transmission -

terpret input data. locked in neutral
(Shut-down).

unit, transmission
(D793).

unit, transmission
(D793).
99/90 7F0F6/0 Incorrect software in - - - -

control unit transmis-
sion.

unit, transmission
(D793).

Connec- Diag-
components menu
Code SPN/FM1
unit, transmission
(D793).

unit, transmission
(D793).
99/95 7F0CA/1F Overload of CAN bus - - - -

detected: Control unit,
transmission could not
currently handle all in-
coming information, be-
cause of too many CAN
enquiries.

unit, transmission
(D793).
E0/01 7F0E1/F Machine speed too high - - - -

to be able to change
down.
E1/01 7F0E2/F Machine speed too high - - - -

to be able to change
travel direction.
E2/01 7F0E3/F The engine speed is too - - - -

high to be able to
change travel direction,
or select the same travel
direction again.
E3/00 7F0E4/E Machine speed limita- - - - -

tion is activated.
E3/01 7F0E4/F Machine speed limita- - - - -

tion is activated regard-
less of whether the
speed is above the limit
value.
E3/02 7F0E4/10 Machine speed is higher - - - -

than the upper limit val-
ue.
E4/00 7F0E5/11 Abnormal deceleration. The transmission - - -

disengages auto-
matic gearing for a
time.

Connec- Diag-
components menu
Code SPN/FM1
E4/01 7F0E5/F Abnormal acceleration. The transmission - - -
disengages auto-
matic gearing for a
time.
E5/01 7F0E0/D The time with active - Calibrate trans- - -

gear exceeded the time mission.
for re-calibration.
E6/00 7F0E6/1F The operator is not in - - - -

the driver’s seat and the
gear selector is not in
neutral and/or the park-
ing brake is not activat-
ed.
E7/01 7F0E7/F Turbine speed exceeds The control unit - - -

the limit value. forces the engine to
idle in order to pre-
vent damage.
E8/01 7F0E8/F Conditions for shifting - - - -

between 2WD and 4WD
are not fulfilled. The ma-
chine must be station-
ary.
E9/01 7F0E9/F Conditions for shifting

between High and Low
are not fulfilled. The ma-
chine must be station-
ary.
xx/49 - Unspecified error. The control unit

identifies the error -
the action depends
on the error.
E.1.01 7F0FA - Calibration of drive The calibration is Download the - -

-05 7F0FD mode pressure, unex- stopped. correct parame-
pected algorithm re- ters and repeat
sponse. calibration.
Make sure that
the machine
does not move.
Check engine
speed re-
sponse.

Connec- Diag-
components menu
Code SPN/FM1
E.1.06 7F0FA - Calibration of drive The control unit Measure the - -
7F0FD/6 mode pressure, during identifies the error clutch pressure
calibration the turbine and the calibration in order to de-
speed signal does not is stopped. tect leaks.
reach down to the low- Check the sig-
est value. nal from the tur-
bine speed
sensor.
Check the stall
speed in order
to detect slip-
ping clutch.

Make sure that
the machine
does not move.
Check engine
speed re-
sponse.
E.1.10 7F0FA - Calibration of drive The calibration is Determine the - -

7F0FD/A mode pressure, trans- stopped. reason why cali-
mission error during cal- bration was
ibration. stopped.

Make sure that
the machine
does not move.
Check engine
speed re-
sponse.

Connec- Diag-
components menu
Code SPN/FM1
7F0FD/E mode pressure, during identifies the error clutch pressure
calibration the turbine and the calibration in order to de-
speed does not de- is stopped. tect leaks.
crease. Check the sig-
nal from the tur-
bine speed
sensor.

7F0FD mode pressure, unex- stopped. correct parame-
Make sure that
the machine
does not move.
Check engine
speed re-
sponse.

7F0FD/10 mode pressure, the tur- identifies the error clutch pressure
bine speed is too low to and the calibration in order to de-
start calibration. is stopped. tect leaks.
Check the sig-
nal from the tur-
bine speed
sensor.

pected algorithm re- ters and resume
Check if the ma-
chine starts to
move.
Check engine
speed re-
sponse.

Connec- Diag-
components menu
Code SPN/FM1
E.1.25 7F0FA - Calibration of drive The control unit Calibrating at - -
7F0FD/19 mode pressure, the identifies the error higher tempera-
starting point of engage- and the calibration tures (90-
ment is too early during is stopped. 100 C).
calibration. Too much Check the
traction. speed sensors
(error code 42/
04 or 42/05).
Check the servo
valves.

7F0FD/1A mode pressure, en- identifies the error higher tempera-
gagement starting point and the calibration tures (90-
cannot be identified. is stopped. 100 C).
Check the
speed sensors
(error code 42/
04 or 42/05).
Check the servo
valves.

7F0FD mode pressure, unex- stopped. correct parame-
pected algorithm re- ters and resume
Check if the ma-
chine starts to
move.
Check engine
speed re-
sponse.

7F0FD/1C mode pressure, turbine identifies the error clutch pressure
speed does not reach a and the calibration in order to de-
value of 0 rpm during the is stopped. tect leaks.
closing phase of calibra- Check the sig-
tion. nal from the tur-
bine speed
sensor.

Connec- Diag-
components menu
Code SPN/FM1
7F0FD/1D mode pressure, turbine identifies the error higher tempera-
speed does not reach and the calibration tures (90-
the correct value during is stopped. 100 C).
the release phase of the Check the
engagement’s starting speed sensors
point during calibration. (error code 42/
04 or 42/05).
Check the servo
valves.
E.2.01 7F0FA - Calibration optimisation The calibration is Download the - -

-05 7F0FD of filling time, unexpect- stopped. correct parame-
ed algorithm response. ters and repeat
calibration.
Make sure that
the machine
does not move.
Check engine
speed re-
sponse.
E.2.06 7F0FA - Calibration optimisation The control unit Measure the - -

7F0FD/6 of filling time, during cal- identifies the error clutch pressure
ibration the turbine and the calibration in order to de-
bine speed
sensor.
Check the stall
speed in order
to detect slip-
ping clutch.

calibration.
Make sure that
the machine
does not move.
Check engine
speed re-
sponse.

Connec- Diag-
components menu
Code SPN/FM1
E.2.10 7F0FA - Calibration optimisation The calibration is Determine the - -
7F0FD/A of filling time, transmis- stopped. reason why cali-
sion error during calibra- bration was
tion. stopped.

Make sure that
the machine
does not move.
Check engine
speed re-
sponse.

7F0FD/E of filling time, during cal- identifies the error clutch pressure
speed does not de- is stopped. tect leaks.
crease. Check the sig-
nal from the tur-
bine speed
sensor.

7F0FD of filling time, unexpect- stopped. correct parame-
calibration.
Make sure that
the machine
does not move.
Check engine
speed re-
sponse.

7F0FD/10 of filling time, the turbine identifies the error clutch pressure
speed is too low to start and the calibration in order to de-
calibration. is stopped. tect leaks.
Check the sig-
nal from the tur-
bine speed
sensor.

Connec- Diag-
components menu
Code SPN/FM1
ed algorithm response. ters and resume
calibration.
Check if the ma-
chine starts to
move.
Check engine
speed re-
sponse.
E.2.25 7F0FA - Calibration optimisation The control unit Calibrating at - -

7F0FD/19 of filling time, the start- identifies the error higher tempera-
ing point of engagement and the calibration tures (90-
is too early during cali- is stopped. 100 C).
bration. Too much trac- Check the
tion. speed sensors
(error code 42/
04 or 42/05).
Check the servo
valves.
E.2.26 7F0FA - Calibration optimisation The control unit Calibrating at - -

7F0FD/1A of filling time, engage- identifies the error higher tempera-
ment starting point can- and the calibration tures (90-
not be identified. is stopped. 100 C).
Check the
speed sensors
(error code 42/
04 or 42/05).
Check the servo
valves.

7F0FD of filling time, unexpect- stopped. correct parame-
ed algorithm response. ters and resume
calibration.
Check if the ma-
chine starts to
move.
Check engine
speed re-
sponse.

Connec- Diag-
components menu
Code SPN/FM1
7F0FD/1C of filling time, turbine identifies the error clutch pressure
speed does not reach a and the calibration in order to de-
value of 0 rpm during the is stopped. tect leaks.
closing phase of calibra- Check the sig-
tion. nal from the tur-
bine speed
sensor.
E.229 7F0FA - Calibration optimisation The control unit Calibrating at - -

7F0FD/1D of filling time, turbine identifies the error higher tempera-
speed does not reach and the calibration tures (90-
the correct value during is stopped. 100 C).
the release phase of the Check the
engagement’s starting speed sensors
point during calibration. (error code 42/
04 or 42/05).
Check the servo
valves.

calibration.
Make sure that
the machine
does not move.
Check engine
speed re-
sponse.

7F0FD/6 of filling time, during cal- identifies the error clutch pressure
bine speed
sensor.
Check the stall
speed in order
to detect slip-
ping clutch.

Connec- Diag-
components menu
Code SPN/FM1
E.3.07 7F0FA - Calibration of control The calibration is Download the - -
-09 7F0FD current for pressure, un- stopped. correct parame-
expected algorithm re- ters and repeat
Make sure that
the machine
does not move.
Check engine
speed re-
sponse.
E.3.10 7F0FA - Calibration of control The calibration is Determine the - -

7F0FD/A current for pressure, stopped. reason why cali-
transmission error dur- bration was
ing calibration. stopped.

Make sure that
the machine
does not move.
Check engine
speed re-
sponse.
E.3.14 7F0FA - Calibration of control The control unit Measure the - -

7F0FD/E current for pressure, identifies the error clutch pressure
during calibration the and the calibration in order to de-
turbine speed does not is stopped. tect leaks.
decrease. Check the sig-
nal from the tur-
bine speed
sensor.

7F0FD current for pressure, un- stopped. correct parame-
Make sure that
the machine
does not move.
Check engine
speed re-
sponse.

Connec- Diag-
components menu
Code SPN/FM1
7F0FD/10 current for pressure, the identifies the error clutch pressure
turbine speed is too low and the calibration in order to de-
to start calibration. is stopped. tect leaks.
Check the sig-
nal from the tur-
bine speed
sensor.

expected algorithm re- ters and resume
Check if the ma-
chine starts to
move.
Check engine
speed re-
sponse.
E.3.25 7F0FA - Calibration of control The control unit Calibrating at - -

7F0FD/19 current for pressure, the identifies the error higher tempera-
starting point of engage- and the calibration tures (90-
ment is too early during is stopped. 100 C).
calibration. Too much Check the
traction. speed sensors
(error code 42/
04 or 42/05).
Check the servo
valves.

7F0FD/1A current for pressure, en- identifies the error higher tempera-
gagement starting point and the calibration tures (90-
cannot be identified. is stopped. 100 C).
Check the
speed sensors
(error code 42/
04 or 42/05).
Check the servo
valves.

Connec- Diag-
components menu
Code SPN/FM1
7F0FD current for pressure, un- stopped. correct parame-
expected algorithm re- ters and resume
Check if the ma-
chine starts to
move.
Check engine
speed re-
sponse.

7F0FD/1C current for pressure, tur- identifies the error clutch pressure
bine speed does not and the calibration in order to de-
reach a value of 0 rpm is stopped. tect leaks.
during the closing phase Check the sig-
of calibration. nal from the tur-
bine speed
sensor.

7F0FD/1D current for pressure, tur- identifies the error higher tempera-
bine speed does not and the calibration tures (90-
reach the correct value is stopped. 100 C).
during the release Check the
phase of the engage- speed sensors
ment’s starting point (error code 42/
during calibration. 04 or 42/05).
Check the servo
valves.

D Error codes – 8 Control system 91
8 Control system
mm mm mm mm mm mm
Error codes machine

page
–
Code Description Limitation Action Connec- Diagnos- Group

tions and tic menu
compo-
nents
1 Communication error Attachment Use diagnostic menu to D791-1 CAN/ 11.6.2 Re-
with attachment con- functions not find incorrect segment. POWER, dundant
trol unit (D791-1). working. menu 2 CAN-bus
2 Communication error Levelling, tilt, Use diagnostic menu to D791-2 CAN/ 11.6.2 Re-
with Control unit, at- overheight find incorrect segment. POWER, dundant
tachment option extension not menu 2 CAN-bus
(D791-2). working.
3 Communication error Left side of Use diagnostic menu to D791-3 CAN/ 11.6.2 Re-
with Control unit, at- bottom lift not find incorrect segment. POWER, dundant
tachment left jack working. menu 2 CAN-bus
pair (D791-3).
4 Communication error Right side of Use diagnostic menu to D791-4 CAN/ 11.6.2 Re-
with Control unit, at- bottom lift not find incorrect segment. POWER, dundant
tachment right jack working. menu 2 CAN-bus
pair (D791-4).
5 Communication error Lighting rear, Use diagnostic menu to D797-R CAN/ 11.6.2 Re-
with Control unit, hydraulic oil find incorrect segment. POWER, dundant
frame rear (D797-R). cooling, over- menu 2 CAN-bus
load system,
extension not
working.
6 Communication error Front light- Use diagnostic menu to D797-F CAN/ 11.6.2 Re-
with Control unit, ing, lift, exten- find incorrect segment. POWER, dundant
frame front (D797-F). sion, brake menu 2 CAN-bus
lights, brake
cooling not
working.
7 Communication error Sliding cab, Use diagnostic menu to D797-O CAN/ 11.6.2 Re-
with Control unit, support jacks, find incorrect segment. POWER, dundant
frame option (D797- joystick con- menu 2 CAN-bus
O). trol mini-
wheel, cab lift
and cab tilt
not working.
8 Communication error Controls in Use diagnostic menu to D795 CAN/ 11.6.2 Re-
with KID control unit steering find incorrect segment. POWER, dundant
(D795) wheel panel menu 2 CAN-bus
and display
not working.

92 D Error codes – 8 Control system

tions and tic menu
compo-
nents
9 Communication error Mini-wheel or Use diagnostic menu to D790-3 CAN/ 11.6.2 Re-
with Control unit, cab joystick con- find incorrect segment. POWER, dundant
option (D790-3). trol not work- menu 2 CAN-bus
ing
11 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 1. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
figuration. and 21
figuration. and 21
figuration. and 21
figuration. and 21
figuration. and 21
figuration. and 21
figuration. and 21
20 Accelerator pedal Poor sensitiv- Calibrate the gas ped- D790-1/K6:11 CALIBRA- 1. Engine
(B690) not calibrated. ity in acceler- al, see the section 8 – B690 TION:
ator pedal. Control system, group DRIVE-
8.5.2.3 Calibrate TRAIN,
DRIVE-TRAIN. menu 1
and 2


tions and tic menu
compo-
nents
9 Communication error Mini-wheel or Use diagnostic menu to D790-3 CAN/ 11.6.2 Re-
with Control unit, cab joystick con- find incorrect segment. POWER, dundant
option (D790-3). trol not work- menu 2 CAN-bus
ing
figuration. and 21
figuration. and 21
figuration. and 21
figuration. and 21
figuration. and 21
figuration. and 21
figuration. and 21
figuration. and 21
20 Accelerator pedal Poor sensitiv- Calibrate the gas ped- D790-1/K6:11 CALIBRA- 1. Engine
(B690) not calibrated. ity in acceler- al, see the section 8 – B690 TION:
ator pedal. Control system, group DRIVE-
8.5.2.3 Calibrate TRAIN,
DRIVE-TRAIN. menu 1
and 2


tions and tic menu
compo-
nents
21 Communication error Gear selec- Use diagnostic menu to D790-1/K13:1 CAN/ 11.6.3 CAN-
with transmission tion not work- check communication. – D793/M2 POWER, bus drivetrain
control unit (D793). ing. Check the wiring be- D790-1/K13:2 menu 3
tween cab control unit – D793/L2
(D790-1) and transmis-
sion control unit
(D793).
22 Communication error Engine does Use diagnostic menu to Volvo: D790- CAN/ 11.6.3 CAN-
with Control unit en- not react to check communication. 1/K13:1, POWER, bus drivetrain
gine (D794). commands Check the wiring be- K13:2 – D794/ menu 3
from cab. tween cab control unit 2, 1
(D790-1) and engine Cummins:
control unit (D794) D790-1/
K13:1, K13:2
– D794/46, 37
23 Setup file cannot be No controls Contact Cargotec sup- D790-1 - 11.5.3.1 Con-
read in cab control working in port. trol unit cab
unit (D790-1). cab.
24 Electric power feed to Cab fan not Check fuse F58-5/3. D790-1/K2:8 - 9.4.3 Cab fan
cab fan less than 18 working. – 58-5/3:2
V.
25 Interference during Error code Switch the ignition off D794 ENGINE, 11.5.3.10
software download. stored in en- and on. menu 8 Control unit
26
Buffer for error codes gine control Repeat software down- engine
27 from Control unit, en- unit (D794). load.
gine (D794), active
28
error code when
29 downloading.
30
31 Incorrect power sup- Control in cab Check fuse F58-5/1. D790-1/K1:2, CAN/ 11.5.1.3 Igni-
ply to cab control unit not working. Check cabling between K1:3, K1:4 – POWER, tion voltage
(D790-1). Voltage un- the control unit and the F58-5/1:1, 1:2 menu 6 (15)
der 18 V or over 32 V. component with diag-
nostic menu.
Check the control unit.


tions and tic menu
compo-
nents
32 Incorrect 5 V refer- Analogue Check cabling between D790-1/K4:5, CAN/ 11.5.3.1 Con-
ence voltage to ana- controls in the the control unit and the K 5:11, K5:13, POWER, trol unit cab
logue cab controls. cab not work- component with diag- K7:2, K 9:7, menu 6
Voltage under 4.9 V ing (mini- nostic menu. K10:3
or over 5.1 V. wheel/joy- Check the component.
stick, control
lever and
controls for
air condition-
ing).
33 No feedback signal The emer- Check fuse F58-3/8. D790-1/ CAN/ 11.5.1.4
for emergency stop gency stop Check cabling between K11:13 – POWER, Emergency
switch voltage from switch can- the control unit and the K3009-1/87 menu 5 stop switch
emergency stop not be disen- component with diag- voltage (15E)
switch voltage relay gaged. All nostic menu.
(K3009-1). hydraulic
functions are
blocked.
34 Faulty signal from Parking brake Check cabling between D791-1/K8:5 HYD, 4.5 Parking
parking brake switch cannot be re- the control unit and the – S107/7 menu 5 brake
(S107); indicates released. component with diag- D791-1/K8:13
leased and applied at nostic menu. – S107/1
same time or nothing Check the switch.
at all.
35 Interference during Error code Switch the ignition off D793 TRANSM, 11.5.3.9 Con-
software download. stored in and on. menu 13 trol unit trans-
36
Buffer for error codes transmission Repeat software down- mission
37 from Control unit, control unit load.
transmission (D793), (D793).
38
active error code
39 when downloading.
40
41 The transistor has Windscreen Check cabling between D790-1/K2:4 CAB, 9.5.7 Wiper
been triggered due to wiper rear not the control unit and the – M650-2/53 menu 3 motor rear
short circuit in the cir- working. component with diag-
cuit for Wiper motor, nostic menu.
rear (M650-2). Check the motor.
42 The transistor has Rotating bea- Check cabling between D790-1/K2:5 LIGHTS, 9.6.8 Rotat-
been triggered due to con not work- the control unit and the – H428 menu 9 ing beacon
short circuit in the cir- ing. component with diag-
cuit for Revolving nostic menu.
beacon (H428). Check the component.


tions and tic menu
compo-
nents
43 The transistor has Working light, Check bulb. D790-1/K2:6 LIGHTS, 9.6.9 Work-
been triggered due to cab left not Check cabling between – E404-1L menu 1 ing light, cab
short circuit in the cir- working. the control unit and the
cuit for Working light, component with diag-
cab left (E404-1L). nostic menu.
44 The transistor has Working light, Check bulb. D790-1/K2:7 LIGHTS, 9.6.9 Work-
been triggered due to cab right not Check cabling between – E404-1R menu 1 ing light, cab
short circuit in the cir- working. the control unit and the
cuit for Working light, component with diag-
cab right (E404-1R). nostic menu.
45 The transistor has Windscreen Check cabling between D790-1/K2:1 CAB, 9.5.1 Wiper
been triggered due to wiper front the control unit and the – M650-1/53 menu 2 front
short circuit in the cir- not working. component with diag-
cuit for Wiper motor, nostic menu.
front (M650-1). Check the motor.
46 The transistor has Cab fan not Check cabling between D790-1/K2:2 CLI- 9.4.3 Cab fan
been triggered due to working. the control unit and the – M657-1/2 MATE,
short circuit in the cir- component with diag- menu 6
cuit for Fan motor nostic menu.
(M657-1). Check the motor.
47 The transistor has Recirculation Check cabling between D790-1/K2:3 CLI- 9.4.2 Fresh
been triggered due to damper to the control unit and the – M612/3 MATE, air and recir-
short circuit in the cir- ventilation not component with diag- menu 6 culation
cuit for Actuator mo- working. nostic menu. damper
tor, recirculation Check the motor.
(M612).
48 The transistor has Heat in cab Check cabling between D790-1/K4:1 CLI- 9.4.5 Water
been triggered due to cannot be ad- the control unit and the – Y673/5 MATE, valve
short circuit in the cir- justed. component with diag- menu 7
cuit for Water valve nostic menu.
(Y673). Check the motor.
49 The transistor has Heat in cab Check cabling between D790-1/K4:2 CLI- 9.4.5 Water
been triggered due to cannot be ad- the control unit and the – Y673/6 MATE, valve
short circuit in the cir- justed. component with diag- menu 7
cuit for Water valve nostic menu.
50 The transistor has Air distribu- Check cabling between D790-1/K4:3 CLI- 9.4.14 Air dis-
been triggered due to tion in cab the control unit and the – Y672/5 MATE, tributor
short circuit in the cir- cannot be ad- component with diag- menu 8
cuit for Damper motor justed. nostic menu.
(Y672) Check the motor.


tions and tic menu
compo-
nents
51 The transistor has Air distribu- Check cabling between D790-1/K4:4 CLI- 9.4.14 Air dis-
been triggered due to tion in cab the control unit and the – Y672/6 MATE, tributor
short circuit in the cir- cannot be ad- component with diag- menu 8
cuit for Damper motor justed. nostic menu.
53 The transistor has Windscreen Check cabling between D790-1/K5:4 CAB, 9.5.4 Wash-
been triggered due to washer rear the control unit and the – M651-2 menu 1 er motor and
short circuit in the cir- and roof not component with diag- reservoir
cuit for Washer mo- working. nostic menu.
tor, roof and rear Check the motor.
(M651-2).
54 The transistor has Flashing haz- Check cabling between D790-1/K5:5 LIGHTS, 9.6.7 Flash-
been triggered due to ard lights not the control unit and the – S109/9 menu 7 ing hazard
short circuit or open working. component with diag- lights
circuit in circuit for in- nostic menu.
dicator lamp Switch, Check the switch.
flashing hazard lights
(S109).
55 The transistor has Reduced or Check bulbs for back- D7901/K6:1, LIGHTS, 9.1 Controls
been triggered due to no background lighting, change K 8:15, K 9:2, menu 13 and instru-
short circuit in the cir- ground light- if needed. K 10:5, all in- ments
cuit for background ing in Check cable harness to puts of type A
lighting in switches switches and background lighting. Digital in
and instruments. instruments
56 The transistor has Indication for Check cabling between D790-1/K7:8 - 7.1.1 Control
been triggered due to tilt lock in con- the control unit and the – S815/5 lever
short circuit or open trol lever not component with diag-
circuit in the circuit for illuminated. nostic menu.
LED indication for tilt Check the switch.
lock in control lever
(S815).
57 The transistor has Indication for Check cabling between D790-1/K7:9 - 7.1.1 Control
been triggered due to levelling lock the control unit and the – S815/7 lever
short circuit or open in control le- component with diag-
circuit in the circuit for ver not illumi- nostic menu.
LED indication for nated. Check the switch.
levelling lock in con-
trol lever (S815).
60 The transistor has Seat heating Check cabling between D790-1/K10:7 CAB, 9.3.3 Heat-
been triggered due to not working. the control unit and the – K383/86 menu 8 ing coils
short circuit or open component with diag-
circuit in the circuit for nostic menu.
Relay seat heater Check the component.
(K383).


tions and tic menu
compo-
nents
61 The transistor has Extra work- Check cabling between D790-1/K10:8 LIGHTS, 9.6.10 Work-
been triggered due to ing lights the control unit and the – K304/86 menu 3 ing lights,
short circuit or open boom not component with diag- boom
circuit in the circuit for working. nostic menu.
Relay extra working Check the component.
lights boom (K304).
62 The transistor has Hour meter Check cabling between D790-1/K10:9 CAN/ 9.3.5 Air sus-
been triggered due to and air sus- the control unit and the – P708, K358/ POWER, pension
short circuit or open pension seat component with diag- 86 menu 7
circuit for simulated not working. nostic menu.
D+ feed for hour me- Check the component.
ter (P708) and Relay
compressor air sus-
pension seat (K358).
63 The transistor has No ignition Check cabling between D790-1/ CAN/ 11.5.1.3 Igni-
been triggered due to voltage to the the control unit and the K10:10 – POWER, tion voltage
short circuit or open machine’s component with diag- K315-1/86 menu 4 (15)
circuit in the circuit for Control units. nostic menu.
Relay ignition voltage Check the component.
(K315-1).
64 The transistor has No emergen- Check cabling between D790-1/ CAN/ 11.5.1.4
been triggered due to cy stop switch the control unit and the K10:11 – POWER, Emergency
short circuit or open voltage to the component with diag- K3009-1/86 menu 5 stop switch
circuit in circuit for re- machine’s nostic menu. voltage
lay for emergency control units. Check the component.
stop switch voltage
(K3009-1).
65 The transistor has No emergen- Check cabling between D790-1/ CAN/ 11.5.1.4
been triggered due to cy stop switch the control unit and the K10:11 – POWER, Emergency
short circuit or open voltage to the component with diag- K3009-1/86 menu 5 stop switch
circuit in circuit for re- machine’s nostic menu. voltage
lay for emergency control units. Check the component.
stop switch voltage
(K3009-2).
66 The transistor has Windscreen Check cabling between D790-1/ CAB, 9.5.4 Wash-
been triggered due to washer not the control unit and the K10:13 – menu 1 er motor and
short circuit in the cir- working. component with diag- M651-1 reservoir
cuit for Washer mo- nostic menu.
tor, windscreen Check the component.
(M651-1).


tions and tic menu
compo-
nents
67 The transistor has Wiper roof not Check cabling between D790-1/ CAB, 9.5.6 Wiper
been triggered due to working. the control unit and the K10:14 – menu 4 motor roof
short circuit or open component with diag- M650-3/53
Wiper motor, roof Check the motor.
(M650-3).
68 The transistor has Pause heater Check cabling between D790-1/ - 9.4 Heating,
been triggered due to not working. the control unit and the K10:15 – ventilation
short circuit or open component with diag- M667 and air condi-
circuit in circuit for nostic menu. tioning
pause heater circula- Check the motor.
tion pump (M667).
69 The transistor has No voltage Check cabling between D790-1/ CAN/ 11.5.1.3 Igni-
been triggered due to feed to en- the control unit and the K10:16 – POWER, tion voltage
short circuit or open gine and component with diag- K315-2/86 menu 4 (15)
circuit in the circuit for transmission. nostic menu.
Relay ignition voltage Check the component.
drivetrain (K315-2).
71 The transistor has Interior light- Check bulb. D790-1/K11:6 LIGHTS, 9.6.12 Interi-
been triggered due to ing in cab not Check cabling between – E434-1 menu 12 or lighting
short circuit in the cir- working. the control unit and the cab
cuit for Interior light- component with diag-
ing, cab (E434-1). nostic menu.
74 The transistor has Horn/loud Check cabling between D790-1/ CAB, 9.7.1 Horn
been triggered due to horn not the control unit and the K11:11 – menu 5
short circuit in the cir- working. component with diag- H850/1,
cuit for horn (H850) nostic menu. K3016/86
or Relay loud horn Check the component.
(K3016)
75 Relay ignition voltage The cab con- Check cabling between - CAN/ 11.5.1.3 Igni-
(K315-1) has jammed trol unit the control unit and the POWER, tion voltage
in position on. (D790-1) is component with diag- menu 4
still ener- nostic menu.
gised and is Check the component.
thereby ac-
tive.


tions and tic menu
compo-
nents
80 No signal from Pres- Air condition- Check drive belt for air D797-R/ CLI- 9.4.10 Pres-
sure switch air condi- ing not work- conditioning compres- K1:37 – S246 MATE, sure switch
tioning (S246), ing. sor. menu 3
despite the AC com- Check that compressor
pressor being activat- for air conditioning is
ed. activated.
the control unit and the
component with diag-
nostic menu.
81 Faulty signal from Ac- Air distribu- Check cabling between D790-1/K4:7 CLI- 9.4.6 Fresh
tuating motor (Y672). tion cannot be the control unit and the – Y672/9 MATE, air and recir-
Signal voltage under changed. component with diag- menu 4 culation
0.2 V or over 4.8 V. nostic menu. damper
Check the motor.
85 Faulty signal from ac- Engine speed Check cabling between D790-1/K6:11 ENGINE, 1 Engine
celerator pedal limited to idle. the control unit and the – R690/2 menu 1
(R690). Signal volt- component with diag-
age under 0.2 V or nostic menu.
over 4.8 V. Check the component.
87 Faulty signal from Lifting/lower- Check cabling between D790-1/K7:3 BOOM, 7.1.1 Control
Control lever (S815- ing not work- the control unit and the – S815-P1/8 menu 1 lever
P1) for lifting/lowering. component with diag-
ing. Signal voltage nostic menu.
under 0.2 V or over Check the switch.
4.8 V.
88 Faulty signal from Extension not Check cabling between D790-1/K7:4 BOOM, 7.1.1 Control
Control lever (S815- working. the control unit and the – S815-P2/4 menu 1 lever
P2) for extension. component with diag-
Signal voltage under nostic menu.
0.2 V or over 4.8 V. Check the switch.
89 Faulty signal from Rotation not Check cabling between D790-1/K7:5 ATTACH, 7.1.1 Control
Control lever (S815- working. the control unit and the – S815-P3/11 menu 1 lever
P3) for rotation. Sig- component with diag-
nal voltage under 0.2 nostic menu.
V or over 4.8 V. Check the switch.
90 Faulty signal from Controllable Check cabling between D790-1/K7:6 ATTACH, 7.1.1 Control
Control lever (S815- tilt not work- the control unit and the – S815-P4/1 menu 1 lever
P4) for tilt. Signal ing. component with diag-
voltage under 0.2 V nostic menu.
or over 4.8 V. Check the switch.


tions and tic menu
compo-
nents
92 Faulty signal from Joystick Check cabling between D790-1/K9:8 STEER- 5.1.2 Mini-
Steering lever (R825- steering or the control unit and the – R825-1/P2 ING, menu wheel
1) or Mini-wheel mini-wheel component with diag- 1 5.1.3 Joystick
(R825-1). Signal volt- not working. nostic menu.
age under 0.2 V or Check the switch.
over 4.8 V.
93 Faulty signal from Joystick Check cabling between D790-1/K9:9 STEER- 5.1.2 Mini-
Mini-wheel (R825-2). steering or the control unit and the – R825-2/H2 ING, menu wheel
Signal voltage under mini-wheel component with diag- 1
0.2 V or over 4.8 V. not working. nostic menu.
Check the switch.
94 Faulty signal from Cab heat can- Check cabling between D790-1/K10:4 CLI- 9.4.5 Water
Water valve, cab not be adjust- the control unit and the – Y673/9 MATE, valve
heating (Y673). Sig- ed. component with diag- menu 4
nal voltage under 0.2 nostic menu.
V or over 4.8 V. Check the motor.
96 Faulty signal from Air condition- Check cabling between D790-1/K4:8 CLI- 9.4.17 Sen-
cab temperature sen- ing not work- the control unit and the – B775-1/2 MATE, sor cab tem-
sor (B775-1) Sensor ing. component with diag- menu 1 perature
indicates tempera- nostic menu.
ture under -43 °C or Check the sensor.
over 105 °C.
outside temperature ing not work- the control unit and the – B774/2 MATE, sor outdoor
sensor (B774). Tem- ing. component with diag- menu 2 temperature
perature signal over nostic menu.
105 °C. Check the sensor.
outlet fan tempera- ing not work- the control unit and the – B775-2/2 MATE, sor tempera-
ture sensor (B775-2) ing. component with diag- menu 2 ture outlet fan
Sensor indicates nostic menu.
temperature under - Check the sensor.
43 °C or over 105 °C.
99 Faulty signal from re- Air condition- Check cabling between D790-1/K4:11 CLI- 9.4.12 Sen-
frigerant temperature ing not work- the control unit and the – B775-3/2 MATE, sor tempera-
sensor (B775-3) Sen- ing. component with diag- menu 2 ture
sor indicates temper- nostic menu. refrigerant
ature under -43 °C or Check the sensor.
over 105 °C.


tions and tic menu
compo-
nents
101 Redundant voltage - Check cabling between D797-F/K2:7 CAN/ 11.5.1.2 Re-
feed left to Control the control unit and the POWER, dundant volt-
unit, frame front component with diag- menu 8 age feed of
(D797-F) does not nostic menu. Control units
reach destination. Check the control unit.
102 Redundant voltage - Check cabling between D797-F/K2:8 CAN/ 11.5.1.2 Re-
feed right to Control the control unit and the POWER, dundant volt-
unit, frame front component with diag- menu 8 age feed of
(D797-F) does not nostic menu. Control units
103 Incorrect power sup- No electric Check fuse F58-2/1, D797-F/K2:1, CAN/ 11.5.1.3 Igni-
ply to Control unit, power feed to change if needed. K2:9, K2:10 – POWER, tion voltage
frame front (D797-F). components. Check cabling between F58-2/1:1, 1:2 menu 8 (15)
Voltage under 18 V or the control unit and the
over 32 V. component with diag-
nostic menu.
104 Faulty emergency Functions Check fuse F58-3/2, D797-F/K2:11 CAN/ 11.5.1.4
stop voltage to Con- normally sup- change if needed. – F58-3/2:1 POWER, Emergency
trol unit, frame front plied emer- Check cabling between menu 8 stop switch
(D797-F). gency stop the control unit and the voltage
switch volt- component with diag-
age have no nostic menu.
feed. All hy-
draulic func-
tions blocked.
105 Incorrect 5 V refer- Regenera- Check cabling between D797-F/K1:8 CAN/ 8.2.1.7 Sen-
ence voltage to pres- tion lifting, the control unit and the – B768-R1/1, POWER, sor hydraulic
sure sensor. Voltage weight indica- component with diag- B768-R2/1, menu 9 pressure lift
under 4.9 V or over tor and over- nostic menu. B768-L1/1, cylinder
5.1 V. load system Check the sensor. B768-L2/1
not working.
106 The transistor has Cooling fan Check cabling between D797-F/K1:14 HYD, 4.8.8 Cooling
been triggered due to brake oil not the control unit and the – M674/1 menu 2 fan
short circuit in the cir- working. component with diag-
cuit for Cooling fan, nostic menu.
brake fluid (M674). Check the motor.
107 The transistor has Left high Check bulb. D797-F/K1:1 LIGHTS, 9.6.1 Head-
been triggered due to beam not Check the lamp holder. – E402L/1 menu 6 lights
short circuit or open working.
circuit in the circuit for
High beam lamp, left the control unit and the
(E402L). component with diag-
nostic menu.


tions and tic menu
compo-
nents
108 The transistor has Right high Check bulb. D797-F/K1:15 LIGHTS, 9.6.1 Head-
been triggered due to beam not Check the lamp holder. – E402R/1 menu 6 lights
circuit in the circuit for Check cabling between
High beam lamp,
right (E402R).
nostic menu.
110 The transistor has Low beams Check bulb. D797-F/K1:42 LIGHTS, 9.6.1 Head-
been triggered due to not working. Check the lamp holder. – E400L/1, menu 6 lights
short circuit or open E400R/1
Low beam lamp the control unit and the
(E400L/E400R).
nostic menu.
111 The transistor has Lift not work- Check cabling between D797-F/K1:2 BOOM, 7.2.5 Control
been triggered due to ing. the control unit and the – Y6005/1 menu 4 valve lift, low-
short circuit in the cir- component with diag- er and exten-
cuit for Solenoid nostic menu. sion
valve, boom up Check the solenoid
(Y6005). valve.
112 The transistor has Lower not Check cabling between D797-F/K1:3 BOOM, 7.2.5 Control
been triggered due to working. the control unit and the – Y6004/1 menu 5 valve lift, low-
valve, boom down Check the solenoid
(Y6004). valve.
113 The transistor has Extension out Check cabling between D797-F/K1:4 BOOM, 7.3.5 Control
been triggered due to not working. the control unit and the – Y6006/1 menu 7 valve lift, low-
valve, boom out Check the solenoid
(Y6006). valve.
114 The transistor has Extension in Check cabling between D797-F/K1:5 BOOM, 7.3.5 Control
been triggered due to not working. the control unit and the – Y6007/1 menu 6 valve lift, low-
valve, boom in Check the solenoid
(Y6007). valve.


tions and tic menu
compo-
nents
115 The transistor has Lifting/lower- Check cabling between D797-F/K1:30 BOOM, 7.2.7 Valve
been triggered due to ing not work- the control unit and the – Y6002/1 menu 2 block lift cyl-
short circuit or open ing. component with diag- inder
Solenoid valve, Check the solenoid
blocking lift, left valve.
(Y6002).
116 The transistor has Lifting/lower- Check cabling between D797-F/K1:31 BOOM, 7.2.7 Valve
been triggered due to ing not work- the control unit and the – Y6001/1 menu 2 block lift cyl-
short circuit or open ing. component with diag- inder
blocking lift, right valve.
(Y6001).
117 The transistor has Regenera- Check cabling between D797-F/K1:32 BOOM, 7.2.7 Valve
been triggered due to tion lift not the control unit and the – Y6051/1 menu 3 block lift cyl-
short circuit or open working. component with diag- inder
Solenoid valve, re- Check the solenoid
generation lift, right valve.
(Y6051).
118 The transistor has Regenera- Check cabling between D797-F/K1:33 BOOM, 7.2.7 Valve
been triggered due to tion lift not the control unit and the – Y6052/1 menu 3 block lift cyl-
short circuit or open working. component with diag- inder
Solenoid valve re- Check the solenoid
generation lift, left valve.
(Y6052).
119 The transistor has Parking brake Check cabling between D797-F/K1:7 HYD, 4.5.3 Sole-
been triggered due to cannot be re- the control unit and the – Y642/1 menu 5 noid valve
short circuit or open leased. component with diag- parking brake
Solenoid valve, park- Check the solenoid
ing brake (Y642). valve.
120 The transistor has Direction indi- Check bulb. D797-F/K1:9 LIGHTS, 9.6.6 Direc-
been triggered due to cator front left Check the lamp holder. – H422/1 menu 8 tion indica-
short circuit or open not working. tors
Lamp, direction indi-
cator, left front
nostic menu.
(H422).


tions and tic menu
compo-
nents
121 The transistor has Direction indi- Check bulb. D797-F/K1:10 LIGHTS, 9.6.6 Direc-
been triggered due to cator front Check the lamp holder. – H423/1 menu 8 tion indica-
short circuit or open right not tors
circuit in the circuit for working. Check cabling between
cator, right front
nostic menu.
(H423).
122 The transistor has Position light Check bulb. D797-F/K1:25 LIGHTS, 9.6.2 Run-
been triggered due to front left not Check the lamp holder. – H416-1/1 menu 5 ning lights
Lamp, position light,
left front (H416-1). component with diag-
nostic menu.
123 The transistor has Position light Check bulb. D797-F/K1:29 LIGHTS, 9.6.2 Run-
been triggered due to front right not Check the lamp holder. – H417-1/1 menu 5 ning lights
Lamp, position light,
right front (H417-1).
nostic menu.
124 Incorrect 24 V refer- Indicator light Check cabling between D797-F/K1:39 CAN/ 4.5.5 Parking
ence voltage to NC parking brake the control unit and the – S200/1, POWER, brake NC
switch parking brake and warning component with diag- S204/1, S216/ menu 9 switch
(S200), NC switch for low brake nostic menu. 1, S220/1 4.3.8 NO
low brake pressure pressure not Check the sensor. (normally
(S204), NO switch switching off. open) switch,
brake lights (S216) Brake lights brake lights
and NC switch de- and declutch
clutch (S220-2). not working. 4.3.7 NC
Gear cannot (normally
closed)
be engaged
switch, brake
because the
signal re- pressure
leased park-
ing brake is
not working.
133 Faulty signal from Overload sys- Check cabling between D797-F/K1:21 OP, menu 7.2.9 Sensor
Sensor hydraulic tem not work- the control unit and the – B768-L1/3 3 [V] hydraulic
pressure lift cylinder ing. All lift component with diag- HYD, pressure lift
left (B768-L1). Signal functions op- nostic menu. menu 6 cylinder
voltage under 0.2 V erate at re- Check the sensor. [bar]
or over 4.8 V. duced speed.
Error code
150 is activat-
ed.


tions and tic menu
compo-
nents
Sensor hydraulic tem not work- the control unit and the – B768-L2/3 3 [V] hydraulic
left (B768-L2). Signal functions op- nostic menu. menu 6 cylinder
voltage under 0.2 V erate at re- Check the sensor. [bar]
or over 4.8 V. duced speed.
Error code
150 is activat-
ed.
Sensor hydraulic tem not work- the control unit and the – B768-R1/3 3 [V] hydraulic
right (B768-R1). Sig- functions op- nostic menu. menu 6 cylinder
nal voltage under 0.2 erate at re- Check the sensor. [bar]
V or over 4.8 V. duced speed.
Error code
150 is activat-
ed.
Sensor hydraulic tem not work- the control unit and the – B768-R2/3 3 [V] hydraulic
right (B768-R2). Sig- functions op- nostic menu. menu 6 cylinder
nal voltage under 0.2 erate at re- Check the sensor. [bar]
V or over 4.8 V. duced speed.
Error code
150 is activat-
ed.
137 Faulty signal from Lift not work- Check cabling between D797-F/K1:16 BOOM, 7.2.5 Control
Solenoid valve, boom ing. the control unit and the – Y6005/2 menu 4 valve lift, low-
up (Y6005). Return component with diag- er and exten-
current does not nostic menu. sion
match control cur- Check the solenoid
rent. valve.
138 Faulty signal from Lower not Check cabling between D797-F/K1:17 BOOM, 7.2.5 Control
Solenoid valve, boom working. the control unit and the – Y6004/2 menu 5 valve lift, low-
down (Y6004). Re- component with diag- er and exten-
turn current does not nostic menu. sion
rent. valve.


tions and tic menu
compo-
nents
139 Faulty signal from Extension out Check cabling between D797-F/K1:18 BOOM, 7.3.5 Control
Solenoid valve, boom not working. the control unit and the – Y6006/2 menu 7 valve lift, low-
out (Y6006). Return component with diag- er and exten-
rent. valve.
140 Faulty signal from Extension in Check cabling between D797-F/K1:19 BOOM, 7.3.5 Control
Solenoid valve, boom not working. the control unit and the – Y6007/2 menu 6 valve lift, low-
in (Y6007). Return component with diag- er and exten-
rent. valve.
145 Faulty signal from Overload sys- Check sensor arm - OP, menu 8.2.1.5 Sen-
Sensor, boom angle tem not work- mounting. 4 sor, boom an-
(B771). Logical error, ing. All lift Check the sensor. gle
the signal does not functions op-
change when lifting erate at re-
or lowering is activat- duced speed.
ed. Error code
150 is activat- nostic menu.
ed.
146 Faulty signal from Overload sys- Check the cable to the - OP, menu 8.2.1.6 Sen-
Sensor, boom length tem not work- sensor. 4 sor, boom
(B777). Logical error, ing. All lift Check the sensor. length
the signal does not functions op-
change when exten- erate at re- Check cabling between
sion is activated. duced speed. the control unit and the
Error code
nostic menu.
150 is activat-
ed.
147 High brake oil tem- Reduced Check that cooling fan D797-F/K2:13 HYD, 4.8 Tempera-
perature. braking abili- is working. – B762/1 menu 2 ture control,
ty. Check that cooler isn’t cleaning and
clogged. brake oil
Check the sensor.
148 Faulty signal from Model year Check the sensor. D797-F/K2:13 HYD, 4.8.10 Sen-
brake oil temperature 2009-: Ma- Check cabling between – B762/1 menu 2 sor brake oil
sensor (Y672). Signal chine speed the control unit and the temperature
voltage under 0.2 V limited to 5 component with diag-
or over 4.8 V. km/h. nostic menu.


tions and tic menu
compo-
nents
149 Incorrect load curve Lifting/lower- Contact Cargotec sup- - - 7.2 Lifting/
or load curve not ing and ex- port. lowering. 7.3
present. tension not Extension
working.
150 Defective overload Overload sys- Check if there are error - OP, menu 8.2.1 Over-
protection. tem not work- codes for sensors in 1–5 load system
This error code can- ing. All lift the overload system.
not be removed with functions op-
Reset. erate at re-
duced speed.
151 Redundant voltage - Check cabling between D797-R/K2:7 CAN/ 11.5.1.2 Re-
unit, frame rear component with diag- menu 10 age feed of
(D797-R) does not nostic menu. Control units
152 Redundant voltage - Check cabling between D797-R/K2:8 CAN/ 11.5.1.2 Re-
unit, frame rear component with diag- menu 10 age feed of
(D797-R) does not nostic menu. Control units
153 Incorrect power sup- - Check fuse F58-2/3, D797-R/K2:1, CAN/ 11.5.1.3 Igni-
ply to Control unit, change if needed. K2:9, K2:10 – POWER, tion voltage
frame rear (D797-R). Check cabling between F58-2/3:1 menu 10 (15)
Voltage under 18 V or the control unit and the
nostic menu.
154 Incorrect power sup- - Check fuse F58-2/3, D797-R/ CAN/ 11.5.1.4
ply to Control unit, change if needed. K2:11 – F58- POWER, Emergency
frame rear (D797-R). Check cabling between 2/3:2 menu 10 stop switch
the control unit and the voltage
nostic menu.
155 Incorrect 5 V refer- Overload sys- Check cabling between D797-R/K1:8 CAN/ 8.2.1.5 Sen-
ence voltage to ana- tems and the control unit and the – B771/1, POWER, sor, boom an-
logue sensors. weight indica- component with diag- B777/1 menu 11 gle
Voltage under 4.9 V tor not work- nostic menu. 8.2.1.6 Sen-
or over 5.1 V. ing. Check the sensor. sor, boom
length, (ana-
logue sensor)


tions and tic menu
compo-
nents
156 The transistor has Cooling fan Check cabling between D797-R/ HYD, 10.6.3 Cool-
been triggered due to hydraulic oil the control unit and the K1:14 – menu 1 ing fan
short circuit in the cir- not working. component with diag- M668/1
cuit for Cooling fan, nostic menu.
hydraulic oil (M668). Check the motor.
157 The transistor has Working light, Check bulb. D797-R/K1:1 LIGHTS, 9.6.10 Work-
been triggered due to boom left not Check the lamp holder. – E404-3L menu 3 ing lights,
short circuit or open working. boom
Lamp, working lights,
boom, left front component with diag-
(E404-3L). nostic menu.
158 The transistor has Working light, Check bulb. D797-R/ LIGHTS, 9.6.10 Work-
been triggered due to boom right Check the lamp holder. K1:15 – E404- menu 3 ing lights,
short circuit or open not working. 3R boom
Lamp, working lights, the control unit and the
boom, right front component with diag-
nostic menu.
(E404-3R).
159 The transistor has Left revers- Check bulb. D797-R/ LIGHTS, 9.6.5 Back-
been triggered due to ing light not Check the lamp holder. K1:28 – menu 11 up light
short circuit or open working. E405L
Lamp, reversing light,
left (E405L).
nostic menu.
160 The transistor has Right revers- Check bulb. D797-R/ LIGHTS, 9.6.5 Back-
been triggered due to ing light not Check the lamp holder. K1:42 – menu 11 up light
short circuit or open working. E405R
Lamp, reversing light, the control unit and the
right (E405R).
nostic menu.
161 The transistor has Overload sys- Check cabling between D797-R/K1:2 OP, menu 8.2.1.4 Sen-
been triggered due to tems indi- the control unit and the – B7221L/A, 1 sor, steering
short circuit or open cates component with diag- B7221R/A axle load
circuit in the circuit for overload. nostic menu.
Sensor, steering axle Check the sensor.
load (B7221L and
B7221R).


tions and tic menu
compo-
nents
162 The transistor has Damping in/ Check cabling between D797-R/K1:2 OP, menu 8.2.1.6 Sen-
been triggered due to out/1.5 m not the control unit and the – B777/A, 1 sor, boom
short circuit or open working. component with diag- B769-3/A, BOOM, length (posi-
circuit in the circuit for nostic menu. B769-4/A menu 8 tion sensor)
Sensor, position sen- Check the sensor.
sor boom length
163 The transistor has Regenera- Check cabling between D797-R/K1:4 BOOM, 7.3.7 Valve
been triggered due to tion extension the control unit and the – Y6046/1 menu 3 block, exten-
short circuit or open not working. component with diag- sion cylinder
Solenoid valve, re- Check the solenoid
generation extension, valve.
(Y6046).
164 The transistor has Extension not Check cabling between D797-R/K1:5 BOOM, 7.3.7 Valve
been triggered due to working. the control unit and the – Y6050/1 menu 2 block, exten-
short circuit or open component with diag- sion cylinder
blocking extension, valve.
(Y6050).
165 The transistor has Back-up Check cabling between D797-R/ LIGHTS, 9.7.5 Back-
been triggered due to alarm not the control unit and the K1:30 – H965/ menu 11 up alarm
short circuit or open working. component with diag- 1
circuit in circuit for re- nostic menu.
versing warning de- Check the component.
vice (H965).
166 The transistor has Attachment Check cabling between D797-R/ HYD, 7.4.2 Valve
been triggered due to functions not the control unit and the K1:31 – menu 6 block, top lift
short circuit or open working. component with diag- Y6003/1 hydraulics
Solenoid valve, top Check the solenoid
hydraulics (Y6003). valve.
167 The transistor has Brake light Check bulb. D797-R/ LIGHTS, 9.6.4 Brake
been triggered due to left not work- Check the lamp holder. K1:32 – menu 11 lights
short circuit or open ing. H411L/1
Lamp, brake light, left the control unit and the
(H411L). component with diag-
nostic menu.


tions and tic menu
compo-
nents
168 The transistor has Brake light Check bulb. D797-R/ LIGHTS, 9.6.4 Brake
been triggered due to right not Check the lamp holder. K1:33 – menu 11 lights
short circuit or open working. H411R/1
Lamp, brake light,
right (H411R).
nostic menu.
169 The transistor has Position light Check bulb. D797-R/K1:7 LIGHTS, 9.6.2 Run-
been triggered due to left rear not Check the lamp holder. – H416-2/1 menu 5 ning lights
Lamp, position light, the control unit and the
left (H416-2).
nostic menu.
170 The transistor has Position light Check bulb. D797-R/K1:9 LIGHTS, 9.6.2 Run-
been triggered due to right rear not Check the lamp holder. – H417-2/1 menu 5 ning lights
Lamp, position light, the control unit and the
right (H417-2). component with diag-
nostic menu.
171 The transistor has Left rear light Check bulb. D797-R/ LIGHTS, 9.6.3 Rear
been triggered due to not working. Check the lamp holder. K1:10 – menu 5 lights
short circuit or open H412L/1
Check the lamp holder.
Lamp, rear light, left
(E421L).
172 The transistor has Left rear light Check bulb. D797-R/ LIGHTS, 9.6.3 Rear
been triggered due to not working. Check the lamp holder. K1:25 – menu 5 lights
short circuit or open H412R/1
Lamp, rear light, right the control unit and the
(E421R). component with diag-
nostic menu.
173 The transistor has Direction indi- Check bulb. D797-R/ LIGHTS, 9.6.6 Direc-
been triggered due to cator rear left Check the lamp holder. K1:29 – H426/ menu 8 tion indica-
short circuit or open not working. 1 tors
Lamp, direction indi- the control unit and the
cator, left rear component with diag-
nostic menu.
(H426).


tions and tic menu
compo-
nents
174 The transistor has Direction indi- Check bulb. D797-R/ LIGHTS, 9.6.6 Direc-
been triggered due to cator rear Check the lamp holder. K1:39 – H427/ menu 8 tion indica-
short circuit or open right not 1 tors
cator, right rear
nostic menu.
(H426).
175 Different signal from Overload sys- Check sensor adjust- D797-R/ OP, menu 8.2.1.4 Sen-
Sensor, steering axle tems indi- ment. K1:11 – 1 sor, steering
load (B7221L and cates Check the sensor. B7221L/C axle load
B722R) for more than overload. D797-R/
10 seconds. K1:12 –
B7221R/C
178 The transistor has Unloading of Check cabling between D797-R/ BOOM, 7.3.8 Valve
been triggered due to hydraulic oil the control unit and the K1:40 – menu 2 block, pump
short circuit or open pumps at component with diag- Y6062/1 unloading
circuit in the circuit for boom not nostic menu.
Solenoid valve, pump working. Check the solenoid
unloading (Y6062). valve.
183 Faulty signal from Overload sys- Check cabling between D797-R/ OP, menu 8.2.1.5 Sen-
Sensor, boom angle tem not work- the control unit and the K1:21 – B771/ 4 sor, boom an-
(B771). Signal volt- ing. All lift component with diag- 3 gle
age under 0.2 V or functions op- nostic menu.
over 4.8 V. erate at re- Check the sensor.
duced speed.
Error code
150 is activat-
ed.
184 Faulty signal from Overload sys- Check cabling between D797-R/ OP, menu 8.2.1.6 Sen-
Sensor, boom length tem not work- the control unit and the K1:22 – B777/ 4 sor, boom
(B777). Signal volt- ing. All lift component with diag- 3 length
age under 0.2 V or functions op- nostic menu.
over 4.8 V. erate at re- Check the sensor.
duced speed.
Error code
150 is activat-
ed.


tions and tic menu
compo-
nents
191 The transistor has Air condition- Check cabling between D797-R/ CLI- 9.4.8 Com-
been triggered due to ing not work- the control unit and the K1:11 – MATE, pressor
short circuit or open ing. component with diag- M645/1 menu 6
circuit in circuit for nostic menu.
192 D797-R/
electromagnetic Check the component. K1:26 –
clutch of AC com-
M645/1
pressor (M677).
NOTE! Error code
191 and 192 belong
to the same user.
193 Only engine alterna- Starter motor Check cabling between D797-R/ ENGINE, 1 Engine
tive Cummins not working. the control unit and the K1:36 – K360/ menu 5
QSM11: component with diag- 86
The transistor has nostic menu.
been triggered due to Check the component.
short circuit or open
Relay starter motor
(K360).
197 High hydraulic oil No limitation. Check that cooling fan D797-R/ HYD, 10.6 Temper-
temperature. is working. K2:13 – B776/ menu 1 ature control,
Check that cooler isn’t 1 cleaning and
clogged. hydraulic oil
Check the sensor.
198 Faulty signal from Incorrect tem- Check the sensor. D797-R/ HYD, 10.6.4 Sen-
Sensor, hydraulic oil perature dis- Check cabling between K2:13 – B776/ menu 1 sor, hydrau-
temperature (B776). play. the control unit and the 1 lic oil
component with diag- temperature
nostic menu.
199 Faulty signal from Incorrect dis- Check the sensor. D797-R/ CAB, 1.2.2 Sensor
fuel level sensor play of fuel Check cabling between K2:15 – B757 menu 7 fuel level
(B757). Resistance amount (emp- the control unit and the
over 180 Ω. ty or full). component with diag-
nostic menu.
201 Redundant voltage - Check cabling between D797-O/K2:7 CAN/ 11.5.1.2 Re-
unit, frame option component with diag- menu 12 age feed of
(D797-O) does not nostic menu. Control units


tions and tic menu
compo-
nents
202 Redundant voltage - Check cabling between D797-O/K2:8 CAN/ 11.5.1.2 Re-
unit, frame option component with diag- menu 12 age feed of
(D797-O) does not nostic menu. Control units
203 Incorrect power sup- - Check fuse F58-2/4, D797-O/ CAN/ 11.5.1.3 Igni-
ply to Control unit, change if needed. K2:10 – F58- POWER, tion voltage
frame option (D797- Check cabling between 2/4:1 menu 12 (15)
O). Voltage under 18 the control unit and the
V or over 32 V. component with diag-
nostic menu.
204 Incorrect emergency Functions Check fuse F58-3/4, D797-O/ CAN/ 11.5.1.4
stop switch voltage to normally sup- change if needed. K2:11 – F58- POWER, Emergency
Control unit frame op- plied emer- Check cabling between 3/4:1 menu 12 stop switch
tion (D797-O). gency stop the control unit and the voltage
switch volt- component with diag-
age have no nostic menu.
feed. All hy-
draulic func-
tions blocked.
211 The transistor has Hydraulic cab Check cabling between D797-O/K1:2 SLIDING- 9.10.4.3 Con-
been triggered due to sliding or lifta- the control unit and the – Y6016/1 CAB, trol valve op-
short circuit in the cir- ble cab not component with diag- menu 3 tion frame
cuit for Solenoid working. nostic menu. 9.10.5.2 Con-
valve, cab forward/up Check the solenoid trol valve op-
(Y6016). valve. tion frame
212 The transistor has Hydraulic cab Check cabling between D797-O/K1:3 SLIDING- 9.10.4.3 Con-
been triggered due to sliding or lifta- the control unit and the – Y6017/1 CAB, trol valve op-
short circuit in the cir- ble cab not component with diag- menu 4 tion frame
cuit for Solenoid working. nostic menu. 9.10.5.2 Con-
valve, cab backward/ Check the solenoid trol valve op-
down (Y6017). valve. tion frame
213 The transistor has Joystick Check cabling between D797-O/K1:4 EL- 5.2.10 Con-
been triggered due to steering or the control unit and the – Y636L1/1 STEER- trol valve joy-
short circuit in the cir- mini-wheel component with diag- ING, menu stick
cuit for Solenoid not working. nostic menu. 4 steering/mini-
valve, steering left Check the solenoid wheel
(Y636L). valve.


tions and tic menu
compo-
nents
214 The transistor has Joystick Check cabling between D797-O/K1:5 EL- 5.2.10 Con-
been triggered due to steering or the control unit and the – Y636R1/1 STEER- trol valve joy-
short circuit in the cir- mini-wheel component with diag- ING, menu stick
cuit for Solenoid not working. nostic menu. 5 steering/mini-
valve, steering right Check the solenoid wheel
(Y636R). valve.
215 The transistor has Support jacks Check cabling between D797-O/ SUP- 7.10.1.2 Con-
been triggered due to not working. the control unit and the K1:30 – PORT- trol valve op-
short circuit or open component with diag- Y6063/1 JACKS, tion frame
circuit in the circuit for nostic menu. menu 3
Solenoid valve, sup- Check the solenoid
port jacks up, valve.
(Y6053).
216 The transistor has Support jacks Check cabling between D797-O/ SUP- 7.10.1.2 Con-
been triggered due to not working. the control unit and the K1:31 – PORT- trol valve op-
short circuit or open component with diag- Y6064/1 JACKS, tion frame
circuit in the circuit for nostic menu. menu 3
Solenoid valve, sup- Check the solenoid
port jacks down, valve.
(Y6064).
217 Solenoid valve, cab Tiltable cab Check cabling between D797-O/ SLIDING- MISSING
tilt up (Y6047). not working. the control unit and the K1:32 – CAB,
component with diag- Y6047/1 menu 3
nostic menu.
Check the solenoid
valve.
218 Solenoid valve, cab Tiltable cab Check cabling between D797-O/ SLIDING- MISSING
tilt down (Y6048). not working. the control unit and the K1:33 – CAB,
component with diag- Y6048/1 menu 4
nostic menu.
Check the solenoid
valve.
219 Solenoid valve, dis- Disengage- Check cabling between D797-O/K1:7 HYD, MISSING
engagement of hy- ment of hy- the control unit and the – Y6057/1 menu 6
draulic oil pumps draulic oil component with diag-
(Y6057). pump when nostic menu.
lowering of Check the solenoid
tiltable cab is valve.
not working.


tions and tic menu
compo-
nents
220 Incorrect 24 V refer- Indication for Check cabling between D797-O/K1:9 SUP- 7.10.1.5 Sen-
ence voltage to Posi- support jacks the control unit and the – B7222L, PORT- sor, raised
tion sensor, support up not work- component with diag- B7222R, JACKS, support jacks
jacks (B7222L, ing. Not pos- nostic menu. B7223L, menu 2 7.10.1.6 Sen-
B7222R, B7223L and sible to select Check the sensor. B7223R sor, lowered
B7223R). gear to oper- support jacks
ate the ma-
chine.
221 Incorrect 24 V refer- Indication for Check cabling between D797-O/ SLIDING- 9.10.5.8 Sen-
ence voltage to Posi- Lowered cab the control unit and the K1:10 – B777- CAB, sor lowered
tion sensor cab lift not working. component with diag- 2/1 menu 4 cab
(B777-2). Door must be nostic menu.
closed so that Check the sensor.
the boom can
be lowered.
Speed limita-
tion is activat-
ed.
237 Faulty signal from Hydraulic cab Check cabling between D797-O/ SLIDING- 9.10.4.3 Con-
Solenoid valve, cab sliding or lifta- the control unit and the K1:16 – CAB, trol valve op-
forward/up (Y6016). ble cab not component with diag- Y6016/2 menu 3 tion frame
Return current does working. nostic menu. 9.10.5.2 Con-
not match control cur- Check the solenoid trol valve op-
rent. valve. tion frame
238 Faulty signal from Hydraulic cab Check cabling between D797-O/ SLIDING- 9.10.4.3 Con-
Solenoid valve, cab sliding or lifta- the control unit and the K1:17 – CAB, trol valve op-
backward/down ble cab not component with diag- Y6017/2 menu 4 tion frame
(Y6017). Return cur- working. nostic menu. 9.10.5.2 Con-
rent does not match Check the solenoid trol valve op-
control current. valve. tion frame
239 Faulty signal from Joystick Check cabling between D797-O/ EL- 5.2.10 Con-
Solenoid valve, steer- steering or the control unit and the K1:18 – STEER- trol valve joy-
ing left (Y636L). Re- mini-wheel component with diag- Y636L/2 ING, menu stick
turn current does not not working. nostic menu. 4 steering/mini-
match control cur- Check the solenoid wheel
rent. valve.
240 Faulty signal from Joystick Check cabling between D797-O/ EL- 5.2.10 Con-
Solenoid valve, steer- steering or the control unit and the K1:19 – STEER- trol valve joy-
ing right (Y636R). mini-wheel component with diag- Y636R/2 ING, menu stick
Return current does not working. nostic menu. 5 steering/mini-
not match control cur- Check the solenoid wheel
rent. valve.


tions and tic menu
compo-
nents
251 Redundant voltage - Check cabling between D791-1/K2:7 CAN/ 11.5.1.2 Re-
feed left to frame con- the control unit and the POWER, dundant volt-
trol unit (D791-1) component with diag- menu 16 age feed of
does not reach desti- nostic menu. Control units
nation.
feed left to frame con- the control unit and the POWER, dundant volt-
trol unit (D791-1) component with diag- menu 16 age feed of
does not reach desti- nostic menu. Control units
nation.
253 Incorrect power sup- Functions Check fuse F58-3/1, D791-1/K2:1/ CAN/ 11.5.1.4
ply to attachment normally sup- change if needed. 9/10 – F52-1 POWER, Emergency
control unit (D791-1). plied emer- Check fuse F52-1, – F58-3/1:1 menu 16 stop switch
Voltage under 18 V or gency stop change if needed. voltage
over 32 V. switch volt-
age have no
feed. No at-
tachment component with diag-
functions op- nostic menu.
erational.
254 Incorrect emergency Functions Check fuse F58-3/1, D791-1/K2:11 CAN/ 11.5.1.4
stop switch voltage to normally sup- change if needed. – F58-3/1 POWER, Emergency
Control unit, attach- plied emer- Check fuse F52-1, menu 16 stop switch
ment (D791-1). gency stop change if needed. voltage
switch volt-
age have no
feed. No at-
tachment
functions op- nostic menu.
erational.
257 The transistor has Working Check bulb. D791-1/K1:1 LIGHTS, 9.6.11 Work-
been triggered due to lights attach- Check the lamp holder. – E406R menu 2 ing lights at-
short circuit or open ment right not tachment
Lamp, working lights, the control unit and the
attachment right
nostic menu.
(E406R).
258 The transistor has Working Check bulb. D791-1/K1:15 LIGHTS, 9.6.11 Work-
been triggered due to lights attach- Check the lamp holder. – E406L menu 2 ing lights at-
short circuit or open ment left not tachment
circuit in the circuit for working.
Lamp, working lights,
attachment left
(E406L). nostic menu.


tions and tic menu
compo-
nents
259 The transistor has Automatic Check cabling between D791-1/K1:28 ATTACH, 7.5 Spread-
been triggered due to spreading the control unit and the – H9003/1 menu 15 ing
short circuit or open 20'-40' not component with diag-
circuit in the circuit for working. nostic menu.
Buzzer, automatic Check the component.
spreading 20’-40’
(H4009).
260 The transistor has Auxiliary at- Check bulb. D791-1/K1:42 LIGHTS, 9.6.11 Work-
been triggered due to tachment Check the lamp holder. – E404-4L, menu 2 ing lights at-
short circuit or open working lights E404-4R tachment
circuit in the circuit for not working.
Lamp, extra working
lights, attachment component with diag-
(E404-4L and E404- nostic menu.
4R).
261 The transistor has Rotation of at- Check cabling between D791-1/K1:2 ATTACH, 7.6.3 Control
been triggered due to tachment not the control unit and the – Y6008/1 menu 11 valve attach-
short circuit in the cir- working. component with diag- ment
cuit for Solenoid nostic menu.
valve, rotation clock- Check the solenoid
wise (Y6008). valve.
262 The transistor has Rotation of at- Check cabling between D791-1/K1:3 ATTACH, 7.6.3 Control
been triggered due to tachment not the control unit and the – Y6009/1 menu 12 valve attach-
short circuit in the cir- working. component with diag- ment
valve, rotation anti- Check the solenoid
clockwise (Y6009). valve.
263 The transistor has Spreading not Check cabling between D791-1/K1:4 ATTACH, 7.5.3 Control
been triggered due to working. the control unit and the – Y6018/1 menu 13 valve attach-
short circuit in the cir- component with diag- ment
valve, spreading out Check the solenoid
(Y6018). valve.
264 The transistor has Spreading not Check cabling between D791-1/K1:5 ATTACH, 7.5.3 Control
valve, spreading in Check the solenoid
(Y6019). valve.


tions and tic menu
compo-
nents
265 The transistor has Side shift of Check cabling between D791-1/K1:30 ATTACH, 7.4.3 Control
been triggered due to attachment the control unit and the – Y6021/1 menu 8 valve attach-
short circuit or open not working. component with diag- ment
Solenoid valve, side Check the solenoid
shift, right (Y6021). valve.
266 The transistor has Side shift of Check cabling between D791-1/K1:31 ATTACH, 7.4.3 Control
been triggered due to attachment the control unit and the – Y6020/1 menu 8 valve attach-
short circuit or open not working. component with diag- ment
Solenoid valve, side Check the solenoid
shift, left (Y6020). valve.
267 The transistor has Twistlock not Check cabling between D791-1/K1:32 ATTACH, 7.9.1.3 Con-
been triggered due to working. the control unit and the – Y6040/1 menu 9 trol valve at-
short circuit or open component with diag- tachment
Solenoid valve, lock Check the solenoid
twistlock, (Y6040). valve.
268 The transistor has Twistlock not Check cabling between D791-1/K1:33 ATTACH, 7.9.1.3 Con-
been triggered due to working. the control unit and the – Y6039/1 menu 9 trol valve at-
short circuit or open component with diag- tachment
Solenoid valve, open Check the solenoid
twistlock, (Y6039). valve.
269 The transistor has Tilt locked, tilt Check cabling between D791-1/K1:7 ATTACH, 7.7.4 Lock
been triggered due to damping and the control unit and the – Y6012-1/1 menu 15 valve, tilt
short circuit or open controllable component with diag-
circuit in the circuit for tilt not work- nostic menu.
Solenoid valve, tilt ing. Check the solenoid
lock 1 (Y6012-1). valve.
270 The transistor has Tilt locked, tilt Check cabling between D791-1/K1:9 ATTACH, 7.7.4 Lock
been triggered due to damping and the control unit and the – Y6012-2/1 menu 15 valve, tilt
short circuit or open controllable component with diag-
circuit in the circuit for tilt not work- nostic menu.
Solenoid valve, tilt ing. Check the solenoid
lock 2 (Y6012-2). valve.


tions and tic menu
compo-
nents
271 The transistor has Twistlocks, Check cabling between D791-1/K1:10 ATTACH, 7.5.10 Posi-
been triggered due to rotation stop, the control unit and the – B769/A, menu 5, 6, tion sensor,
short circuit or open and spread- component with diag- B777-2/A, 7, 21 spreading
circuit in circuit for ing not work- nostic menu. B7225/A, 7.6.10 Sen-
voltage feed to ating. Check the sensor. B7202R/A, sor, rotation
tachment position B7204R/A, stop
sensor. B7205R/A,
B7203R/A, 7.9.1.8 Sen-
B7202L/A, sor alignment
B7204L/A, 7.9.1.9 Sen-
B7205L/A, sor, twist-
B7203L/A, locks
B7224/A 8.2.1.6 Sen-
sor, boom
length (posi-
tion sensor)
272 The transistor has Indicator light, Check bulb. D791-1/K1:25 ATTACH, 7.9.1 Twist-
been triggered due to open twist- Check the lamp holder. – H562/1 menu 10 locks
short circuit or open locks, not
Indicator light, open
twistlocks (H562).
nostic menu.
273 The transistor has Indicator light Check bulb. D791-1/K1:29 ATTACH, 7.9.1 Twist-
been triggered due to alignment Check the lamp holder. – H564/1 menu 10 locks
short circuit or open twistlock not
circuit in circuit for working. Check cabling between
alignment indicator the control unit and the
light (H564).
nostic menu.
274 The transistor has Indicator light, Check bulb. D791-1/K1:39 ATTACH, 7.9.1 Twist-
been triggered due to locked twist- Check the lamp holder. – H563/1 menu 10 locks
short circuit or open locks, not
Indicator light, locked the control unit and the
twistlocks (H563).
nostic menu.
287 Faulty signal from Rotation of at- Check cabling between D791-1/K1:16 ATTACH, 7.6.3 Control
Solenoid valve, rota- tachment not the control unit and the – Y6008/2 menu 11 valve attach-
tion clockwise working. component with diag- ment
(Y6008). Return cur- nostic menu.
rent does not match Check the solenoid
control current. valve.


tions and tic menu
compo-
nents
288 Faulty signal from Rotation of at- Check cabling between D791-1/K1:17 ATTACH, 7.6.3 Control
Solenoid valve, rota- tachment not the control unit and the – Y6009/2 menu 12 valve attach-
tion anticlockwise working. component with diag- ment
289 Faulty signal from Spreading not Check cabling between D791-1/K1:18 ATTACH, 7.5.3 Control
Solenoid valve, working. the control unit and the – Y6018/2 menu 13 valve attach-
spreading out component with diag- ment
290 Faulty signal from Spreading not Check cabling between D791-1/K1:19 ATTACH, 7.5.3 Control
Solenoid valve, working. the control unit and the – Y6019/2 menu 14 valve attach-
spreading in (Y6019). component with diag- ment
Return current does nostic menu.
not match control cur- Check the solenoid
rent. valve.
298 Twistlock sensor indi- Lifting and ex- Check that Sensors - ATTACH, 7.9.1.9 Sen-
cates that left twist- tension not twistlock are clean and menu 7 sor twistlocks
lock is between open working. correctly adjusted.
and locked position. Check cabling between
nostic menu.
299 Twistlock sensor indi- Lifting and ex- Check that Sensors - ATTACH, 7.9.1.9 Sen-
cates that right twist- tension not twistlock are clean and menu 7 sor twistlocks
lock is between open working. correctly adjusted.
and locked position. Check cabling between
nostic menu.
300 Alignment sensor in- Twistlock not Check that the align- - ATTACH, 7.9.1.8 Sen-
dicates unreasonable working. ment sensors are clean menu 6 sor alignment
distance. and correctly adjusted.
Check that alignment
pin runs smoothly.
nostic menu.


tions and tic menu
compo-
nents
unit, attachment op- component with diag- menu 17 age feed of
tion (D791-2) does nostic menu. Control units
not reach destination. Check the control unit.
unit, attachment op- component with diag- menu 17 age feed of
tion (D791-2) does nostic menu. Control units
not reach destination. Check the control unit.
303 Incorrect power sup- Levelling, tilt Check fuse F58-3/1 D791-2/K2:1, CAN/ 11.5.1.4
ply to Control unit, at- and special and F52-1, change if K2:9, K2:10 – POWER, Emergency
tachment option function not needed. F52-1 – F58- menu 17 stop switch
(D791-2). Voltage un- working. Check cabling between 3/1 voltage
der 18 V or over 32 V. the control unit and the
nostic menu.
304 Incorrect emergency Functions Check fuse F58-3/1 D791-2/K2:11 CAN/ 11.5.1.4
stop switch voltage to supplied with and F52-1, change if – F52-1 – POWER, Emergency
Control unit, attach- emergency needed. F58-3/1 menu 17 stop switch
ment option (D791- stop switch Check cabling between voltage
2). voltage lack the control unit and the
feed. Level- component with diag-
ling, tilt and nostic menu.
special func-
tion not work-
ing.
311 The transistor has Levelling not Check cabling between D791-2/K1:2 ATTACH, 7.8.3 Control
valve, levelling right Check the solenoid
(Y6035). valve.
valve, levelling left Check the solenoid
(Y6036). valve.


tions and tic menu
compo-
nents
313 The transistor has Controllable Check cabling between D791-2/K1:4 ATTACH, 7.7.5 Control
been triggered due to tilt not work- the control unit and the – Y6010/1 menu 16 valve attach-
short circuit in the cir- ing. component with diag- ment
valve, tilt out (Y6010). Check the solenoid
valve.
valve, tilt in (Y6011). Check the solenoid
valve.
315 The transistor has Levelling is Check cabling between D791-2/K1:30 ATTACH, 7.8.6 Valve
been triggered due to locked, con- the control unit and the – Y6034-1/1 menu 18 block, level-
short circuit or open trollable level- component with diag- ling cylinders
circuit in the circuit for ling and float nostic menu.
Solenoid valve, level- position not Check the solenoid
ling lock(Y6034-1). working. valve.
been triggered due to locked, con- the control unit and the – Y6034-2/1 menu 18 block, level-
short circuit or open trollable level- component with diag- ling cylinders
ling lock (Y6034-2). working. valve.
317 Incorrect output sig- WARNING D791-2/K1:32

nal special function.







tions and tic menu
compo-
nents
337 Faulty signal from Levelling not Check cabling between D791-2/K1:16 ATTACH, 7.8.3 Control
Solenoid valve, level- working. the control unit and the – Y6035/2 menu 17 valve attach-
ling right (Y6035). component with diag- ment
rent. valve.
ling left (Y6036). Re- component with diag- ment
turn current does not nostic menu.
rent. valve.
Solenoid valve, tilt tilt not work- the control unit and the – Y6010/2 menu 14 valve attach-
out (Y6010). Return ing. component with diag- ment
current does not nostic menu.
rent. valve.
Solenoid valve, tilt in tilt not work- the control unit and the – Y6011/2 menu 15 valve attach-
(Y6011). Return cur- ing. component with diag- ment
rent does not match nostic menu.
control current. Check the solenoid
valve.
unit, attachment left component with diag- menu 18 age feed of
jack pair (D791-3) nostic menu. Control units
does not reach desti- Check the control unit.
nation.
unit, attachment left component with diag- menu 18 age feed of
nation.
353 Incorrect power sup- Left lifting Check fuse F58-3/1 D791-3/K2:1 CAN/ 11.5.1.4
ply to Control unit, at- jacks not and F52-2, change if – F52-2 – POWER, Emergency
tachment left jack working. needed. F58-3/1 menu 18 stop switch
pair (D791-3). Volt- Check cabling between voltage
age under 18 V or the control unit and the
nostic menu.


tions and tic menu
compo-
nents
354 Incorrect emergency Functions Check fuse F58-3/1 D791-3/K2:11 CAN/ 11.5.1.4
stop switch voltage to supplied with and F52-2, change if – F52-2 – POWER, Emergency
Control unit, attach- emergency needed. F58-3/1 menu 18 stop switch
ment left jack pair stop switch Check cabling between voltage
(D791-3). voltage lack the control unit and the
feed. Left lift- component with diag-
ing jacks not nostic menu.
working.
357 The transistor has Working Check bulb. D791-3/K1:1 - 9.6.11 Work-
been triggered due to lights left lift- Check the lamp holder. – E404-6L/1 ing lights at-
short circuit or open ing jacks not tachment
Working lights left lift- the control unit and the
ing jacks (E404-6L). component with diag-
nostic menu.
been triggered due to locked, con- the control unit and the – Y6034-1/1, menu 18 block, level-
short circuit or open trollable level- component with diag- Y6034-2/1 ling cylinders
ling lock(Y6034-1) working. valve.
and Solenoid valve,
levelling lock(Y6034-
2).
360 The transistor has Left lifting Check cabling between D791-3/K1:42 COMBI, 7.9.2.5
been triggered due to jacks not the control unit and the – Y6053L/1 menu 16 Valve, oper-
short circuit or open working. component with diag- ating position
Solenoid valve, oper- Check the solenoid
ating position valve.
(Y6053L).
valve, levelling right Check the solenoid
(Y6035). valve.
valve, levelling left Check the solenoid
(Y6036). valve.


tions and tic menu
compo-
nents
363 The transistor has Left lifting Check cabling between D791-3/K1:4 COMBI, 7.9.2.3 Con-
been triggered due to jacks not the control unit and the – Y6057L/1 menu 11 trol valve, lift-
short circuit or open working. component with diag- ing jacks
Solenoid valve, front Check the solenoid
knee in (Y6057L). valve.
knee out (Y6056L). valve.
Solenoid valve, rear Check the solenoid
knee in (Y6059L). valve.
knee out (Y6058L). valve.
Solenoid valve, low- Check the solenoid
ering front jack valve.
(Y6013L).
jack up (Y6060L). valve.


tions and tic menu
compo-
nents
ering rear jack valve.
(Y6014L).
jack up (Y6061L). valve.
371 The transistor has Indicator light Check bulb. D791-3/K1:10 COMBI, 7.9.2 Lifting
been triggered due to alignment lift- Check the lamp holder. – H566R/1 menu 7 jacks
short circuit or open ing jack right
circuit in the circuit for front not Check cabling between
Indicator light working. the control unit and the
(H566R).
nostic menu.
been triggered due to alignment lift- Check the lamp holder. – H567R/1 menu 7 jacks
short circuit or open ing jack right
circuit in the circuit for rear not work- Check cabling between
Indicator light ing. the control unit and the
(H567R). component with diag-
nostic menu.
been triggered due to alignment lift- Check the lamp holder. – H566L/1 menu 7 jacks
short circuit or open ing jack left
circuit in the circuit for front not
Indicator light working. the control unit and the
nostic menu.
been triggered due to alignment lift- Check the lamp holder. – H567L/1 menu 7 jacks
short circuit or open ing jack left
circuit in the circuit for rear not work-
Indicator light ing. the control unit and the
nostic menu.


tions and tic menu
compo-
nents
clamp (Y6054L). valve.
clamp release valve.
(Y6055L).
377 The transistor has Left lifting Check cabling between D791-3/K1:26 COMBI, 7.9.2.9 Sen-
been triggered due to jacks not the control unit and the – B7212L/A, menu 2, 3, sor, operat-
short circuit or open working. component with diag- B7213L/A, 4, 5, 6 ing position
circuit in the circuit for nostic menu. B7214L/A, 7.9.2.10 Sen-
voltage feed to posi- Check the sensor. B7215L/A, sor, knee
tion sensor, left jack B7216L/A,
7.9.2.13 Sen-
pair. B7217L/A,
sor, lifting
B7218L/A,
B7219L/A, jacks
B7220L/A 7.9.2.15 Sen-
sor, align-
ment
7.9.2.16 Sen-
sor, clamp-
ing position
ling right (Y6035). component with diag- ment
rent. valve.
ling left (Y6036). Re- component with diag- ment
turn current does not nostic menu.
rent. valve.


tions and tic menu
compo-
nents
unit, attachment right component with diag- menu 19 age feed of
nation.
unit, attachment right component with diag- menu 19 age feed of
nation.
403 Incorrect power sup- Right lifting Check fuse F58-3/1 D791-4/K2:1 CAN/ 11.5.1.4
ply to Control unit, at- jacks and and F52-2, change if – F52-2 – POWER, Emergency
tachment right jack controllable needed. F58-3/1 menu 19 stop switch
pair (D791-4). Volt- tilt not work- Check cabling between voltage
age under 18 V or ing. the control unit and the
nostic menu.
404 Incorrect emergency Control Check fuse F58-3/1 D791-4/K2:11 CAN/ 11.5.1.4
stop switch voltage to switch can- and F52-2, change if – F52-2 – POWER, Emergency
Control unit, attach- not be disen- needed. F58-3/1 menu 19 stop switch
ment right jack pair gaged. Right Check cabling between voltage
(D791-4). lifting jacks the control unit and the
and controlla- component with diag-
ble tilt not nostic menu.
working.
407 The transistor has Working Check bulb. D791-4/K1:1 - 9.1.11 Work-
been triggered due to lights left lift- Check the lamp holder. – E404-6R ing lights at-
short circuit or open ing jacks not tachment
Working lights left lift- the control unit and the
ing jacks (E404-6R). component with diag-
nostic menu.
410 The transistor has Right lifting Check cabling between D791-4/K1:42 COMBI, 7.9.2.5
been triggered due to jacks not the control unit and the – Y6053R/1 menu 16 Valve, oper-
short circuit or open working. component with diag- ating position
Solenoid valve, oper- Check the solenoid
ating position valve.
(Y6053R).


tions and tic menu
compo-
nents
valve, tilt out (Y6010). Check the solenoid
valve.
valve, tilt in (Y6010). Check the solenoid
valve.
413 The transistor has Right lifting Check cabling between D791-4/K1:4 COMBI, 7.9.2.3 Con-
been triggered due to jacks not the control unit and the – Y6057R/1 menu 11 trol valve, lift-
knee in (Y6057R). valve.
knee out (Y6056R). valve.
knee in (Y6059R). valve.
short circuit in the cir- working. component with diag- ing jacks
valve, rear knee out Check the solenoid
(Y6058L). valve.
ering front jack valve.
(Y6013R).


tions and tic menu
compo-
nents
jack up (Y6060R). valve.
ering rear jack valve.
(Y6014R).
jack up (Y6061R). valve.
been triggered due to front jacks Check the lamp holder. – H580/1 menu 9 jacks
short circuit or open raised not
Indicator light (H580).
nostic menu.
been triggered due to front jacks Check the lamp holder. – H581/1 menu 9 jacks
short circuit or open lowered not
Indicator light (H581).
nostic menu.
been triggered due to clamping po- Check the lamp holder. – H578/1 menu 8 jacks
short circuit or open sition lifting
circuit in the circuit for jacks front not
Indicator light (H578). working.
nostic menu.


tions and tic menu
compo-
nents
been triggered due to clamping po- Check the lamp holder. – H579/1 menu 8 jacks
short circuit or open sition lifting
circuit in the circuit for jacks rear not Check cabling between
Indicator light (H579). working.
nostic menu.
425 The transistor has Right lifting D791-4/K1:2 COMBI, 7.9.2.3 Con-
been triggered due to jacks not – Y6054R menu 15 trol valve, lift-
short circuit or open working. ing jacks
Solenoid valve,
clamp (Y6054R).
426 The transistor has Right lifting D791-4/K1:3 COMBI, 7.9.2.3 Con-
been triggered due to jacks not – Y6055R menu 15 trol valve, lift-
short circuit or open working. ing jacks
Solenoid valve,
clamp release
(Y6055R).
427 The transistor has Right lifting Check cabling between D791-4/K1:26 COMBI, 7.9.2.9 Sen-
been triggered due to jacks not the control unit and the – B7212R/A, menu 2, 3, sor, operat-
short circuit or open working. component with diag- B7213R/A, 4, 5, 6 ing position
circuit in the circuit for nostic menu. B7214R/A, 7.9.2.10 Sen-
voltage feed to posi- Check the sensor. B7215R/A, sor, knee
tion sensor, right jack B7216R/A,
pair. B7217R/A, 7.9.2.13 Sen-
B7218R/A, sor, lifting
jacks
B7219R/A,
B7220R/A 7.9.2.15 Sen-
sor, align-
ment
7.9.2.16 Sen-
sor, clamp-
ing position
Solenoid valve, tilt tilt not work- the control unit and the – Y6010/2 menu 16 valve attach-
out (Y6010). Return ing. component with diag- ment
current does not nostic menu.
rent. valve.


tions and tic menu
compo-
nents
Solenoid valve, tilt in tilt not work- the control unit and the – Y6011/2 menu 17 valve attach-
(Y6010). Return cur- ing. component with diag- ment
rent does not match nostic menu.
control current. Check the solenoid
valve.
451 Redundant voltage - Check cabling between 795/K1:7 CAN/ 11.5.1.2 Re-
feed left to KID con- the control unit and the POWER, dundant volt-
trol unit (D795) does component with diag- menu 14 age feed of
not reach destination. nostic menu. Control units
452 Redundant voltage - Check cabling between 795/K1:8 CAN/ 11.5.1.2 Re-
feed right to KID con- the control unit and the POWER, dundant volt-
trol unit (D795) does component with diag- menu 14 age feed of
not reach destination. nostic menu. Control units
460 No messages re- Incorrect val- Use diagnostic menu to D795/K1:10, CAN/ 11.6.2 Re-
ceived on CAN-buffer ues in operat- check CAN-bus K1:11, K1:12, POWER, dundant
1. ing menus. K1:13 menu 1, 2, CAN-bus
21
461 No messages re- Error codes Use diagnostic menu to D795/K1:5, CAN/ 11.6.2 Re-
ceived on CAN-buffer from other check CAN-bus K1:6 POWER, dundant
2. Control units menu 1, 2, CAN-bus
cannot be 21
shown.
500 Time for service. - Check that servicing - - 8.2.6 Service

has been performed. If indicator
servicing has been per-
formed following the
Cargotec service
schedule, reset the
service indicator; see
section 8 Control sys-
tem, group 8.2.6 Serv-
ice indicator.


E Schematics 1
E Schematics
Table of Contents E Schematics

mm mm mm mm mm mm
10 Common hydraulics....................................................................................... 3
Hydraulic diagrams, compilation ............................................................................ 3
Hydraulic diagram base machine (hydraulic oil pump alternative Rexroth) ........... 4
Hydraulic diagram base machine (hydraulic oil pump alternative Sauer-Danfoss) 6
Hydraulic diagram joystick control (hydraulic oil pump alternative Rexroth) .......... 8
Hydraulic diagram joystick control (hydraulic oil pump alternative
Sauer-Danfoss) .................................................................................................... 10
Hydraulic diagram top lift (hydraulic oil pump alternative Rexroth) ...................... 12
Hydraulic diagram top lift (hydraulic oil pump alternative Sauer-Danfoss) ........... 14
Hydraulic diagram top lift, tilt lock and controllable tilt (hydraulic oil pump
alternative Rexroth) .............................................................................................. 16
Hydraulic diagram top lift, tilt lock and controllable tilt (hydraulic oil pump
alternative Sauer-Danfoss) ................................................................................... 18
Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling
(hydraulic oil pump alternative Rexroth) ............................................................... 20
Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling
(hydraulic oil pump alternative Sauer-Danfoss) ................................................... 22
Hydraulic diagram combi yoke (part 1 of 3)
Hydraulic diagram combi yoke (part 1 of 3)
Hydraulic diagram combi yoke (part 2 of 3) ......................................................... 28
Hydraulic diagram combi yoke (part 3 of 3) ......................................................... 30
Hydraulic diagram sliding cab (hydraulic oil pump alternative Rexroth) ............... 32
Hydraulic diagram sliding cab (hydraulic oil pump alternative Sauer-Danfoss) ... 34
Hydraulic diagram cab lift and support jacks
Hydraulic diagram cab lift and support jacks
Hydraulic diagram sliding cab and support jacks
Hydraulic diagram sliding cab and support jacks
11 Common electrics ........................................................................................ 44
Circuit diagram, description ................................................................................. 44
Component designations ...................................................................................... 46
Circuit diagrams, compilation ............................................................................... 46

2 E Schematics

E Schematics – 10 Common hydraulics 3
mm mm mm mm mm mm
Hydraulic diagrams, compilation

page
–
Designation Drawing number

Hydraulic diagram base machine (hydraulic oil pump alternative Rexroth) page 4 A40740.0100
Hydraulic diagram base machine (hydraulic oil pump alternative Sauer-Danfoss) page 6 A40740.0400
Hydraulic diagram joystick control (hydraulic oil pump alternative Rexroth) page 8 A48056.0100
Hydraulic diagram joystick control (hydraulic oil pump alternative Sauer-Danfoss) page 10 -
Hydraulic diagram top lift (hydraulic oil pump alternative Rexroth) page 12 A40853.0100
Hydraulic diagram top lift (hydraulic oil pump alternative Sauer-Danfoss) page 14 -
Hydraulic diagram top lift, tilt lock and controllable tilt (hydraulic oil pump alternative Rexroth) page A40853.0200
16
Hydraulic diagram top lift, tilt lock and controllable tilt (hydraulic oil pump alternative Sauer-Danfoss) -
page 18
Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling (hydraulic oil pump alter- A43123.0100
native Rexroth) page 20
Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling (hydraulic oil pump alter- -
native Sauer-Danfoss) page 22
Hydraulic diagram combi yoke (part 1 of 3) (hydraulic oil pump alternative Rexroth) page 24 A41791.0100
Hydraulic diagram combi yoke (part 1 of 3) (hydraulic oil pump alternative Sauer-Danfoss) page 26 -
Hydraulic diagram combi yoke (part 2 of 3) page 28 A41791.0100
Hydraulic diagram combi yoke (part 3 of 3) page 30 A41791.0100
Hydraulic diagram sliding cab (hydraulic oil pump alternative Rexroth) page 32 A40855.0100
Hydraulic diagram sliding cab (hydraulic oil pump alternative Sauer-Danfoss) page 34 A54505.0100
Hydraulic diagram cab lift and support jacks (hydraulic oil pump alternative Rexroth) page 36 A43276.0100
Hydraulic diagram cab lift and support jacks (hydraulic oil pump alternative Sauer-Danfoss) page 38 -
Hydraulic diagram sliding cab and support jacks (hydraulic oil pump alternative Rexroth) page 40 A40854.0100
Hydraulic diagram sliding cab and support jacks (hydraulic oil pump alternative Sauer-Danfoss) -
page 42

–
page
4
1 3 4 5
C+ C-
VDRF03.02GB
C+ 2 C- C+ 6 C-
8
B
PT
7
11
9 10
VA VA D VB
VA D T VA D T
ACC B 16 H
17 15 14
12
45 47 B1 A1 B2 A2 M
44 A
13
P H
46 PP
T H
10
11
LS
25
28
P M T
T T 29
Rexroth)
P P
D
24
18
Workshop manual DRF 400–450

PSS PS
27 26 L R
E Schematics – 10 Common hydraulics
43 40 34 30
36
33 23
39
20
33 33 33 19
X1 X2 X1
33 X2
T P
38 31 LS CF EF LS
42 21
T PP
B1 B2 B1 B2
P
37 32
22
S L1 L2 L4 L3 S L1 L2 L4 L3
41 35
(hydraulic oil pump alternative
010869 (A40740.0100 ver. 8)

Hydraulic diagram base machine
1. Lift cylinder 25. Oil return from attachment

2. Valve block lift cylinder 26. Oil filter brake system
3. Extension cylinder 27. Oil filter
4. Valve block extension cylinder 28. Cooler hydraulic oil
5. Lift cylinder 29. Bypass valve, hydraulic oil cooler
6. Valve block lift cylinder 30. Hydraulic oil fine-filter
7. Brake pressure accumulator 31. Priority valve
8. Brake valve 32. Pump cooling and filtration of hydraulic oil
9. Parking brake caliper 33. Non-return valve
10. Brake cylinder 34. Pressure supply to attachment
11. Wheel brake 35. Hydraulic oil pumps 3 and 4
12. Drive axle block 36. Shuttle valve
13. NO (normally open) switch, disengagement 37. Oil pump brake system
14. NO (normally open) switch, brake lights 38. Valve block top lift hydraulics
15. NO (normally open) switch, parking brake 39. Shuttle valve
16. Accumulator charging valve 40. Attachment relief valve
17. NC (normally closed) switch, brake pressure 41. Hydraulic oil pumps 1 and 2
18. Cooler brake system 42. Pressure limiting valve
19. Thermal bypass valve 43. Valve block pump unloading
20. Breather filter, brake fluid tank 44. Pressure reducer
21. Oil tank brake system 45. Servo pressure accumulator
22. Breather filter hydraulic oil tank 46. Servo filter
23. Steering valve 47. Control valve lifting/lowering and extension

–
page
6
VDRF03.02GB
1 2 3 4 5 6
C+ C-
C+ C- C+ C- 8
11
9 10
VA VA D VB
VA D T VB D T
17 ACC B 16 H
15 14
45 12
B1 A1 B2 A2 M
44 A
P H 46 PP 13
47
T H 10
11
LS
25
28
P M T
T T 29
P P
D 26

48 24
48 PSS PS 18
27
Sauer-Danfoss)
40 36 34 30
2 1
3 23
33 392 1 20
43 3
33 X1 X1
19
33 T P
38 LS CF EF
42 LS
B1 B1
T PP 21
P
37 32 31
35 22
41
S L2 L1 S L2 L1
Hydraulic diagram base machine
012445 [A40470.0400 ver 01]

1. Lift cylinder 25. Oil return from attachment

2. Valve block lift cylinder 26. Oil filter brake system
3. Extension cylinder 27. Oil filter
4. Valve block extension cylinder 28. Cooler hydraulic oil
5. Lift cylinder 29. Bypass valve, hydraulic oil cooler
6. Valve block lift cylinder 30. Hydraulic oil fine-filter
7. Brake pressure accumulator 31. Priority valve
8. Brake valve 32. Oil pump brake system
9. Parking brake caliper 33. Non-return valve
10. Brake cylinder 34. Pressure supply to attachment
11. Wheel brake 35. Hydraulic oil pump 2
12. Drive axle block 36. Shuttle valve
13. NO (normally open) switch, disengagement 37. Pump cooling and filtration of hydraulic oil
14. NO (normally open) switch, brake lights 38. Valve block top lift hydraulics
15. NO (normally open) switch, parking brake 39. Shuttle valve
16. Accumulator charging valve 40. Attachment relief valve
17. NC (normally closed) switch, brake pressure 41. Hydraulic oil pump 1
18. Cooler brake system 42. Pressure limiting valve
19. Thermal bypass valve 43. Valve block pump unloading
20. Breather filter, brake fluid tank 44. Pressure reducer
21. Oil tank brake system 45. Servo pressure accumulator
22. Breather filter hydraulic oil tank 46. Servo filter
23. Steering valve 47. Control valve lifting/lowering and extension
24. Steering cylinder 48. High-pressure filter

8 E Schematics – 10 Common hydraulics
Hydraulic diagram joystick control

page
–

Rexroth)
LS
R
T
2
P
L
LS
T
4
TP
EF
P
CF
PP
A
B
6
LS
L3
X2
1
L4
P
T1
7
B2
L2
X1
010516 (A40856.0100 ver. 2)

L1
S
B1

1. Control valve option frame

3. Steering valve
4. Priority valve
5. Shuttle valve
6. Shuttle valve joystick control
7. Hydraulic oil pumps 3 and 4

Hydraulic diagram joystick control

page
–

Sauer-Danfoss)
LS
R
T
2
P
L
LS
T
4
TP
EF
P
CF
PP
A
B
6
LS
1
P
T1
L1
X1
L2
S
B1
7
013012


3. Steering valve
4. Priority valve
5. Shuttle valve
6. Shuttle valve joystick control
7. Non-return valve

Hydraulic diagram top lift (hydraulic

page
–
8 oil pump alternative Rexroth)
TPB
P2B
T2B
T3B
8
PS
LSPB
7
A
6
B
A
9
B
5
A
B
4
3
A
B
3
P1
T1
11
10
1
C
A
12
B
A
13
T
T
L3
C2-
X2
L4
C2+ C1+
2
B2
010512 (A40853.0100 ver. 4)

L2
PP
X1
C1-
S L1
P
P
B1
B
14
1

1. Tilt cylinder
2. Damping block
4. Valve block rotation motor
5. Side shift cylinders
6. Spreading motor
7. Valve block spreading motor
8. Twistlock cylinders
10. Filter hydraulic oil
11. Filter hydraulic oil (high-pressure filter)

13. Shuttle valve

Hydraulic diagram top lift (hydraulic

page
–
8 oil pump alternative Sauer-Danfoss)
TPB
P2B
T2B
T3B
8
PS
LSPB
7
A
6
B
A
9
B
5
5
A
B
4
3
A
B
3
P1
T1
11
10
1
A
T
T
12
2
14
C2-
13
L1
X1
L2
C2+ C1+
2
S
PP
15
B1
C1-
15
16
P
P
012496
1

1. Tilt cylinder
2. Damping block
6. Spreading motor

12. Valve block top lift hydraulics
13. Shuttle valve
14. Attachment relief valve

Hydraulic diagram top lift, tilt lock

page
–
and controllable tilt (hydraulic oil

TPB
P2B
T2B
T3B
8
PS
LSPB
8
A
B
7
A
6
9
A
5
5
B
A
B
4
3
A
3
P1
T1
10
11
1
12
A
13
T
L3
X2
C1+ C2-
L4
T
2
C2+
B2
010514 (A40853.0200 ver. 5)

PP
L2
X1
S L1
C1-
B1
P
P
B
14
1

1. Tilt cylinder
2. Damping block
6. Spreading motor

13. Shuttle valve

Hydraulic diagram top lift, tilt lock

page
–
and controllable tilt (hydraulic oil

pump alternative Sauer-Danfoss)
TPB
P2B
T2B
T3B
8
PS
LSPB
8
A
B
7
A
6
9
A
5
5
B
A
B
4
3
A
3
P1
T1
10
11
1
A
T
12
C1+ C2-
13 2
14
T
L2 L1
X1
2
C2+
PP
S
C1-
15
B1
15
16
P
P
B
013010
1

1. Tilt cylinder
2. Damping block
6. Spreading motor

13. Shuttle valve

Hydraulic diagram top lift, tilt lock,

page
–
controllable tilt and hydraulic

levelling (hydraulic oil pump
T3
TP
T2
PS
8
8
A
7
B
6
A
5
14
B
5
15
16
A
3
B
3
9
14
A
B
1
A
T
T
C2-
A
C1+
T
C2+
2
PP
B
C1-
P
P
A
1
P1
T1
12
10
11
L4 L3
X2
010515 (A431213.0100 ver. 3)

13
B2
L1 L2
X1
S
B1

1. Tilt cylinder
2. Damping block
6. Spreading motor
11. Shuttle valve
12. Oil filter
14. Levelling cylinders
15. Valve block, levelling cylinders
16. Overcentre valve, levelling

Hydraulic diagram top lift, tilt lock,

page
–
controllable tilt and hydraulic

levelling (hydraulic oil pump
T3
TP
T2
PS
8
8
A
7
B
6
A
5
B
5
9
10
11
A
3
B
3
12
9
A
B
1
A
T
T
C2-
A
C1+
T
C2+
2
PP
B
C1-
P
P
A
1
P1
T1
13
1
14
2
15
L1
X1
L2
S
17
18
B1
16
013011
17

1. Tilt cylinder
2. Damping block
6. Spreading motor
13. Oil filter
15. Shuttle valve

–
page
24
010526:A 010532:D
2C1+
VDRF03.02GB
P C1- C2+ C2- T
B A
3
1 1
5 6 8
4 7
P PP T T
9 9
10
11

010526:B 010526:C
010532 :E
B A B A B A B A B A B A PS
1413
TP
15 X1 X2
T1
P2
B1 B2
010532:F
T2
Hydraulic diagram combi yoke
(part 1 of 3) (hydraulic oil pump
S L1 L2 T3
L4 L3
P1
12
010520 (A41791.0100 ver. 1 - part 1/3)
1. Tilt cylinder
2. Damping block
6. Spreading motor
14. Shuttle valve


page
–
(part 1 of 3) (hydraulic oil pump

010532 :E
010532:F
010532:D
T3
T2
P2
TP
PS
8
A
7
B
6
A
B
5
9
10
11
A
4
B
3
12
9
A
B
1
A
T
T
C2-
A
2C1+
T
C2+
PP
B
C1-
P
P
B
A
1
B
010526:C
010526:B
P1
T1
1
13
2
010526:A
14
L1
X1
L2
S
15
B1
15
16
013016

1. Tilt cylinder
2. Damping block
6. Spreading motor
14. Shuttle valve


page
–
(part 2 of 3)
Rexroth: 010520:A
1 TP P2 T2 T3 Sauer-Danfoss: 013016:A
A
3
A
5
A
P T
B
6
A
7
B
8
B
9
010526 (A41791.0100 ver. 2 - part 2/3)
10
P1
Rexroth: 010520:B Rexroth: 010520:C

Sauer-Danfoss: 013016B Sauer-Danfoss: 013016:C

1. Control valve lifting jacks left

2. Lowering cylinder front lifting jacks
3. Valve block lowering front lifting jacks
4. Valve block extension front lifting jacks
5. Clamping cylinder front lifting jacks
6. Valve block operating position front lifting jacks
7. Clamping cylinder rear lifting jacks
8. Valve block extension rear lifting jacks
9. Valve block lowering rear lifting jacks
10. Lowering cylinder rear lifting jacks


page
–
(part 3 of 3)
Rexroth: 010520:D
Sauer-Danfoss: 013016:D T3 T2 P2 TP
1
A 3
A
5
B
6
A
7
B
8
B
9
010532 (A41791.0100 ver. 1 - part 3/3)
10
P1
T1
Rexroth: 010520:E Rexroth: 010520:F

Sauer-Danfoss: 013016:E Sauer-Danfoss: 013016:F

1. Control valve lifting jacks right

2. Lowering cylinder front lifting jacks
3. Valve block lowering front lifting jacks
4. Valve block extension front lifting jacks
5. Clamping cylinder front lifting jacks
6. Valve block operating position front lifting jacks
7. Clamping cylinder rear lifting jacks
8. Valve block extension rear lifting jacks
9. Valve block lowering rear lifting jacks
10. Lowering cylinder rear lifting jacks

Hydraulic diagram sliding cab

page
–

Rexroth)
2
TP
A
B
3
4
5
LS
1
L3
X2
L4
P
T1
6
B2
L2
X1
L1
010517 (A40855.0100 ver. 1)

S
B1


2. Hydraulic motor sliding cab
4. Shuttle valve
5. Shuttle valve option

Hydraulic diagram sliding cab

page
–

Sauer-Danfoss)
3
1
L1
013013 (A54505.0100 ver. 1)

L2
S
7


4. Shuttle valve
7. Non-return valve

Hydraulic diagram cab lift and

page
–
support jacks (hydraulic oil pump

4
3
3
2
65
TP
T3
A
B
A
7
B
10
9
LS
L3
1
X2
L4
P
T1
11
B2
L2
010518 (A43276.0100 ver. 1)

X1
L1
S
B1


2. Accumulator
3. Hydraulic cylinder support jacks
4. Valve block support jacks
5. Load control valve
6. Hydraulic cylinder vertically adjustable cab
7. Restriction
9. Shuttle valve
10. Shuttle valve option frame

Hydraulic diagram cab lift and

page
–

4
3
3
2
65
TP
T3
A
B
A
7
B
9
LS
L1
1
L2
P
T1
S
10
11
013014


2. Accumulator
4. Valve block support jacks
5. Load control valve
6. Hydraulic cylinder vertically adjustable cab
8. Shuttle valve
9. Shuttle valve option frame

Hydraulic diagram sliding cab and

page
–

3
2
2
4
P
A
B
A
5
B
6
7
8
LS
L4 L3
X2
1
P
T1
9
B2
010519 (A40854.0100 ver.1)

L1 L2
X1
S
B1


3. Overcentre valve support jacks
5. Restriction
7. Shuttle valve

Hydraulic diagram sliding cab and

page
–

3
2
2
4
P
A
B
A
5
B
7
LS
L1
1
L2
P
T1
S
8
013015


3. Overcentre valve support jacks
6. Shuttle valve
8. Non-return valve

44 E Schematics – 11 Common electrics
11 Common electrics
mm mm mm mm mm mm
Circuit diagram, description

page
–
A circuit diagram is divided into circuit names (drawing numbers) and

consists of a set of numbered pages.
The circuits and their contents are governed by the following set of
rules:
• 20015.0001 electrical 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 dia-
gram:
Connectors
Connectors in the wiring start with an X followed by a number and end
-XM674m -XM674f
2 2 with f = female or m = male. If a connector is connected to a compo-
nent then the component number is inherited into the connector’s
number, e.g. XB72002Rm which is the connector for Sensor align-
ment front right (B7202R).
Under the connector’s number the pin is specified with numbers or let-
013017
-X37-201 ters depending on the connector.

• X000-X199: In the cab.
• X200-X299: On the frame.
• X300-X399: On the boom.
• X400-: On the attachment.
• X37-: All grounding points start with X37, e.g. X37-201, which is a
grounding point on the frame.
X37-A, X37-B, X37-C and X37-D are grounding points in electron-
ic box, cab.
Zero references are in the control units.
Components
+CHASSIS Components are described with component number (S220-2) and a
-S220-2 short descriptive text. Components (sensors, switches, etc.) are
P shown in standby mode i.e. de-energised mode or not mechanical
standby mode.
1 1 2 1
• S indicates the type of component, see Component designations
013018
DECLUCHING
3,0MPa
page 46.
• 220 is component number and indicates the function the compo-
nent has.
• -2 indicates that it is the second component of this type for the
specific diagram.

E Schematics – 11 Common electrics 45
Cable labelling
A01012 0525 W212D

All cables are either white (ground signal) or grey (other wiring) and la-
belled with numbers.
Cable numbering is interpreted as follows:
A01011 0524 W212C
• 0525: the number on a cable can usually be traced to a pin in a
connector, in this example, connector X052 pin 5.
A01010 0523 W212B
• W212: cables that start with W and serial number cannot be
traced directly to a connector.
A01016 0527 W212E
• A01012: cables that start with A are in the electronic box in the
cab.
013019
W212A
• W212D: cables that end with a capital letter are jointed in the wir-
ing from a main cable with the same number. Each joint will have
its own letter.
References
0 An arrow symbol means that the circuit continues on another page in
the circuit diagram at the specified coordinates. Sometimes there are
1
00816 also references for components that can then be part of a component
/4.0_1.B1 5 1
013020
00816
whose other parts are on a different diagram. In some cases there is
/9.10_1.A2 also a help text where the cable connects.
Example: /11.5_1.D3 means page 11.5_1 coordinate D3.
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 ref-
-X411
21 K1:21 Analog In 0-5V +BOOM erence to the compilation of the control unit’s connections. Together
/0.0_4.D5 -D791-1 with this there are descriptive texts that specify control unit and signal.
013021
MEASUREPOINT SCALE For more information about the different connection types on the con-
trol units, see section 11 Common electrics , group 11.5.5 Wiring.
Fuses
Fuse boxes always start with F5. Example: F58-3 means fuse box 3
with 8 fuses.
For most fuse boxes there is also a table and an explanation of the cir-
cuits that the various fuses protect.

Component designations
page
–
The components in circuit diagrams have a prefix and number, the

prefix describes the type of component, the number which component.
Component list with component number, prefix and designation is pro-
vided as an appendix after the circuit diagrams.
Prefix Description
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 Motor. Example: electric motor.
P Measuring instrument, testing equipment. Example: operating hour gauge.
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

page
–
Circuit diagrams are attached as an appendix in the following order.
Sheet Designation
0.0-1 Circuit Cross references
0.0-2 Circuit Cross references
0.0-3 Circuit Cross references Opt
0.0-4 Circuit Cross references Att
0.0-5 Circuit Cross references Att
0.0-6 Circuit Cross references Att Combi
1.0-1 Circuit Engine 1240&1250
1.0-2 Circuit Engine Cummins
1.0-3 Circuit Engine Cummins
1.1-1 Circuit drivetrain
2.0-1 Circuit Dana TE 32000

Sheet Designation
2.0-1A1 Circuit Dana TE 32000FF
2.1-1 Circuit drivetrain
4.0-1 Circuit Brake system
4.0-2 Circuit Brake system
5.2-1 Circuit Steering lever/mini-wheel
5.2-2 Circuit Steering lever/mini-wheel
5.2-3 Circuit Steering lever/mini-wheel and Combi att
5.2-4 Circuit Steering lever/mini-wheel and Combi att
7.1-1 Circuit Joystick
7.2-1 Circuit Boom Up/Down
7.3-1 Circuit Boom In/Out
7.5-1 Circuit Spreading Valves
7.5-2 Circuit Spreading Auto
7.5-3 Circuit Spreading Sensor
7.6-1 Circuit Rotation
7.7-1 Circuit Tilt locking
7.7-2 Circuit Tilt + Levelling
7.7-3 Circuit Tilt + Levelling
7.9-1 Circuit Twistlocks
7.9-2 Circuit Twistlocks
7.9-3 Circuit Combi Att

Sheet Designation
7.9-15 Circuit Over Height
7.9-16 Circuit Over Height
7.10-1 Circuit Hyd Support jacks
7.10-2 Circuit Hyd Support jacks
7.10-3 Circuit Printer
8.2-1 Circuit OP + Scale
8.2-2 Circuit OP + Scale
8.2-3 Circuit Bypassing
8.2-4 Circuit RMI
9.1-1 Circuit Extra Sensor Instr.
9.1-2 Circuit Extra Equipment
9.1-4 Circuit Sensor Instr.
9.1-5 Circuit Option Cab
9.1-6 Circuit Extra Equipment Boom nose
9.3-1 Circuit Cab Driver’s Seat
9.3-2 Circuit Cab Driver’s Seat
9.4-1 Circuit Climate system
9.4-2 Circuit Climate system
9.5-1 Circuit Wipers
9.6-1 Circuit Work lighting
9.6-2 Circuit Extra Work Light Att
9.6-3 Circuit Extra Work Light Boom
9.6-5 Circuit Lighting
9.6-9 Circuit Entry lighting
9.6-10 Circuit Extra Work Light Frame
9.7-1 Circuit Alarm Audible signals
9.7-2 Circuit Alarm Audible signals

Sheet Designation
9.7-3 Circuit Indicators, Hazard flashers
9.7-4 Circuit Back-up alarm
9.8-1 Circuit Radio
9.9-9 Circuit Camera
9.10-1 Circuit Sliding/Vertically adjustable cab
9.10-2 Circuit Tiltable cab
9.14 Circuit Central lubrication
10.0-1 Circuit Hydraulics
11.5-1 Circuit Current
11.5-5 Circuit Current Att
11.5-6 Circuit Current KDU OPT
11.5-7 Circuit 24 V
11.5-8 Circuit 12V + Comm. Radio
11.5-9 Circuit Current Att
11.6-3 Circuit CAN BUS opt. Frame KDU
11.6-4 Circuit CAN BUS Att
Electrically op-
erated mirrors
1 Circuit diagram Mirrors
Cab tilt
1 Circuit diagram Cab tilt


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E Schema - Koponentförteckning / E Schematics - List of Components 1
NUMBER SVENSKA ENGLISH

A 32 Kretskort elcentral Printed circuit board, Junction box
A 685 Reglerenhet termostat AC Control unit, termostat AC
A 779 Reglersystem återladdning (EC) Control system, recharging (EC)
A 782 Logik interface 2 drivmotorer Logic (interface) two main motors (EC)
A 783 Logik interface gaspådrag Logic (interface) throttle
A 784 Logik interface bromsregl Logic (interface) brake control
A 785 Logik interface styrsystem Logic (interface) control system
A 786 Servoförstärkare styrsystem Servo amplifier steering system
A 799 Logik allm (option) Logic, general (option)
A 806 Aggregat klimatanläggning Aggregate, air conditioner
A 810 Kondensor AC, fläkt Condensor AC, fan
A 827 Växellåda Gearbox
A 900 Radio/bandspelare Radio/tape recorder
A 905 Kommunikationsradio Communication radio
A 907 Monitor Monitor
A 908 Kamera Camera
A 909 Skrivare Printer
A 911 Dataterminal Dataterminal
A 912 Alkolås Interlock device
A 940 Logik batterivakt Logic switch , battery watch
A 950 Logik transistortändning Logic transistor ignition
A 955 Logik övervarvningsskydd (LPG) Logic overspeed protection (LPG)
A 960 Logik rev-spärr/aut-vxl Logic unit, reversing interlock/automatic gear
changing
A 961 Motor/kupevärmare Engine- and cab heater
A 6850 Reglerenhet termostat AC Control unit termostat AC
A 7790 Reglersystem återladdning (EC) Control system recharging (EC)
A 7800 Reglersystem drivmotor (EC) Control system main motor (EC)
A 7810 Reglersystem pumpmotor (EC) Control system pump motor (EC)
A 7820 Logik interface 2 drivmotorer Logic (interface) two main motors (EC)
A 7830 Logik interface gaspådrag Logic (interface) throttle
A 7840 Logik interface bromsregl Logic (interface) brake control
A 7850 Logik interface styrsystem Logic (interface) control system
A 7860 Servoförstärkare styrsystem Servo amplifier steering system
A 7990 Logik allm (option) Logic general (option)
A 8100 Kondensor AC fläkt Condensor AC fan
A 9002 Radio/bandspelare Radio/tape recorder
A 9050 Kommunikationsradio Communication radio
A 9070 Monitor Monitor
A 9080 Kamera Camera
A 9090 Skrivare Printer
A 9110 Dataterminal Dataterminal
A 9400 Logik batterivakt Logic switch battery watch
A 9500 Logik transistortändning Logic transistor ignition
A 9550 Logik övervarvningsskydd (LPG) Logic overspeed protection (LPG)
A 9600 Logik rev-spärr/aut-vxl Logic unit reversing interlock/automatic gear
changing
A 9610 Logik Motor/kupevärmare Logic engine- and cab heater
A 9620 Logik slitageind kol elmotor Logic indication of wear brush electrical motor
A 9888 test
A 9932 Kretskort elcentral Printed circuit board Junction box
B 649 Termostat klimatannläggning Thermostat, air condition
B 690 Fartreglage (EC) Speed control (EC)
B 697 Elbroms Electric brake
B 751 Givare varvtal turbin Transmitter, speed turbin
B 752 Givare varvtal inre växellåda Transmitter, speed internal gear chain
Verkstadsmanual / Workshop manual DRF 400–450 VDRF03.02SE/GB


B 753 Varvtalsgivare motor Transmitter, engine revolution
B 754 Givare lufttryck Transmitter, air pressure
B 755 Givare hydraulfilter indikering Transmitter, hydraulics filter indication
B 756 Temperatur kylvätska motor Transmitter, engine coolant temperature
B 757 Bränslenivågivare Transmitter, fuel level
B 758 Varvtalsgivare v-låda Transmitter, gear box revolution
B 759 Nivåindikator kylvätska Transmitter, coolant level
B 760 Givare rev-spärr/aut-vxl trans Transmitter, reversing interlock / automatic gear
change system (on gearbox output shaft)
B 761 Givare rev-spärr/aut-vxl motor Transmitter, reversing interlock / automatic gear
changing system (engine speed)
B 762 Givare temp,spolkrets bromsar Transmitter, brake flushing circuit
B 763 Givare nivå hydraulolja Transmitter, hydraulic fluid level
B 764 Givare servotryck växellåda Transmitter, gear box servo pressure
B 765 Givare oljetryck v-låda Transmitter, oil pressure gear box
B 766 Givare oljetemp. v-låda Transmitter, oil temperature gear box
B 767 Givare oljetryck motor Transmitter, oil pressure engine
B 768 Givare oljetryck hydraulik Transmitter, hydraulic pressure
B 769 Givare ändläge Transmitter, end position
B 770 Givare rattutslag Transmitter, steering wheel angle
B 771 Givare vinkel Transmitter, angle
B 772 Givare temp bromsolja Transmitter, temperature brake fluid
B 773 Givare närvaro Transmitter, presence
B 774 Givare utomhustemp Transmitter, ambient temperature
B 775 Givare temp klimatanläggning Transmitter, temperature air condition
B 776 Givare temp hydraulolja Transmitter, hydraulic temperature
B 777 Givare läge Transmitter, position
B 778 Givare drivbrytning Transmitter, drive break
B 789 Givare allmän Transmitter, common
B 902 Högtalare Loud speaker
B 6490 Termostat klimatannläggning Thermostat air condition
B 6900 Fartreglage Speed control
B 6970 Elbroms Electric brake
B 7200 Givare axeltryck Sensor axle pressure
B 7224 Givare, mätläge våg Sensor, measurepoint scale
B 7225 Givare, rotationsstopp Sensor, rotation stop
B 7226 Givare, tryck lyftcylinder Sensor, pressure lift cylinder
B 7227 Givare, tryck klämma Sensor, pressure clamp
B 7228 Givare lyfthöjd analog Sensor lift height analogue
B 7229 Givare tiltvinkel analog Sensor tilt angle analogue
B 7230 Givare ultraljud last position Sensor, ultrasonic load position
B 7231 Givare, Over Height, Ben uppe Sensor, Over Height, Leg upper position
B 7232 Givare,IR Last position Givare,IR Load position
B 7233 Givare lambda sond Sensor lambda sond
B 7234 Givare vatten i bränsle Transmitter water in fuel
B 7235 Givare temp avgaser Sensor exhaust temperature
B 7235 Givare kraft Sensor force
B 7236 Givare tryck avgaser Sensor exhaust pressure
B 7510 Givare varvtal turbin Transmitter speed turbin
B 7520 Givare varvtal inre växellåda Transmitter speed internal gear chain
B 7530 Givare varvtal motor Transmitter engine speed
B 7540 Givare lufttryck Transmitter air pressure
B 7550 Givare hydraulfilter indikering Transmitter hydraulics filter indication
B 7560 Givare temperatur kylvätska motor Transmitter engine coolant temperature
B 7570 Givare bränslenivå Transmitter fuel level
B 7580 Givare kardanaxel varvtal Transmitter drive shaft speed


B 7590 Givare nivåindikator kylvätska Transmitter coolant level
B 7600 Givare rev-spärr/aut-vxl trans Transmitter reversing interlock / automatic gear
change system (on gearbox output shaft)
B 7610 Givare rev-spärr/aut-vxl motor Transmitter reversing interlock / automatic gear
changing system (engine speed)
B 7620 Givare temp,spolkrets bromsar Transmitter brake flushing circuit
B 7630 Givare nivå hydraulolja Transmitter hydraulic fluid level
B 7640 Givare servotryck växellåda Transmitter gear box servo pressure
B 7650 Givare oljetryck v-låda Transmitter oil pressure gear box
B 7660 Givare oljetemp. v-låda Transmitter oil temperature gear box
B 7670 Givare oljetryck motor Transmitter oil pressure engine
B 7680 Givare oljetryck hydraulik Transmitter hydraulic pressure
B 7690 Givare ändläge Transmitter end position
B 7700 Givare rattutslag Transmitter steering wheel angle
B 7710 Givare vinkel Transmitter angle
B 7720 Givare temp bromsolja Transmitter temperature brake fluid
B 7730 Givare närvaro Transmitter presence
B 7740 Givare temp omgivning Transmitter ambient temperature
B 7750 Givare temp klimatanläggning Transmitter temperature air condition
B 7760 Givare temp hydraulolja Transmitter hydraulic temperature
B 7770 Givare läge Transmitter position
B 7780 Givare varvtal fläkt Transmitter fan speed
B 7890 Givare allmän Transmitter common
B 9020 Högtalare Loud speaker
C 821 KONDENSATOR CAPACITOR
C 8210 Kondensator Capacitor
D 740 FleetManager kontrollenhet FleetManager control unit
D 742 FleetManager kortläsare FleetManager card device
D 743 FleetManager accelerations givare FleetManager acceleration sensor
D 744 Galvaniskt isolerad CAN brygga Galvanic insulated CAN bridge
D 780 Reglersystem drivmotor Control system traction motor
D 781 Reglersystem pumpmotor Control system pump motor
D 790 Elektronisk kontrollenhet ECU, hytt Electronic Control Unit ECU, cab
D 791 Elektronisk kontrollenhet aggregat Electronic Control Unit, attachment
D 792 Elektronisk kontrollenhet styrning Electronic Control Unit, steering system
D 793 Elektronisk kontrollenhet växellåda Electronic Control Unit, gearbox
D 794 Elektronisk kontrollenhet motor Electronic Control Unit, engine
D 796 Elektronisk kontrollenhet, lasthantering Electronic Control Unit, Loadhandling
D 797 Elektronisk kontrollenhet, ram Electronic Control Unit, frame
D 798 Elektronisk kontrollenhet, stolvändning Electronic Control Unit, seat rotation
D 2000 Elektronisk kontrollenhet, proportionalventil Electronic control unit, propotional valve
D 7420 Kortläsare Card device
D 7430 Accelerations givare Acceleration sensor
D 7900 Elektronisk Kontrollenhet ECU Electronic Control Unit, ECU
D 7910 Elektronisk Kontrollenhet aggregat Electronic Control Unit attachment
D 7920 Elektronisk Kontrollenhet styrning Electronic Control Unit steering system
D 7930 Elektronisk Kontrollenhet växellåda Electronic Control Unit gearbox
D 7940 Elektronisk Kontrollenhet motor Electronic Control Unit engine
D 7950 Elektronisk kontrollenhet Display Electronic Control Unit Display
D 7960 Elektronisk Kontrollenhet lasthantering Electronic Control Unit Loadhandling
D 7970 Elektronisk Kontrollenhet ram Electronic Control Unit frame
D 7980 Elektronisk Kontrollenhet stolvändning Electronic Control Unit seat rotation
D 9001 Fjärrkontroll Remote Control
E 400 G-lampa vä fram Light bulb, roading light left hand front
E 400 G-lampa hö fram Light bulb, roading light right hand rear
E 401 G-lampa vä bak Light bulb, roading light left hand front


E 401 G-lampa hö bak Light bulb, roading light right hand rear
E 402 G-lampa fjärrljus Light bulb, distance light
E 403 G-lampa lastljus Light bulb, mast light
E 404 G-lampa arbetsljus Light bulb, working light
E 405 G-lampa backljus Light bulb, rear light
E 406 G-lampa cont belysning vänster Container light left-hand
E 406 G-lampa cont belysning höger Container light right-hand
E 408 G-lampa park ljus vä fram Light bulb, parking light, left-hand forward
E 408 G-lampa park ljus hö fram Light bulb, parking light, right-hand forward
E 429 G-lampa cigarettändare belysning Light bulb, cigarett lighter illumination
E 431 G-lampa instrument belysning Light bulb, instrument illumination
E 432 G-lampa handsfack belysning Light bulb, glove pocket light
E 433 G-lampa instegs belysning Light bulb, step-in lighting
E 434 G-lampa innerbelysning Light bulb, interior lighting
E 435 G-lampa låsbelysning Light bulb, reading lighting
E 436 G-lampa identifikationsljus Light bulb, identification light
E 437 G-lampa identifikationsljus/takskylt Light bulb, identification light/roof sign
E 438 G-lampa motorrumsbelysning Light bulb, engine compartment light
E 439 Nummerskyltsbelysning Light license plate
E 440 G-lampa värmereglage belysning Light bulb, heating control light
E 456 G-lampa backljus blackout IR vänster Light bulb, rear light blackout IR left-hand
E 456 G-lampa backljus blackout IR höger Light bulb, rear light blackout IR right-hand
E 458 G-lampa fram blackout vänster Light bulb, roading light blackout left-hand
E 458 G-lampa fram blackout höger Light bulb, roading light blackout right-hand
E 459 G-lampa fram blackout IR vänster Light bulb, roading light blackout IR left-hand
E 459 G-lampa fram blackout IR höger Light bulb, roading light blackout IR right-hand
E 460 G-lampa arb.belysning hytt blackout IR vä Light bulb, working light cab blackout IR left
E 460 G-lampa arb.belysning hytt blackout IR hö Light bulb, working light cab blackout IR right
E 461 G-lampa arb.bel. bom 20' blackout IR vä Light bulb, working light boom20' b.out IR left
E 461 G-lampa arb.bel. bom 20' blackout IR hö Light bulb, working light boom20' b.out IR right
E 462 G-lampa arb.bel. bom 40' blackout IR vä Light bulb, working light boom40' b.out IR left
E 462 G-lampa arb.bel. bom 40' blackout IR hö Light bulb, working light boom40' b.out IR right
E 464 G-lampa cont belysning IR vänster Light bulb,Container light IR left-hand
E 464 G-lampa cont belysning IR höger Light bulb,Container light IR right-hand
E 669 Värmare kupe/ motor diesel Heater compartment/engine diesel
E 802 Eluppvärmd backspegel Electrical heated observation mirror
E 803 Eluppvärmd stol Electrical heated seat
E 804 Cigarettändare Cigarett lighter
E 805 Elvärme hytt Electrical heating cab
E 808 Eluppvärmd lufttorkare Electrical heater air dryer
E 835 Tändstift Ignition plug
E 888 Lufttork, kompressor Air Dryer, Compressor
E 962 Logik slitageind kol elmotor Logic indication of wear, brush electrical motor
E 4000 Glödlampa halvljus Light bulb dipped light
E 4020 Glödlampa helljus Light bulb Headlight
E 4040 Glödlampa arbetsljus Light bulb working light
E 4050 Glödlampa backljus Light bulb rear light
E 4080 Glödlampa park ljus fram Light bulb parking light forward
E 4290 Glödlampa cigarettändare belysning Light bulb cigarett lighter illumination
E 4310 Glödlampa instrument belysning Light bulb instrument illumination
E 4320 Glödlampa handsfack belysning Light bulb glove pocket light
E 4330 Glödlampa instegs belysning Light bulb step-in lighting
E 4340 Glödlampa innerbelysning Light bulb interior lighting
E 4350 Glödlampa läsbelysning Light bulb reading lighting
E 4360 Glödlampa identifikationsljus Light bulb identification light
E 4370 Glödlampa sökljus Light bulb search light


E 4380 Glödlampa motorrumsbelysning Light bulb engine compartment light
E 4390 Nummerskyltsbelysning Light license plate
E 6690 Värmare kupe/ motor diesel Heater compartment/engine diesel
E 8000 Förvärmare motor Start element
E 8020 Eluppvärmd backspegel Electrical heated observation mirror
E 8030 Eluppvärmd stol Electrical heated seat
E 8040 Cigarettändare Cigarett lighter
E 8050 Elvärme hytt Electrical heating cab
E 8091 Eluppvärmd lufttorkare Electrical heater air dryer
E 8092 Eluppvärmd ruta Electrical heated window
E 8350 Tändstift Ignition plug
E 8881 Elektrisk värme ruta Electrical heated window
F 51 Säkringshållare 1-polig Fuse holder, 1-pole
F 62 Batterihandske 2-polig Battery connector, 2-pole
F 64 Batterihandske 4-polig Battery connector, 4-pole
F 9951 Säkringshållare 1-polig Fuse holder 1-pole
F 9959 Säkringshållare Fuse holder
G 30 Batteri Battery
G 658 Generator (extra) Alternator extra
G 659 Generator utan laddregulator Alternator without loading regulator
G 660 Generator med laddregulator Alternator with loading regulator
G 662 Laddregulator Loading regulator
G 6600 Generator Alternator with loading regulator
G 6620 Laddregulator Loading regulator
G 9930 Batteri Battery
H 410 G-lampa broms ljus vä fram Light bulb, brake light, left-hand forward
H 410 G-lampa broms ljus hö fram Light bulb, brake light, right-hand forward
H 411 G-lampa broms ljus vä bak Light bulb, brake light, left-hand rear
H 411 G-lampa broms ljus hö bak Light bulb, brake light, right-hand rear
H 412 G-lampa bak ljus vä bak Light bulb, rear light, left-hand rear
H 412 G-lampa bak ljus hö bak Light bulb, rear light right-hand rear
H 413 G-lampa bak ljus vä fram (VBFS) Light bulb, rear light, left-hand forward (VBFS)
H 413 G-lampa bak ljus hö fram (VBFS) Light bulb, rear light,right-hand forward (VBFS)
H 416 G-lampa sidomarkering vä fram Light bulb, side position light, left-hand forward
H 416 G-lampa sidomarkering vä bak Light bulb, side position light, left-hand rear
H 417 G-lampa sidomarkering hö fram Light bulb, side position light, right -hand forward
H 417 G-lampa sidomarkering hö bak Light bulb, side position light, right-hand rear
H 420 G-lampa positionsljus vänster Light bulb, position light, left-hand
H 421 G-lampa positionsljus höger Light bulb, position light, right-hand
H 422 G-lampa körvisare vä fram Light bulb, direction indicator left-hand forward
H 423 G-lampa körvisare hö fram Light bulb, direction indicator right-hand forwrd
H 426 G-lampa körvisare vä bak Light bulb, direction indicator left-hand rear
H 427 G-lampa körvisare hö bak Light bulb, direction indicator right-hand rear
H 428 G-lampa roterande varningsljus Light bulb, flashing beacon lamp
H 445 G-lampa körvisare vä (extra) Light bulb, extra direction indicator left
H 446 G-lampa körvisare hö (extra) Light bulb, extra direction indicator right
H 451 G-lampa dimbakljus vänster Light bulb, fog light rear left


H 452 G-lampa dimbakljus höger Light bulb, fog light rear right
H 453 G-lampa bromsljus/körvisare vänster Light bulb, brake light/dir. indicator left-hand
H 453 G-lampa bromsljus/körvisare höger Light bulb, brake light/dir. indicator right-hand
H 454 G-lampa bromsljus blackout vänster Light bulb, brake light blackout left-hand
H 454 G-lampa bromsljus blackout höger Light bulb, brake light blackout right-hand
H 457 G-lampa positionsljus blackout vänster Light bulb, position light blackout left-hand
H 457 G-lampa positionsljus blackout höger Light bulb, position light blackout right-hand
H 463 G-lampa bak ljus vänster bak, blackout Light bulb, rear light left-hand rear, blackout
H 463 G-lampa bak ljus höger bak, blackout Light bulb, rear light right-hand rear, blackout
H 465 G-lampa röd saxagregat ute Light-bulb, red extender exended
H 466 G-lampa orange vertikalhålning på Light bulb, orange vertical hold on
H 467 G-lampa grön klämtryck OK Light bulb, green clamp pressure OK
H 468 G-Lampa Röd Maxlast Light bulb,Red Overload
H 500 Kont lampa körvisare Indicating lamp, direction indicator
H 501 Kont lampa körvisare (extra) Indicating lamp, direction indicator extra
H 503 Varn lampa oljetryck motor Warning lamp, oil pressure engine
H 504 Kont lampa helljus Indicating lamp, main beam
H 505 Varn lampa laddning Warning lamp, loading
H 506 Varn lampa laddning (extra) Warning lamp, loading extra
H 507 Varn lampa färdbroms Warning lamp, brake
H 508 Varn lampa parkerings broms Warning lamp, parking brake
H 509 Varn lampa nivå kylvatten Warning lamp, coolant level
H 510 Kont lampa diff spärr Indicating lamp, diff. interlock
H 512 Varn lampa temp momentförst Warning lamp, temperature converter
H 514 Kont lampa överväxel Indicating lamp, overdrive clutch
H 519 Kont lampa halvljus Indicating lamp, dipped lights
H 524 Kont lampa luftfilter Indicating lamp, air filter
H 525 Kont lampa UNIKAT Indicating lamp, UNIKAT
H 528 Kont lampa förvärmning Indicating lamp, preheating
H 530 Kont lampa framhjuls styrning Indicating lamp, forward wheel steering
H 531 Kont lampa 4-hjuls styrning Indicating lamp, 4-wheel steering
H 532 Kont lampa crab styrning Indicating lamp, crab steering
H 533 Kont lampa hyd.pump Indicating lamp, emergency hyd. pump
H 547 Varn lampa centralvarning Warning lamp, central warning
H 549 Varn lampa oljetryck v-låda Warning lamp, oil pressure gear box
H 550 Varn lampa hyttlåsning Warning lamp, cab lock
H 551 Varn lampa temp v-låda Warning lamp, temperature gear box
H 552 Varn lampa bromstryck Warning lamp, brake pressure
H 554 Varn lampa temp spolkrets bromsar Warning lamp, temp. cooling system brakes
H 555 Varn lampa temp kylvatten mot Warning lamp, temperature coolant engine
H 556 Varn lampa låsning vändskiva Warning lamp, interlocking of turntable
H 560 Varn lampa temp drivmotor el Warning lamp, temperature, drive motor
H 561 Varn lampa temp pumpmotor el Warning lamp, temperature, pump motor
H 562 Varn lampa öppen twistlock Warning lamp, unlocked twist lock
H 563 Varn lampa låst twistlock Warning lamp, locked twist lock
H 564 Varn lampa anliggning Warning lamp, alignement
H 565 Varn lampa temp motor el Warning lamp ,temperature motor
H 569 Kont lampa elvärme Indicating lamp, electric heater
H 569 Kont lampa elvärme Indicating lamp, electric heater
H 570 Varn lampa överkoppling säkerhetssystem Warning lamp, by-pass safety system
H 571 Kont lampa bränslenivå Indicating lamp, fuel level
H 572 Varningslampa lyfthöjd Warning lamp lifting height
H 573 Kontroll lampa motor information Indicator lamp engine information
H 574 Kontroll lampa stödben nere Indicator lamp support jacks down
H 575 Kontroll lampa stödben ur arb.läge Indicator lamp support jacks out of working pos


H 576 Kontroll lampa anliggning främre ben Indicator lamp, alignment front legs
H 577 Kontroll lampa anliggning bakre ben Indicator lamp, alignment rear legs
H 578 Kontroll lampa klämläge främre ben Indicator lamp, clamp position front legs
H 579 Kontroll lampa klämläge bakre ben Indicator lamp, clamp position rear legs
H 580 Kontroll lampa främre ben uppe Indicator lamp, front legs upper position
H 581 Kontroll lampa främre ben nere Indicator lamp, front legs lower position
H 582 Varningslampa överlast Warning lamp overload
H 583 Kontroll lampa anliggning ett ben Indicator lamp, alignment one leg
H 584 Kontroll lampa anliggning alla ben Indicator lamp, alignment all legs
H 599 Kont lampa option Indicating lamp, option
H 850 Signalhorn Horn
H 853 Summer Buzzer
H 965 Backvarnare Reversing alarm
H 4110 Glödlampa broms ljus Light bulb brake light
H 4120 Glödlampa bakljus Light bulb rear light
H 4130 Glödlampa bakljus fram (VBFS) Light bulb rear light forward (turnable seat)
H 4160 Glödlampa sidomarkering Light bulb side position light
H 4200 Glödlampa positionsljus Light bulb position light
H 4220 Glödlampa körriktningsvisare Light bulb direction indicator
H 4280 Glödlampa roterande varningsljus Light bulb flashing beacon lamp
H 4510 Glödlampa dimljus Light bulb fog light
H 4650 Glödlampa saxaggregat Light-bulb extender
H 4660 Glödlampa vertikalhållning Light bulb vertical hold
H 4670 Glödlampa klämtryck Light bulb clamp pressure
H 4680 Glödlampa Maxlast Light bulb Overload
H 5000 Kontrollampa tryck lyfttång Indicating lamp pressure lift tong
H 5001 Varningslampa Over Height ben uppe Warn. Lamp Over Height leg upper pos
H 5002 Kontrollampa köriktningsvisare Indicating lamp direction indicator
H 5030 Varningslampa oljetryck motor Warning lamp oil pressure engine
H 5040 Kontrollampa helljus Indicating lamp main beam
H 5050 Varningslampa laddning Warning lamp charging
H 5070 Varningslampa färdbroms Warning lamp brake
H 5080 Varningslampa parkerings broms Warning lamp parking brake
H 5090 Varningslampa nivå kylvätska Warning lamp coolant level
H 5100 Kontrollampa diff spärr Indicating lamp diff. interlock
H 5120 Varningslampa temp momentförst Warning lamp temperature converter
H 5140 Kontrollampa överväxel Indicating lamp overdrive clutch
H 5190 Kontrollampa halvljus Indicating lamp dipped lights
H 5240 Kontrollampa luftfilter Indicating lamp air filter
H 5250 Kontrollampa avgasfilter Indicating lamp exhaust filter
H 5280 Kontrollampa förvärmning Indicating lamp preheating
H 5300 Kontrollampa framhjuls styrning Indicating lamp forward wheel steering
H 5310 Kontrollampa 4-hjuls styrning Indicating lamp 4-wheel steering
H 5320 Kontrollampa crab styrning Indicating lamp crab steering
H 5330 Kontrollampa hyd.pump Indicating lamp emergency hyd. pump
H 5470 Varningslampa central varning Warning lamp central warning
H 5490 Varningslampa oljetryck v-låda Warning lamp oil pressure gear box
H 5500 Varningslampa hyttlåsning Warning lamp cab lock
H 5510 Varningslampa temp v-låda Warning lamp temperature gear box
H 5520 Varningslampa bromstryck Warning lamp brake pressure
H 5540 Varningslampa temp spolkrets bromsar Warning lamp temp. cooling system brakes
H 5550 Varningslampa temp kylvatten motor Warning lamp temperature coolant engine
H 5560 Varningslampa låsning vändskiva Warning lamp interlocking of turntable
H 5600 Varningslampa temp drivmotor el Warning lamp temperature drive motor
H 5610 Varningslampa temp pumpmotor el Warning lamp temperature pump motor
H 5620 Varningslampa öppen twistlock Warning lamp unlocked twist lock


H 5630 Varningslampa låst twistlock Warning lamp locked twist lock
H 5640 Varningslampa anliggning Warning lamp alignement
H 5650 Varningslampa temp motor el Warning lamp ,temperature motor
H 5690 Kontrollampa elvärme Indicating lamp electric heater
H 5700 Varningslampa förbikoppling säkerhetssystem Warning lamp by-pass safety system
H 5710 Kontrollampa bränslenivå Indicating lamp fuel level
H 5720 Varningsingslampa lyfthöjd Warning lamp lifting height
H 5730 Kontrollampa motor information Indicator lamp engine information
H 5740 kontrollampa stödben nere Indicator lamp support jacks down
H 5750 Kontrollampa stödben ur arb.läge Indicator lamp support jacks out of working pos
H 5760 Kontrollampa anliggning ben Indicator lamp alignment leg

H 5780 Kontrollampa klämläge ben Indicator lamp clamp position leg
H 5800 Kontrollampa ben uppe Indicator lamp legs upper position
H 5820 Varningsingslampa överlast Warning lamp overload
H 5990 Kontrollampa option Indicating lamp option
H 5991 Kontrollampa säkerhetsbälte Indicating lamp fasten seat belt
H 5992 Kontrollampa ministyrning Indicating lamp micro steering
H 8500 Signalhorn Horn
H 8530 Summer Buzzer
H 9003 Varningssignal aut. rörelse Warning alarm aut. movement
H 9650 Backalarm Reversing alarm
K 300 Relä hel/halvljus Relay, main/dipped beam
K 301 Relä dimljus Relay, fog light
K 302 Relä fjärrljus Relay, distance light
K 303 Relä lastljus Relay, mast light
K 304 Relä arbetsljus Relay, working light
K 305 Relä backljus Relay, reversing light
K 306 Relä helljus Relay, main beam
K 307 Relä halvljus Relay, dipped beam
K 308 Relä bromsljus Relay, brake light
K 309 Relä parkeringsbroms Relay, parking light
K 310 Relä körvisare vä Relay, direction indicator left
K 311 Relä körvisare hö Relay, direction indicator right
K 312 Relä startelement Relay,element preheater
K 313 Relä vändbar förarstol Relay, rotating driver´s seat (VBFS)
K 314 Relä parkeringsbroms Relay, parking brake
K 315 Relä tändningslås Relay, ignition key
K 316 Relä torkare Relay, wiper
K 317 Relä strålkastartorkare Relay, roading lights wiper
K 318 Relä AT-regulator Relay, AT-regulator
K 319 Relä varningsblinkers Relay, hazard blinkers
K 320 Relä elektrisk stopp Relay, electical stop
K 321 Relä intervalltorkare Relay, intermittent wiper
K 322 Relä kylvätskenivå Relay, coolant level
K 323 Relä blinkers Relay, blinkers
K 324 Relä rangespärr Relay, range interlock
K 325 Relä blinkande bromsljus (back) Relay, flashing brake lights (reversing)
K 326 Relä blinkande bromsljus (runt) Relay, flashing hazard brake lights
K 327 Relä växel neutral Relay, gear neutral
K 328 Relä växelskifte Relay, gear shift
K 329 Relä växel hög/låg Relay, high/low gear
K 330 Relä startspärr Relay, start interlock
K 331 Relä drivning fram Relay, forward driving
K 332 Relä drivning bak Relay, reversing driving
K 333 Tidrelä förvärmning Time relay, automatically preheating


K 334 Relä frikoppling/drivbrytning Relay, free wheel/drive disconnection
K 335 Relä växelventil 1:a (diesel, gas) Relay, gear change valve 1-gear (diesel,LPG)
K 336 Relä växelventil 2:a (diesel, gas) Relay, gear change valve 2-gear (diesel,LPG)
K 337 Relä drivriktning motor Relay, motor drive direction
K 338 Relä kylfläkt drivmotor Relay, cooling fan drive motor
K 339 Relä kylfläkt elskåp Relay, cooling fan electrical box
K 340 Tidrelä fördröjt tillslag Time relay, start delay
K 341 Tidrelä fördröjt frånslag Time relay, stop delay
K 342 Relä drivning 2/4 hjul Relay, switching 2/4 WD
K 343 Relä dimbakljus Relay, fog light rear
K 344 Relä momentförstärkare Relay, torque amplifier
K 345 Relä låsning vändskiva Relay, interlocking of turntable
K 346 Relä frikoppling stollåsning Relay, releasing of seat interlocking
K 347 Relä stolvändning/ljussignal Relay, multifunction, seat rotation/light signal
K 348 Relä fläktmotor värmare Relay, fan heating
K 349 Relä fartreglage Relay, speed control
K 350 Relä pumpkontaktor/pumpkontroll Relay, pump contactor/pump control
K 351 Relä hyttlyft upp Relay, cab hoist up
K 352 Relä hyttlyft ner Relay, cab hoist down
K 353 Relä säkerhetsslinga Relay, safety loop
K 354 Relä styrsystem Relay, signal control system
K 355 Relä sensorstyrning Relay, sensor control
K 356 Skiftrelä längskörning/tvärskörning Shift relay, length/sideways driving
K 357 Relä roterande varningsljus Relay, hazard beacon
K 358 Relä komressor luft Relay, compressor air
K 359 Relä Hydrauloljekylare Relay hydraulic oil cooler
K 360 Relä startsolenoid Relay, starting solenoid
K 361 Relä kompressor AC Relay, compressor air conditione
K 362 Relä vattenventil AC Relay, water valve air conditioner
K 363 Relä kondensor AC Relay, condenser air conditione
K 364 Relä stolsbrytare Relay seat switch
K 365 Relä fönsterhiss upp Relay, electrical screen elevator up
K 366 Relä fönsterhiss ner Relay, electrical screen elevator down
K 367 Relä styrning Relay, steerin
K 368 Relä lågt bromstryck Relay, low brake pressure
K 369 Relä centralsmörjning Relay, central lubrication
K 370 Relä centralsmörjning, aggregat Relay, central lubrication, attatchment
K 371 Relä lyfthöjd Relay, liftheight
K 372 Relä blinkande varn.ljus, höjdbegränsn. Relay, flashing beacon, lifting height limiter
K 373 Relä bakljus Relay light
K 375 Huvudkontaktor reglersystem Main contactor, operating control
K 376 Kontaktor fram reglersystem Contactor, forward operating control
K 377 Kontaktor bak reglersystem Contactor, reversing operating control
K 378 Kontaktor by-pass reglersystem/Fältförsvagning Contactor, ¿by-pass¿ operating control/ Field
weakening
K 379 Kontaktor pumpmotor Contactor, pump motor
K 380 Kontaktor Contactor
K 381 Kontaktor återladdning Contactor, recharging
K 382 Relä, förbikoppling säkerhetssystem Relay, by-pass safety system
K 383 Relä, Stolsvärme Relay, heated seat
K 384 Relä vattenseparator Relay, waterseparator
K 385 Relä bränslepump insprutning Relay, fuel injection pump
K 386 Relä, hög motortemperatur. Relay, high motor temperature
K 387 Relä alternativ gaspedal Relay alternative throttle pedal
K 388 Relä, Extra färdriktningsväljare Relay, Extra direction selector
K 389 Relä, Pausvärme Relay, Paus heat


K 399 Relä option Relay, option
K 3000 Relä hel/halvljus Relay main/dipped beam
K 3001 Relä rotation Relay, rotation
K 3001 Relä rotation Relay rotation
K 3002 Relä tilt Relay, tilt
K 3002 Relä tilt Relay tilt
K 3003 Relä sidoföring Relay, side shifting
K 3004 Relä längdinställning Relay, length adjustment
K 3005 Relä twist lock Relay, twist lock
K 3006 Relä spridning Relay, spreading
K 3007 Relä lyft/sänk Relay, lifting/lowering
K 3008 Relä hydraulfunktion extra Relay, extra hydraulic function
K 3009 Relä manöverbrytare hydr Relay, operating switch
K 3010 Relä bromsljus vxl std/blackout Relay, brake light shift std/blackout
K 3010 Relä dimljus Relay fog light
K 3011 Relä backljus vxl std/blackout Relay, reversing light shift std/blackout
K 3012 Relä arb.bel hytt vxl std/blackout Relay, working light cab, shift std/blackout
K 3013 Relä arb.bel. bom 20' vxl std/blackout Relay,working light boom20' shift std/b.out
K 3014 Relä arb.bel. bom 40' vxl std/blackout Relay,working light boom40' shift std/b.out
K 3015 Relä vxl bromsljus/blinkers vä Relay, shift brake light/direction indicator left
K 3015 Relä vxl bromsljus/blinkers hö Relay, shift brake light/direction indicator right
K 3016 Relä signalhorn relay, horn
K 3017 Relä containerbelysning Relay, Container light
K 3018 Relä containerbelysning IR Relay, Container light IR
K 3040 Relä arbetsljus Relay working light
K 3050 Relä backljus Relay reversing light
K 3060 Relä helljus Relay main beam
K 3070 Relä halvljus Relay dipped beam
K 3080 Relä bromsljus Relay brake light
K 3090 Relä parkeringsbroms Relay parking light
K 3100 Relä körriktningsvisare Relay direction indicator
K 3120 Relä förvärmning Relay preheater
K 3130 Relä vändbar förarstol Relay rotating driver´s seat (VBFS)
K 3140 Relä parkeringsbroms Relay parking brake
K 3150 Relä tändningslås Relay ignition key
K 3160 Relä torkare Relay wiper
K 3170 Relä strålkastartorkare Relay roading lights wiper
K 3190 Relä varningsingsblinkers Relay hazard blinkers
K 3200 Relä elektrisk stopp Relay electical stop
K 3210 Relä intervalltorkare Relay intermittent wiper
K 3220 Relä kylvätskenivå Relay coolant level
K 3230 Relä blink Relay blinkers
K 3270 Relä växel neutral Relay gear neutral
K 3280 Relä växelskifte Relay gear shift
K 3290 Relä växel hög/låg Relay high/low gear
K 3300 Relä startspärr Relay start interlock
K 3305 Relä VBFS, backljus Relay, rotating driver´s seat, reversing light
K 3306 Relä VBFS, helljus Relay, rotating driver´s seat, main beam
K 3307 Relä VBFS, halvljus Relay, rotating driver´s seat, dipped beam
K 3308 Relä VBFS, bromsljus Relay, rotating driver´s seat, brake light
K 3310 Relä VBFS, körvisare vä Relay, rotating driver´s seat, direction indicator left
K 3311 Relä VBFS, körvisare hö Relay, rotating driver´s seat, direction indicator
right
K 3312 Relä drivning fram Relay forward driving
K 3320 Relä drivning bak Relay reversing driving


K 3330 Relä, säkerhetsbälte Relay, seat belt
K 3331 Relä VBFS, drivning fram Relay, rotating driver´s seat, forward driving
K 3332 Relä VBFS, drivning bak Relay, rotating driver´s seat, reversing driving
K 3333 Tidrelä förvärmning Time relay automatically preheating
K 3340 Relä frikoppling/

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Reachstackers 40-45 tonnes

9 Frame, body, cab and accessories

G Terminologi och Index

Table of Contents A Foreword

Workshop manual DRF 400-450 VDRF03.02GB

VDRF03.02GB Workshop manual DRF 400-450

About the Workshop Manual

Thank you for choosing Cargotec as your machine supplier. We hope

The instructions are based on the use of generally available standard

About the machine version

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

Only use equipment approved by Cargotec.

Workshop manual DRF 400-450 VDRF03.02GB

Warnings inform on potential dangers which can, if the warnings are

Important information marked with NOTE facilitates the work process,

Read the Operator’s Manual

Read the Operator’s Manual

Read the Maintenance Manual

The symbol to the left is sometimes found on the machine. It refers to

important information in the Maintenance Manual.

Read the Maintenance Manual

VDRF03.02GB Workshop manual DRF 400-450

Workshop manual contents

The Workshop Manual contains information to facilitate maintenance

B Safety Keep in mind for your safety.

C Preventive maintenance Reference to maintenance manual: Preventive maintenance.

E Schematics Wiring diagrams, hydraulic diagrams and list of electrical components.

Workshop manual DRF 400-450 VDRF03.02GB

Function group structure

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

VDRF03.02GB Workshop manual DRF 400-450

References between different information types

The maintenance manual and workshop manual are mainly divided

Function descriptions Hydraulic diagrams

Component descriptions Error codes

Diagnostics Wiring diagrams

• From Function description to Component description, to enable

Workshop manual DRF 400-450 VDRF03.02GB

Product alternatives and optional equipment

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

Optional equipment refers to options that can be added to standard

VDRF03.02GB Workshop manual DRF 400-450

Function descriptions are schematic overviews that describe how a

Workshop manual DRF 400-450 VDRF03.02GB

Example of function description

VDRF03.02GB Workshop manual DRF 400-450

Symbol explanation function descriptions

D790-1 13. Bulb

13 14 14. Control system, two control units with CAN-bus

Workshop manual DRF 400-450 VDRF03.02GB

About the documentation

The documentation to the machine comprises the following sections:

Documentation is ordered from your Cargotec dealer.

VDRF03.02GB Workshop manual DRF 400-450

Cargotec’s ambition is that you who work with maintenance of a Ka-

To: Cargotec Sweden AB

Date: .................................... - .................. - ..................

Section / page number: ......................................................................................................................................

Workshop manual DRF 400-450 VDRF03.02GB

VDRF03.02GB Workshop manual DRF 400-450

Table of Contents B Safety

Workshop manual DRF 400-450 VDRF03.02GB

VDRF03.02GB Workshop manual DRF 400-450

General safety information