Workshop Manual - DCF 180-250

Forklift trucks 18-25 tonnes
Publ. no VDCF06.01GB
Workshop Manual in original WORKSHOP MANUAL
DCF 180-250
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Workshop Manual
2 Transmission
DCF 180-250
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
G Terminology and index

A:1
A Foreword
Contents A Foreword
Foreword ............................................................................................................ A:3
About the Workshop Manual........................................................................... A:3
General ...................................................................................................... A:3
Conditions .................................................................................................. A:3
Storage....................................................................................................... A:3
About machine version............................................................................... A:3
Copyright .................................................................................................... A:3
Reading instructions ....................................................................................... A:4
Warning information ................................................................................... A:4
Important information ................................................................................. A:4
Read operator's manual ............................................................................. A:4
Read the Maintenance manual .................................................................. A:4
The workshop manual's contents............................................................... A:5
Function group structure ............................................................................ A:6
References between different information types ........................................ A:7
Product alternatives and optional equipment ............................................. A:8
Machine card.............................................................................................. A:9
Function descriptions ............................................................................... A:10
About the documentation .............................................................................. A:12
The documentation's parts ....................................................................... A:12
Ordering documentation........................................................................... A:12
Feedback ...................................................................................................... A:13
Form for copying ...................................................................................... A:13
Workshop Manual DCF 180-250 VDCF06.01GB

A:2
VDCF06.01GB Workshop Manual DCF 180-250

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

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

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

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

prohibited.

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

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

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

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

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

Function group structure

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

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

information. The maintenance manual only contains the information
needed for preventive maintenance and simpler troubleshooting.
The workshop manual contains more in-depth information and repair
instructions.
References between sections in the same manual are indicated with

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

not given. If more information about a function group is required then
the primary recommendation is to search under the same function
group in the other manual. For more in-depth information on where
different types of information are located and what references are
made, see References between different information types, page A:7.

References between different information types

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

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

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

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

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

Product alternatives and optional equipment

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

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

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

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

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

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

In many cases these can be associated with options and product
alternatives. For more information about handling of product
alternatives and optional equipment, see Product alternatives and
optional equipment, page A:8. The machine card is supplied with the
spare parts catalogue.
The machine card is divided in the same function groups as the spare
parts catalogue, maintenance and workshop manuals. For practical
reasons, the machine card only uses the first and second level in the
function group register. The function groups are written in groups of
four characters, e.g. group 0107 corresponds to group 1.7 Cooling
system in the manual.
For more information about how the machine card is used for ordering
spare parts, see the spare parts catalogue's foreword.
If the information on the machine card is not of any assistance, contact

Cargotec.
NOTE
All documents that accompany the machine are non-registered
documents and there will be no notification of changes.

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

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

as valves, sensors, etc.
1
2
11
3
10
8
5
7
6
015646
Example of function description

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

Symbol explanation function descriptions

Symbol explanation function descriptions
1 2
The following symbols are used in the function descriptions. The
3 4 symbols are based on standard symbols used in wiring and hydraulic
diagrams.
1. Electric control signal
5 6 2. Electric force
3. Hydraulic control signal
4. Hydraulic force
5. Hydraulic motor
7 8 M 6. Hydraulic oil pump with variable displacement
7. Hydraulic oil pump with fixed displacement
8. Electric motor
9 10
9. Accumulator
10. Disc brake
11. Filter
11 12
12. Radiator
13. Bulb
ECU795
14. Control system, two control units with CAN-bus
13 14
ECU796 15. Restriction
16. Adjustable restriction
17. Inductive position sensor
15 16
18. Electrically controlled servo valve
17 18 19. Thermal bypass valve
20. Temperature-controlled switch
19 ˚C 20 ˚C 21. Temperature sensor
22. Pressure sensor
21 ˚C 22 Pa
23. Pressure-controlled switch
24. Hydraulic cylinder
23 Pa 24 25. Double-acting hydraulic cylinder
26. Spring brake cylinder
25 27. Valve block
28. Shuttle valve
29. Non-return valve
26 27 30. Hydraulic oil pump (transmission)
28 29
010587
30

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

The documentation's parts
The documentation for the machine consists of the following parts:
Operator's manual
The operator's manual is delivered with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
supplied for the machine as a separate documentation kit.
Supplementary documentation
There is supplementary documentation that can be ordered for the
machine.
• Workshop manual.
• Supplier documentation for engine, transmission, and drive axle.
Ordering documentation
Documentation is ordered from your Cargotec dealer.
Always indicate publication number when ordering.
For publication number, see machine card.

A Foreword – Feedback A:13
Feedback
Form for copying
Cargotec's ambition is that you who work with maintenance of Kalmar
machines shall have access to correct information.
Your feedback is important to be able to improve the information.
Copy this form, write down your views and send it to us. Thanks for
your help!
To: Cargotec Sweden AB

Technical Documentation
Torggatan 3
SE-340 10 Lidhult
SWEDEN
Fax: +46 372 263 93
From:
Company / Sender: ..........................................................................................................................................
Phone: ...............................................................................................................................................................
E-mail: .................................................................................................................................................................
Date: .................................... - .................. - ..................

Manual in-
formation
Name / Publication number: .............................................................................................................................
Section / page number: ................................................................................................................................

................
Sugges-
tions,
.............................................................................................................................................................................
views, re-
marks,
etc.
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................

A:14

B:1
B Safety
Contents B Safety
Safety.................................................................................................................. B:3
General safety information.............................................................................. B:3
Safety concerns everyone!......................................................................... B:3
A near accident is a warning! ..................................................................... B:3
Safety instructions........................................................................................... B:4
General ...................................................................................................... B:4
Service position .......................................................................................... B:4
Hydraulic system, depressurising............................................................... B:5
Oils ............................................................................................................. B:5
Fuel system ................................................................................................ B:6
AdBlue........................................................................................................ B:7
Clothing, etc. .............................................................................................. B:7
Several mechanics on the same machine.................................................. B:8
Working under the machine ....................................................................... B:8
Lifting heavy components .......................................................................... B:9
Vibration ..................................................................................................... B:9
Noise .......................................................................................................... B:9
Dissolvent................................................................................................. B:10
Fire and explosion risk ..............................................................................B:11
Fluid or gas under pressure ..................................................................... B:14
Coolant ..................................................................................................... B:14
Refrigerant ............................................................................................... B:15
Air pollution .............................................................................................. B:15
Tensioned springs .................................................................................... B:16
Electric motors ......................................................................................... B:16
Rotating components and tools................................................................ B:17
Tyres and rims.......................................................................................... B:17
Lifting equipment ...................................................................................... B:18
Spare parts............................................................................................... B:19
Non-ionised radiation ............................................................................... B:20
Environment.................................................................................................. B:21
General .................................................................................................... B:21

B:2

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

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

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

B:4 B Safety – Safety instructions
Safety instructions
General
Read and observe the following safety instructions below before
starting to work with the machine:
• Service position, page B:4
• Hydraulic system, depressurising, page B:5
• Oils, page B:5
• Fuel system, page B:6
• AdBlue, page B:7
• Clothing, etc., page B:7
• Several mechanics on the same machine, page B:8
• Working under the machine, page B:8
• Lifting heavy components, page B:9
• Vibration, page B:9
• Noise, page B:9
• Dissolvent, page B:10
• Fire and explosion risk, page B:11
• Fluid or gas under pressure, page B:14
• Coolant, page B:14
• Refrigerant, page B:15
• Air pollution, page B:15
• Tensioned springs, page B:16
• Electric motors, page B:16
• Rotating components and tools, page B:17
• Tyres and rims, page B:17
• Lifting equipment, page B:18
• Spare parts, page B:19
• Non-ionised radiation, page B:20
Service position
General
General
Service position is used for service, maintenance and other situations

when the machine needs to be secured.
Service position entails:

• The machine is parked, i.e. parking brake applied.
014404
• Forks and trolley in totally lowered position.

• Engine off.
Machine with forks and lifting carriage in totally lowered
position • System voltage switched off (with the battery disconnector).

B Safety – Safety instructions B:5
Hydraulic system, depressurising

1 Machine in service position see Service position, page B:4.
2 Depressurise the hydraulic system by opening the drain valve on

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

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

AdBlue
handling AdBlue.
CAUTION
AdBlue can cause irritation in the event of contact with
the skin and eyes and inhalation.
Health hazard!
Handle with care and avoid skin contact, wear protective
gloves. In the event of skin contact and spillage on
clothing, rinse the skin with large amounts of water and
change contaminated clothing and gloves. In the event
of contact with the eyes, rinse thoroughly with water for
several minutes and seek medical advice if necessary.
If inhaled, breathe fresh air and seek medical advice
if necessary.
CAUTION
AdBlue spilled on hot components evaporates quickly.
Irritation of the eyes and respiratory system.
Turn your head away. Vaporised AdBlue can act
corrosive to eyes and mucous membranes in the throat.
In the event of contact with the eyes, rinse thoroughly
with water for several minutes and seek medical advice
if necessary. If inhaled, breathe fresh air and seek
medical advice if necessary.
IMPORTANT
Do not spill AdBlue on the ground and in water.
Spillage on the ground must be absorbed with sand or
other absorbent non-combustible material.
Clothing, etc.
Clothes should be in good repair. Remove loosely hanging garments
(e.g. tie, scarf). Do not wear clothes with wide sleeves, wide trouser
legs, etc.
Remove jewellery as it may conduct electricity and get caught in

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

Several mechanics on the same machine
WARNING
If several mechanics are working on the same vehicle,
extra care must be taken so that accidental movements
do not injure any other person. Communicate so that
everyone knows where everyone is, and what they are
doing.
Risks
Work with wheels or axle suspension, mountings, etc., may result in
components on the other side moving and causing damage or injury.
Operations controlled from the operator's station, e.g. all movement of

lifting equipment, may cause severe personal injury.
Safety precautions
• Make sure that the machine's lifting equipment is completely
lowered or secured in some other way.
• Move the battery disconnector to position zero and remove the key.
• Be aware of the risks when several persons are working around
the vehicle.
• Make your co-workers aware of what you are working with.
• Do not work with the drive wheels on the both sides of the machine
at the same time.
Working under the machine
Working under cab
There must be no loose objects in a cab when tilted.
The cab must always be tilted to its end position and secured with
a stopping device.
If the work requires that the cab not be tilted to its end position or if
working on the cab suspension, the cab must always be secured with
a stopping device.
On machines with raisable cab, the cab must be secured in the raised
position with the lock for this purpose.
Working under the frame
A raised vehicle may not, for any reason, be supported or raised in

parts that belong to the wheel suspension or steering. Always support
under the frame or wheel axle.
Risks
Mechanical or hydraulic tools and lifting devices may fall over or
accidentally lower due to malfunctions or incorrect use.
Safety precautions
• Use axle stands and supports that stand securely.
• Lifting tools should be inspected and type approved for use.

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

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

back and forth, which can cause severe crushing injuries or material
damage.
Safety precautions
Lifting with lifting device. Use lifting tools or other tools, in particular
when there are such tools available adapted for specific work
operations. See the 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 often good protection to reduce crushing
and cutting injuries to fingers.
• Always use protective shoes.
Vibration
Use of vibrating tools, e.g. impact nut runner or grinder, for an extended
period of time may cause injuries as vibration is transmitted from the
tool to hands. In particular when fingers are cold.
Safety precautions
• Use heavy gloves that protect against the cold and the transfer of
vibrations.
• Switch between work duties to give the body time to rest.
• Vary your work position and grip so that your body is not affected
in only one position by the vibration.
Noise
Noise louder than 85 dB (A) that lasts for longer than 8 hours is
considered to damage hearing. (Limit values may differ between
different countries.) High pitches (high frequencies) do more damage
than low pitches with the same sound level. Noise in the form of
impulse sounds may also be damaging, e.g. hammer strikes.

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

damage to the central nervous system. This manifests itself in
sleeping problems, depression, nervousness, poor memory and
general tiredness. Continuous inhalation of petrol and diesel fumes is
suspected to cause cancer.
Safety precautions
• Avoid inhaling dissolvent fumes by providing good ventilation, or
wearing a fresh-air mask or respiratory device with a suitable filter
for the toxic gases.
• Never leave a dissolvent container without tight-sealing lid.
• Use dissolvents with a low content of aromatic substances. This
reduces the risk of injury.
• Avoid skin contact.
• Use protective gloves.
• Make sure that work clothes are dissolvent-resistant.

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

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

transmission, keep in mind that the oil may be hot and cause burn
injuries.
Welding on or in the vicinity of the machine. If diesel or other oils

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

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

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

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

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

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

Fluid or gas under pressure

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

it falls against a hard surface. Gas may jet out from damaged valves.
Risks
Risk of damage/injury in connection with work on:

• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Tyre changing.
• Air conditioning.
• Cooling system.
Safety precautions
• Use protective goggles and protective gloves.
• Never work in a pressurised system.
• Never adjust a pressure limiting valve to a higher pressure than
the manufacturer's recommendations.
• A hydraulic hose that swells, e.g. at a connection, shows evidence
that it is about to rupture. Replace it as soon as possible! Check
the connections thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• A discarded pressure accumulator must first be depressurised and
then punctured before it is discarded (to avoid risk of explosion).
Carefully, drill a hole with 3 mm diameter after depressurising.
• Never use your hands to check for any leaks. A fine jet from a
hydraulic hose may have such high pressure that it easily cuts
through e.g. a hand and causes very severe injuries.
• First open the cooling system cap for the filling point slowly, so
that the high pressure is released. Exercise caution. Hot steam
and coolant may jet out.
Coolant
The coolant in the machine's cooling system consists of water,
anti-corrosion compound and anti-freeze fluid, for example, ethylene
glycol.
Coolant must not be drained into the sewer system or directly onto
the ground.
Risks
The cooling system is at high pressure when the engine is warm. Hot
coolant may jet out and cause scalding in the event of leaks or when
the cap on the expansion tank (filling point) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous

and hazardous to health.

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

accredited/authorised and trained personnel in accordance with
national legislation and local regulations.
Risks
The air conditioning operates at high pressure. Escaping refrigerant

can cause frostbite.
Refrigerant that is heated (e.g. when repairing leaking climate/AC

system), generates gases that are very dangerous to inhale.
Safety precautions
• Use special instructions and equipment for refrigerant according to
the manual when working on the air conditioning system. Special
certification and authorisation must often be held by the person
who may do the work. (Observe national legislation and local
regulations!)
• Use protective gloves and protective safety glasses if there is
a risk of leaks.
• Make sure that heat-producing sources or objects are not close by
(cigarette glow, welding flame).
Air pollution
Air pollutants are the impurities in the air around us and are regarded
as hazardous to health. Certain impurities are more prevalent in
certain environments.
The following health-hazardous air pollution is particularly prominent in

workshops:
• Carbon monoxide (fumes) is contained in exhaust gases.
Odourless and therefore particularly dangerous.
• Nitrogen oxides (nitrous gases) are present in exhaust fumes.
• Welding smoke is particularly hazardous to health when welding
on oily surfaces, galvanised or lacquered materials.
• Oil mist for example, is formed when applying anti-corrosion
agent.
• Grinding dust and gases are generated when grinding and
heating plastics, lacquer, anti-corrosion agents, lubricants, paint,
etc.
• Isocyanates 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 present
in aerosol) when cutting, grinding or welding. May cause mucous
membrane irritation with asthma-like symptoms and impaired lung
function. Even brief exposure to high concentrations may cause
problems with persistent hypersensitivity.
Safety precautions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are
formed.
• Use suitable protective gloves and breathing protection when there
is a risk of oil mist. Make sure that the protection is oil-resistant.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eyewash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine in the workshop.
Connect extraction equipment to the exhaust pipe so that exhausts
are routed out from the workshop.
Tensioned springs
Examples of tensioned springs:
1. Torque springs in, e.g. pedals
2. Thrust spring (cup springs) in parking brake cylinder
3. Lock rings
4. Gas springs
Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries amongst other things.
Parking brake springs are tensioned with high force and can cause very
severe accidents if they are accidentally released in an uncontrolled
manner.
Gas springs and gas-charged shock absorbers are tensioned with high
force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety precautions
• Use protective safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manuals when performing
maintenance and replacing parts and components.
• Always use the tools recommended.
Electric motors
Safety precautions
Always switch off the battery disconnector when working on electric
motors.
Always block the machine's wheels, make sure that the parking brake
is activated and that the gear selector is in neutral position before
starting any work on the machine.

Rotating components and tools

Examples of rotating components and tools:
• Cooling fan
• Drive belts
• Propeller shafts
• Drills
• Grinding machines
Risks
Rotating components, e.g. fans or shafts, can cause severe injury

if touched.
Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothing or hair gets caught and becomes wound
into the machine.
Safety precautions
• Do not use gloves when working with a drill.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or trouser legs.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair net or similar.
• Remove large or loose hanging jewellery from hands, arms and
neck.
Tyres and rims
DANGER
Tyres should be regarded as pressure reservoirs. If
handled incorrectly, they constitute fatal danger.
Parts could be thrown out with explosive force and
cause severe injuries.
Never repair damaged tyres, wheel rims or lock rings.
Tyre changes must be performed by authorised
personnel.
Risks
Dismantling of wheels: Tyres, rims and lock rings may be ejected.
Inflating of tyres: Tyres, rims or lock rings may be ejected.
Safety precautions
• Always deflate the tyre before starting to work on the wheel.
• Check that tyres, rims and lock rings are not damaged. Never
repair damaged wheel rims or lock rings.
• Wheels shall be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
• Use protective screen and protective safety glasses.

Lifting equipment
When working on the machine in general, and with the machine's lifting
equipment in particular, the greatest caution must be exercised with
respect to securing the mast and carriage.
Always make a habit of lowering the carriage to its lowest position

before working on the machine.
Risks
If the machine's lifting equipment is not lowered or secured, there is a

risk of crushing.
Risk of crushing is particularly great when depressurising the hydraulic

system, see Hydraulic system, depressurising, page B:5.
Safety precautions
Do not begin work until the carriage has been fully lowered. If the
nature of the work requires the carriage to be raised then this must
be secured in some way.

Spare parts
WARNING
For safety reasons, the following spare parts may only
be replaced with genuine spare parts:
• Brake valve
• Drive axle
• Valve for mini-wheel/joystick control
• Steering valve (Orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Rim
• Solid wheels
• Control valve, hydraulic servo
• Mast, carriage
• Lift cylinder incl. load control valve
• Separate load control valve
• Lifting chains
• Chain tightener and shaft
• Forks, fork carrier
• Lift cylinder
• Tilt cylinder
• Twistlock
• Control breaker (for hydraulic function)
• Hydraulic cylinders, cab tilt
• Accumulator
• Tilt valve
• Main valve load handling
• Accumulator charging valve
• All control units

Non-ionised radiation
WARNING
Optional equipment such as two-way radio, RMI,
telephone, etc. may emit non-ionising radiation.
Risk of interference with active or non-active medical
products.
Use two-way radio, RMI, telephone, etc. when no
persons with active or non-active medical products are
in the vicinity.
NOTE
When persons with active or non-active medical products are not
nearby, telephone and two-way radio may be used in the cab.
Equipment should not be used during operation or load handling as
this takes away from the operator's concentration.
Cargotec will not assume any responsibility for installed optional
equipment, which is not installed by Cargotec or an installer
approved by Cargotec.

B Safety – Environment B:21
Environment
General
The ever-increasing industrialisation of our world is having a significant
impact on our global environment. Nature, animals and people are
subjected daily to risks in connection with various forms of chemical
handling.
There are still no fully environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle, perform
service on or repair machines must use the tools, assisting devices and
methods necessary to protect the environment in an environmentally
sound manner.
By following the simple rules below, you will contribute to protecting

our environment.
Recycling
Conscientious recycling of the machine is the starting point for the life
cycle to come full circle, and for being able to recycle and make use of
material in new products. According to calculations by Cargotec, the
machine is more than 90% recyclable by weight.
Environmentally hazardous waste
Components such as batteries, oils, and various chemicals and other

items that may constitute environmentally hazardous waste must be
handled and taken care of in an environmentally safe and sound
manner.
Discarded batteries contain substances hazardous to personal health

and the environment. Therefore, handle batteries in an environmentally
safe manner and according to national regulations.
Oils and fluids
Oils freely discharged cause environmental damage and can also be a

fire hazard. Therefore, when emptying and draining oils or fuel, take
appropriate action to prevent unnecessary spills.
Waste oils and fluids should always be taken care of by an authorised

disposal company.
Pay close attention to oil leaks and other fluid leaks! Rectify leakage
immediately.
Air conditioning
The refrigerant in the air conditioning for the cab adds to the
"greenhouse effect" if released into the open air. Special training is
required for all service work on the air conditioning. Many countries
also require certification by a governing authority for such work. When
scrapping an air conditioning unit, the refrigerant shall be taken care
of by a certified company.
Working in a contaminated area
The machine must be equipped for work in contaminated areas

(environmentally polluted or health-hazardous area) before work is
started. Also, there are special local rules in force for such handling
and when servicing such a machine.

B:22 B Safety – Environment
Declarations
The machine does not contain asbestos.
The machines contains lead in batteries and in electric cabling. In

certain models, there are lead castings as counterweight.
If the machine is equipped with air conditioning, refrigerant of type

R134a is used, in an amount totalling between 1-3 kg.

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

section A Foreword.

C:2

0:1
0 Complete machine
Contents 0 Complete machine

Complete machine..............................................................................................0:3

0:2

0 Complete machine – Complete machine 0:3
0 Complete machine
Complete machine, description
Kalmar DCF 180-250 is a fork-lift truck. The machine has a lifting
capacity of 18-25 tonnes depending on the model.
The engine is a six-cylinder four-stroke direct injection diesel engine.
The transmission is hydro-mechanical with gears constantly in mesh.
It has three forward gears and three reverse gears. Engine power is
transmitted using a torque converter.
The driveline/axle consists of propeller shaft and a rigid drive axle with
hub reduction. Drive takes place on the front wheels.
The service brakes are wet multiple disc brakes which are attached to
the drive wheel hub. The parking brake is the disc brake type and
operates on the drive axle input shaft.
Steering operates on the rear wheels with a double acting hydraulic
cylinder. The steering axle is suspended in the frame with pendulum
suspension.
The wheels are mounted on the hubs with nuts and washers. Double
wheels are fitted on the drive axle; single wheels on the steering axle.
The wheel rims are detachable.
Load handling comprises components and functions for handling loads.
The load is lifted with forks secured on a carriage fitted onto a mast.
Load handling is divided into lifting/lowering, tilt, side shift, spreading,
levelling and load carrier functions.
• Lifting/lowering is the function for lifting and lowering the trolley.
• Side shifting is to move the forks sideways along the carriage. The
relative distance between the forks is maintained.
• Spreading is adjusting the width between the forks on the carriage.
• Tilt is used to angle the load in the longitudinal direction of the
machine with the help of the mast.
• Levelling is angling the load in the lateral direction of the machine.
• Load carrier function is to hold or grip the load.
The control system consists of functions for warning the operator of
dangerous situations and faults. The control system has diagnostic
resources that simplify troubleshooting.
The frame carries the machine. Mounted in the frame are engine,
transmission, drive axle and steering axle, etc. The sides of the frame
house tanks for fuel, AdBlue and hydraulic oil. The cab is positioned
centrally and can be tilted laterally.
Troubleshooting, general work

instructions
When troubleshooting, it is important that the work is structured
and logical. The purpose of the troubleshooting described in the
maintenance manual is to exclude components as the source of a
fault so that the real source can be identified. A suggested structured
work method is described below.
When troubleshooting, it is important to understand how the machine
functions. Certain faults can be identified directly using function
descriptions. Sections 0–12 contain descriptions of the various
functions of the machine.

0:4 0 Complete machine – Complete 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
• AdBlue
• Engine oil
• Transmission oil
• Hydraulic oil
• Coolant
• Washer fluid
3 Check if there are error codes.
4 If there are error codes, use the error code lists as a guide. See
Troubleshooting with an error code, example, page 0:5.
The error code lists contain recommended actions for every error
code. Error code lists are available in section D Error codes.
5 If there is no error code or the problem persists, use the function

description for the function affected in section 0–12.
The function description contains information on which
components are involved in the function and how these
components work together. In some cases, there is information
on what conditions are required in order for it to be possible to
activate the function. Measurement points are marked with flags
(C for measuring outlet, D for diagnostic menu).
Troubleshooting without an error code,

example
1 Choose suitable section 0–12 to locate the function and
subfunction that have caused the symptom.
2 Read the function description for the function in question to get

an overall understanding of which components are affected and
how these interact.
3 Use the function description and check the signals for the function
affected in order to locate where in the function chain that the
signal or reaction is incorrect.
4 The fault is probably between the two units where the signal is
incorrect. Start by checking the component that should be sending
the signal.
5 If the component that is to send the signal seems to be intact,

check the transmission of the signal (electric cables or hydraulic
hoses).
For electric cables, see Troubleshooting cable harnesses, page
0:6.
For hydraulic hoses, see Troubleshooting hydraulic hoses, page
0:7.
6 If the cables or hoses between the components seem to be intact,

then check the component that receives the signal.

Troubleshooting with an error code,

example
Error codes are indicators of malfunctions detected by the control
system. Many error codes are connected to electrical malfunctions but
there are also error codes that interpret associations between one or
several signals that indicate a non-electrical malfunction. It is important
to not draw conclusions too hastily based on an error code.
1 Read out error codes from the display, e.g. error code 357.
2 Use the error code lists and search information about the error
code, see "Example of error code information in error code list"
below.
The error code lists are available in section D Error codes.
For detailed instructions for reading out error code, see section
D Error codes.
3 Follow the instructions in the field "Action".
4 Use diagnostic menus and circuit diagrams to determine if the

input signal to the control unit is correct; see section 8 Control
system, group 8.4 Diagnostics as well as section E Schematics.
5 Use Last alarms to see which alarm has been saved, see section
8 Control system, group 8.4.5 Last alarms.
6 Use the function group to find more information if needed.

In section 0–12 there is function description, the function's included
components and their position as well as, in certain cases, work
instructions for how components are checked, cleaned or adjusted.
7 If possible, eliminate component faults by testing the component

individually.
Electric components can sometimes be checked with resistance
measurements using a multimeter.
Hydraulic components are usually controlled by measuring the
pressure (which is described in the function group). Sometimes
valves can be activated mechanically in order to determine if the
malfunction is electric or hydraulic.
8 If the component's measurement values are correct, continue by

troubleshooting electric cables and hydraulic hoses.
For electric cables, see Troubleshooting cable harnesses, page
0:6.
For hydraulic hoses, see Troubleshooting hydraulic hoses, page
0:7.
9 If the wiring is not defective, then connect the cable to the control
unit.
NOTE
The system voltage must be switched off with the battery
disconnector!
10 Disconnect the cable harness from the component in question.
11 Switch on the system voltage with the battery disconnector.
12 Turn the ignition key to operating position.
13 Check that voltage reaches the component.

0:6 0 Complete machine – Complete machine
Table Example of error code information in error code list
Error
code Description Limitation Action
357 Brake system, accumulator pressure Reduction of engine speed. Check the accumulator.
low.
Troubleshooting cable harnesses
NOTE
Perform troubleshooting for all cables in the same way to avoid
damage to control units, components or measuring equipment.
1 Study the circuit diagram in question, check where the suspected

cable is connected and if, and if so where, it is spliced.
2 Turn off the system voltage with the battery disconnector.
3 Unplug the connector at the control unit or component in question.
CAUTION
Wipe and re-grease the connectors.
Risk of corrosion on contact surfaces.
Clean all connectors loosened during troubleshooting
using electronic cleaner 923836.0826 and re-grease
them with connector grease 923836.0552.
4 Check if there is an open circuit.
NOTE
Some components cannot be checked without power supply to
the component. In such an event, proceed to point 5.
a. Measure resistance between connections to the component in

the connector at the control unit or component.
b. The resistance must correspond with the component.
Otherwise there may be an open circuit or short circuit in
cable harness and/or component.
5 Check if there is a short circuit to the frame:

a. Unplug the connector at both the control unit and the
component in question.
b. Measure the resistance in one cable at a time. Measure
between the cable and a frame-connected part of the machine.
c. The multimeter should show infinite resistance.

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

Safety.
2 Study the hydraulic diagram in question, check between which

components the suspect hose is connected and if, and if so where,
it is spliced.
3 Locate the hose on the machine.

Start at one component and follow the hose to the next component.
4 Inspect the entire hose and splicing points with respect to chafing
damage, pinching damage and leaks.
Replace damaged hoses. When removing a hydraulic hose,
O-ring replacement is always recommended on the hoses that
have them fitted (ORFS).

0:8

1:1
1 Engine
Contents 1 Engine
1 Engine..................................................................................................................1:3
1.1 Controls and instruments ...............................................................................1:22
1.1.1 Ignition.......................................................................................................1:22
1.1.2 Accelerator ................................................................................................1:22
1.2 Fuel system....................................................................................................1:23
1.2.1 Fuel tank ...................................................................................................1:23
1.2.2 Sensor fuel level........................................................................................1:24
1.6 Air intake and exhaust outlet..........................................................................1:25
1.6.1 Air cleaning system ...................................................................................1:25
1.6.3 Exhaust system .........................................................................................1:25
1.6.4 Intercooler .................................................................................................1:26
1.6.8 SCR system ..............................................................................................1:27
1.6.9 Pipes and hoses........................................................................................1:29
1.7 Cooling system ..............................................................................................1:30
1.7.4 Radiator and expansion tank ....................................................................1:31
1.7.5 Cooling fan ................................................................................................1:33
1.7.7 Coolant ......................................................................................................1:33
1.7.8 Coolant level sensor..................................................................................1:37
1.7.10 Engine heater ............................................................................................1:37
1.9 Control system, engine ..................................................................................1:38
1.9.1 Engine control unit ....................................................................................1:38
1.11 Start/stop........................................................................................................1:39
1.11.1 Starter motor .............................................................................................1:39
1.11.2 Stopping device.........................................................................................1:40
1.11.3 Automatic engine stop 5 minutes after driver's seat is empty ..................1:40
1.11.5 Warning and engine power limitation ........................................................1:40

1:2

1 Engine – Engine 1:3
1 Engine
Engine, general
The machine is equipped with the Volvo TAD761VE.
Component supplier documentation
The workshop manual only describes components and work
descriptions that concern installation in the machine. For descriptions
and instructions for the engine's components and systems, refer to the
relevant supplier documentation.
References to supplier documentation are only provided in exceptional

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

1:4 1 Engine – Engine
Engine, function description

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

Engine heater with Disconnected (start lock-out is activated when cable is Engine heater, description, page 1:37
start lock-out connected).
0
P I
II
III °C
bar
D15 D9 .
9 <° D1 1,4 rpm

<°
15 kph
5,10,16,21
ECU790
EDU795 F
14,17,20 N
R
1
19 4 5
ECU793 ECU794 UDS

2,6,11,13,22,31 24,27,28,30
18 7 M 3 8 SENSORS 12 H2O
M
23 26
29
014282
25
Pos Explanation Signal description Reference

1 The ignition sends a voltage signal U = 24 V Section 9 Frame, body, cab and accessories,
to all control units (ECU) when the group 9.1 Controls and instruments.
ignition key is turned to position
1 and preheats the primary air if
needed.
2 If preheating has been activated with U = 24 V See section 11 Common electrics, group 11.5.3
the ignition key, the engine control Engine control unit
unit (ECU794) feeds voltage to the
preheating coil via a preheating relay.
3 The preheating element warms the - -
engine intake air.
4 The ignition key lock sends a voltage U = 24 V Section 9 Frame, body, cab and accessories,
signal to the general control unit group 9.1 Controls and instruments.
general (ECU790) when the ignition
D4: Diagnostic menu, see section 8 Control
key is turned to the start position.
system, group 8.4.1.1 View inputs, menu 2,
ECU790 input K1:17.
5 Control unit general (ECU790) sends - See Section 11 Common electrics, group 11.6
start signal on the CAN bus. communication


6 The engine control unit (ECU794) U = 24 V -
supplies power to the starter motor.
7 The starter motor cranks the engine. - -
8 The engine sensors send signals to - See section 11 Common electrics, group 11.5.3
the engine control unit (ECU794), Engine control unit
which controls the injectors so that
the engine starts.
9 Throttle pedal sends voltage signal U = 0.5-4.5 V Section 9 Frame, body, cab and accessories,
proportional to downward pressing group 9.1 Controls and instruments.
Lower voltage than 0.5 V
to Control unit general (ECU790).
and higher voltage than D9: Diagnostic menu, see section 8 Control
4.5 V is used to detect system, group 8.4.1.1 View inputs, menu 4,
faults in cable harnesses ECU790 input K1:26.
and controls.
10 The general control unit (ECU790) Checked by control See section 11 Common electrics, group 11.5.3
sends an rpm request message to system, error shown with General control unit
the engine control unit (ECU794) error code.
See Section 11 Common electrics, group 11.6
on the CAN-bus via display unit
communication
(EDU795).
11 The engine control unit (ECU794) - See section 11 Common electrics, group 11.5.3
increases engine rpm. Engine control unit
12 Sensor coolant level sends a U=5V Sensor coolant level, description, page 1:37
voltage signal to Control unit, engine
(ECU794) if the coolant level is low
in the expansion tank.
13 The engine control unit (ECU794) Checked by control See Section 11 Common electrics, group 11.6
transmits engine data and warning system, error shown with communication
messages on the CAN bus. error code.
14 Control unit terminal (EDU795) - Section 9 Frame, body, cab and accessories,
shows engine data via display group 9.1 Controls and instruments.
figures.
15 Sensor, fuel level (B757) sends a R = 4–73 ohm Sensor, fuel level, description, page 1:24
resistance signal proportional to
the fuel level in the tank to Control
unit, general (ECU790). An alarm
ECU790 input K2:08
is shown in the display if the fuel
level is below 15% for more than 40
seconds.
16 The general control unit (ECU790) Checked by control See Section 11 Common electrics, group 11.6
transmits low fuel level on the CAN system, error shown with communication
bus. error code.
17 The terminal control unit (EDU795) - Section 9 Frame, body, cab and accessories,
shows the fuel level in the operating group 9.1 Controls and instruments.
menu.
18 Speed limitation - See Supplier documentation, transmission
The output shaft speed sensor
(B758) sends the general control
unit (ECU793) pulses with frequency
proportional to the rpm of the output
shaft.
19 The transmission control unit Checked by control See Section 11 Common electrics, group 11.6
(ECU793) transmits speed on CAN system, error shown with communication
bus. error code.
20 The terminal control unit (EDU795) - See section 11 Common electrics, group 11.5.3
shows speed in the display. Terminal control unit


21 If output shaft speed is so high that it - See Section 11 Common electrics, group 11.6
is at the machine's speed limitation communication
limit, then Control unit, general
(ECU790) sends reduce rotation
speed on the CAN bus.
22 Control unit, engine (ECU794) - See section 11 Common electrics, group 11.5.3
reduces rotation speed until it is Engine control unit
correct.
23 AdBlue level and temperature sensor U = 0.5-4.5 V SCR system, description, page 1:27.
sends Control unit SCR (UDS) a
voltage signal proportional to the
AdBlue level and temperature in the
tank.
24 In the event of cold AdBlue, Control U = 24 V SCR system, description, page 1:27.
unit SCR (UDS) voltage feeds the
water valve.
25 The water valve leads warm water to - SCR system, description, page 1:27.
the AdBlue tank to heat it.
26 Exhaust gas temperature sensor U = 0.5-4.5 V SCR system, description, page 1:27.
sends Control unit SCR (UDS) a
voltage signal proportional to the
temperature of the exhaust gases.
There is a damper located after the
intercooler that helps to increase
the temperature of the exhaust gas
when necessary.
27 The NOx sensor continuously U = 0.5-4.5 V SCR system, description, page 1:27.
measures the amount of nitrogen
oxide in exhaust gases and sends
the voltage signal to the Control unit
SCR (UDS).
28 The Control unit SCR (UDS) voltage U = 24 V SCR system, description, page 1:27.
feeds the AdBlue pump.
29 The AdBlue pump pumps AdBlue - SCR system, description, page 1:27.
from the AdBlue tank. The right
amount of AdBlue is injected into
the silencer inlet depending on
the amount of nitrogen oxides in
exhaust gases. AdBlue and exhaust
gases are mixed before passing the
catalytic converter (SCR), which is
located centrally in the silencer.
30 If the levels of nitrogen oxides in - SCR system, description, page 1:27.
the exhaust gases are too high, the
Control unit SCR (UDS) sends a
request to the engine Control unit
(D794) on the CAN bus to restrict the
engine speed.
31 Control unit, engine (D794) limits the - See section 11 Common electrics, group 11.5.3
engine speed. Engine control unit

Engine, component position
4
6
3 7
2
9
1
10
11
12
13
14
15
16
17
18
014761
19
21 20
Volvo TAD761VE left side (in machine's direction of travel)
1. Sensor flywheel speed 12. Fuel filter
2. Crankcase ventilation 13. Sensor fuel pressure
3. Filling point engine oil 14. Control unit, engine (D794)
4. Injector and preheating (6 pcs.) 15. Sensor oil pressure
5. Sensor coolant level (B757) 16. Oil plug
6. Sensor coolant temperature 17. Dipstick
7. Thermostat housing 18. Fuel pre-filter
8. Alternator 19. Sensor water in fuel
9. Water pump 20. Water separator
10. Fuel pump 21. Sensor camshaft rpm
11. Oil filter

4
3
2 5
1
11
10
014762
9
8
Volvo TAD761VE, right side (in machine's direction of travel)
1. Expansion tank 7. Starter motor
2. Filling coolant 8. Intercooler
3. Air preheating downstream of intercooler 9. Condenser
4. Sensor charge air pressure and temperature 10. Transmission oil cooler
5. Sensor fuel pressure (distribution pipe) 11. Radiator, engine
6. Turbo

1 2 3 4 6
12
0
11 P I
II 7
8 III
014408
10
Machine electrical components

1. Steering control unit (ECU792) 8. Accelerator
2. Control unit hydraulics (ECU796) 9. Fuse (15A), control unit engine (ECU794), located
on the flywheel housing
3. Control unit general (ECU790)
10. Fuse (30A), control unit SCR and AdBlue pump,
4. Fuel tank
located on the flywheel housing
5. Sensor fuel level (B757)
11. Transmission control unit (ECU793)
6. Control unit terminal (EDU795)
12. Control unit engine (ECU794)
7. Ignition

Engine, replacement
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Remove the partition wall between the engine compartment and the
cab.
a) The air cleaner is mounted on the partition wall.
Release the hose connection from the turbocharger.
Protect the air inlet to the engine and the hose with a seal, e. g.
a plastic bag.
b) Disconnect the electrical connection for control unit, transmission

(ECU 793) that is fitted on the partition wall.

c) Fuel hoses, remove the fuel pipes for the fuel pre-filter.
Plug all connections immediately to protect the fuel system from
impurities.
NOTE
Drain and collect liquids before detaching hoses.
d) Undo the four screws for the partition wall.

Lift away the partition wall.
3 Disconnect the requisite hoses and cables before lifting out the engine
and transmission.
NOTE
a) Cables, undo the connector by the engine control unit (ECU794)

and remove the cables.

b) Engine grounding, loosen the screw on the right-hand side of

the machine.
014914
c) Detach the hydraulic connections for the cab tilting cylinder and
the tank connections from the steering and brake valve.
d) Drain the AC system and disconnect the hose that is routed from
the compressor to the cab.
Disconnect the hose from the condenser as well.
014919
e) Detach the pipe from the turbocharger.

f) Support under the SCR catalyst and detach the brackets.
014920
g) Drain the hydraulic oil tank.

Mark up and detach the hydraulic hoses from the pumps.
Also remove the servo hoses for control valve, load handling,
which is in the way when the engine package is lifted.
NOTE
Plug all connections immediately to protect the hydraulic system
from impurities.
4 Connect lifting equipment to the engine and transmission.

5 Take up the slack in the hoisting equipment.
NOTE
Do not lift the engine.
014923

6 Loosen the screws in the engine brackets on both sides.
014886
7 Detach the transmission brackets from both sides of the

transmission.
014864
8 Detach the universal drive shaft from the transmission.

9 Lift out the engine and transmission.
10 Lift the engine away.
014863
NOTE
Beware of balance before the engine is lifted.

Separating engine and transmission

11 Remove the plugs in front of the flywheel on the right-hand side
of the engine.
Use the outer hole to turn the engine round.
12 Remove the flex plate's fastening bolts (x4). Rotate the engine
(use Volvo special tool 999 3590), until the flex plate's screws are
visible in the inner hole. The flex plate has four attachment points
to be loosened.
NOTE
Turn the engine over to access each screw on the flex plate.
014343
13 Remove the bolts (x12) between engine and transmission.

14 Separate the engine and transmission.

NOTE
If the flex plates are damaged during engine replacement, they
must be replaced.
15 Move the engine brackets from the removed engine to the new
engine. Torque tighten to 220 Nm.
014887
Assembling the engine and transmission

16 Apply lubricating grease to the converter connection - both on the
engine and the transmission.
17 Insert two studs into the flywheel housing as a guide when the
engine is installed.

18 Check that the clips are aligned directly over the holes in the flex
plate.
19 Align one of the holes on the flywheel so that it is centred in the

inner hole in the flywheel housing.
20 Lift the transmission into place. Make sure that the studs on the
flywheel come into correct alignment and do not damage the flex
plate.
NOTE
If the flex plates are damaged during engine replacement, they
must be replaced.
21 Install the bolts that affix the transmission and engine, but do
not tighten the bolts fully. Leave about a millimetre between the
engine and transmission to facilitate installation of the nuts for the
flex plate/flywheel.
22 Fit the nuts that fix the flex plates at the flywheel in two steps. First
fit the nuts without tightening. Then rotate the flywheel one more
revolution and torque tighten the nuts to 40 Nm (oiled screw).
NOTE
23 Tighten the bolts that attach the transmission and engine.

Radiator
24 Loosen the radiator's hose connections from the old engine,
loosen the attachment and transfer the radiator to the new engine.
Connect the radiator's hoses to the engine.
Reassembly in the machine
25 Connect lifting equipment to the engine and transmission and lift
them into place.

26 Fit the screws in the engine bracket.

Torque tighten to 169 Nm.
014886
27 Screw the transmission into the transmission brackets. (Tighten to

a torque of 169 Nm). Refit the universal drive shaft.
28 Remove the hoisting equipment from the engine.
29 Connect hoses and cables as necessary.
30 Refit the partition wall between the engine compartment and the
cab.
31 Fill the hydraulic oil system and air conditioning.
32 Check and top up fluids as necessary.
33 Bleed air from the engine's fuel system before starting.
014866
34 Connect hoses and cables as necessary.

a) Plug in the connector at Control unit, engine (ECU794).
b) Connect the engine's ground to the right-hand side of the machine.

c) Connect the hydraulic connections for the cab tilting cylinder and
the tank connections from the steering and brake valve.
d) Connect the hose to the compressor (from the cab).

Connect the hose to the condenser as well.
014919
e) Connect the pipe to the turbocharger.

f) Attach the SCR catalyst to the engine.
014920
g) Connect the hydraulic hoses in accordance with the markings.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
35 Refit the partition wall between the engine compartment and the cab.
a) Affix the four screws for the partition wall.

b) Connect the hose connection to the turbocharger.
c) Connect the electrical connection for control unit, transmission

(ECU 793) that is fitted on the partition wall.
d) Connect the fuel pipes to the fuel pre-filter.

1:22 1 Engine – Controls and instruments
1.1 Controls and instruments

1.1.1 Ignition
Ignition key lock, replacement
2 Remove the steering wheel and steering panel covers; see section
9 Frame, body, cab and accessories, group 9.1.1 Multi-function
lever.
3 Unplug the connector from the ignition key lock.

4 Replace the ignition key lock.
5 Refit in the reverse order.
008398
NOTE
Torque tighten the nut in the centre of the steering wheel to 40 Nm
(±5 Nm).
1.1.2 Accelerator
Accelerator pedal, replacement
2 Remove the three screws that hold the accelerator to the floor.
1 3 Undo the accelerator pedal connector.
4 Remove the accelerator pedal.
5 Fit in reverse order.
NOTE
The accelerator pedal is factory calibrated, but must to be
recalibrated after replacement.
3
006083
1. Accelerator
2. Screws
3. Contact
Accelerator pedal, calibration

See section 8 Control system.

1 Engine – Fuel system 1:23
1.2 Fuel system

Fuel system, description
The fuel tank is located on the left-hand side of the machine and is
equipped with a sensor for the fuel level. The amount of fuel in the tank
is shown in an operating menu on the display in the cab. Fuel prefilter
with water trap and fuel filter are on the engine. The water trap is
equipped with electrical indication, an error code appears in the display
when the water trap must be emptied of water.
For component locations, see the section 1 Engine.
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can injure
the skin, resulting in severe injuries.
Risk of personal injury.
Use protective gloves and protective safety glasses,
avoid skin contact with fuel. If a component is being
loosened then hold a rag over the connection as
protection and collect the fuel. Fuel acts corrosive to
eyes and skin, and mucous membranes in the throat.
1.2.1 Fuel tank

Fuel tank, description
The fuel tank consists of a separate unit that is screwed in the frame.
The fuel tank is located on the left-hand side of the machine.
2
1
3
014210
1. Fuel filling
2. Drain plug, under tank
3. Fuel tank

1:24 1 Engine – Sensor fuel level
1.2.2 Sensor fuel level

Sensor, fuel level, description
The sensor is inserted into the fuel tank from above.
1 Sensor, fuel level (B757) sends a resistance signal proportional to the

fuel level in the tank to Control unit, general (ECU790). An alarm is
shown on the display if the fuel level is below 15% for more than
40 seconds.
014888
1. Sensor fuel level
Fuel level sensor, checking

The sensor can be checked with a multimeter and by measuring the
resistance which should be 4-73 ohm during movement of the float
from the highest to the lowest level on the sensor.
Sensor fuel level, replacement

2 Open the hood.
3 Separate the connector and release the cable.

4 Unscrew the sensor.
5 Screw in a new sensor. Assemble the connector and attach the
cable with a cable tie.
008320
1. Sensor fuel level

1 Engine – Air intake and exhaust outlet 1:25
1.6 Air intake and exhaust outlet

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

fresh air and exhaust gases is essential for efficient engine operation.
Particles are collected in the filter material when the air filters clean
the air to the engine. Over time, a great deal of particle matter is
collected and the filter does not let through sufficient air for efficient
combustion, the filter must then be changed. The filter indicator
A measures the negative pressure on the engine side of the filter. When
the filter is clogged the negative pressure is higher and the indicator
indicates that it is time to replace the filter.
014077
C B
Air cleaning system overview, engine alternative Volvo

A Position for air filter reservoir
B Filter indicator
C Dust reservoir
1.6.3 Exhaust system

Exhaust system, description
The exhaust system is mounted in the frame. Heat protection is fitted
between the engine and exhaust system to protect cables, etc. A flex
pipe between the turbo and silencer takes up engine movement. On
the outside of the machine, there is heat protection fitted over the
exhaust system.
WARNING
Hot exhaust system!
Risk of burn injuries!
Never touch the turbo, silencer or catalytic converters
when the machine is running or just after it has been
turned off!

1:26 1 Engine – Intercooler
Exhaust outlet, component location

1. End pipe with heat protection
2. Connection to turbocharger
3. Flex pipe
4. Exhaust pipe
5. SCR catalyst
3
5
4
015647
1.6.4 Intercooler
Intercooler, description
The charge air is cooled by an air-air intercooler in the upper part
of the cooling unit.
See also Cooling system, description, page 1:30.

014471
1
Cooling unit
1. Intercooler

1 Engine – SCR system 1:27
Intercooler, replacement
2 Removing the radiator assembly; see Radiator, replacement, page

1:32.
3 Remove the bolts which secure the fan shroud.
4 Remove the radiator section by undoing the screws.
1.6.8 SCR system

SCR system, description
SCR technology (Selective Catalytic Reduction) - catalytic converters -
are used to meet statutory emission requirements.
Diesel engines with even more efficient combustion in combination

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

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

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

1:28 1 Engine – SCR system
SCR system, component placement
2
1
6
11
9 8
10
014288
1. NOx sensor 7. Sensor level and temperature AdBlue
2. SCR catalyst 8. Exhaust pipe
3. Catalyst 9. AdBlue tank
4. End pipe 10. Control unit SCR (UDS) with AdBlue pump and filter
5. Heat protection 11. Water valve
6. Injection unit

1 Engine – Pipes and hoses 1:29
1.6.9 Pipes and hoses

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

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

1:30 1 Engine – Cooling system
1.7 Cooling system

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

• Coolant pump, located in the engine.
• Expansion tank, located in the engine compartment.
• Thermostat, located in the engine
• Cooling fan, located in front of the radiator
• Engine oil cooler, located in the engine
• Transmission oil cooler, part of cooling unit (centre).
• Water cooler, part of the cooling unit (to the far left)
• Intercooler, part of the cooling unit (to the far right)
Engine cooling work as follows:

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

1 Engine – Radiator and expansion tank 1:31
1.7.4 Radiator and expansion tank

Radiator and expansion tank, description
Radiator for the engine is located in the cooling unit which is placed
1
behind the engine.
The function of the cooler unit is to cool:

• The engine's coolant (cooled in position 5).
• The transmission's oil (cooled in position 4).
See also section 2 Transmission, group2.6.3 Oil cooler.
• Charge air (cooled in position 2).
See also Intercooler, description, page 1:26.
See also Cooling system, description, page 1:30.
4
014826
3
2
Cooling unit
1. Expansion tank
2. Intercooler
3. Condenser
4. Transmission oil cooler
5. Radiator, engine

1:32 1 Engine – Radiator and expansion tank
Radiator, replacement
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.
2 Remove the hood over the engine compartment, see section 9

Frame, body, cab and accessories, group 9.13.2 Hood, engine
compartment.
3 Drain the coolant and transmission oil out of the system.

4 Detach the hoses for intercooler, engine and transmission cooling
and for the radiator's expansion tank.
Also detach the hoses for the condenser .
014897
Drain cock
5 Remove the screws that secure the cooler unit to the frame.
6 Carefully lift the cooler unit out of the frame.

1 Engine – Cooling fan 1:33
1.7.5 Cooling fan

Drive belt, replacement
2 Loosen the belt tensioner and lock it with a drift (position 1).
3 Remove the belt from the coolant pump (position 2) first.
4 Install the new belt.
Let back the belt tensioner and check that the belt is positioned
correctly in the grooves, and that it is tensioned correctly.
1
014242
1.7.7 Coolant
Coolant, changing
Cooling efficiency is impaired due to deposits in the radiator and in the
engine's cooling ducts. Consequently, the system must always be
cleaned when replacing the coolant.
WARNING
The cooling system is pressurised. Steam or hot fluid
may spurt out.
Risk or scalding or burn injuries!
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled before filling.
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid skin contact, wear protective
glasses and protective gloves. In the event of skin
contact, wash your hands.

1:34 1 Engine – Coolant
IMPORTANT
Machines with ECC or AC are equipped with a combined
heating and cooling unit, which can result in a risk of
freezing if the machine is operated without coolant.
Risk of freezing and damage to the heating and cooling
unit!
The electrical connections on the AC compressor must
be disconnected when cleaning the radiator with water
or agents without antifreeze properties.
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.
NOTE
Before draining, stop the engine and remove the filler cap.
Draining
1 Remove the filler cap from the cooling system's expansion tank.
C B A
014063
A Position for coolant reservoir (expansion tank)

B Filling point
C Sight glass

1 Engine – Coolant 1:35
2 Open all drain points. Drain the coolant from the radiator and
engine block using the drainage hose.
The drainage nipples and located on the radiator and on the
right-hand side of the engine block or under the oil cooler.
3 Check that all coolant drains out.
NOTE
Any deposits inside the tap/plug must be cleaned away,
otherwise there is a risk that the coolant may remain and cause
freezing damage.
Let the drainage taps or plugs remain open and make sure that
the heating control is set to full heat while cleaning.
4 Insert a hose in the filler hole in the expansion tank and flush with
clean water, until the draining water is clear.
5 If impurities remain after flushing for a long time, it's possible to
clean with coolant. Otherwise, continue with step Filling point,
page 1:36.
Cleaning with coolant

1 Fill the cooling system. Only use the recommended concentrated
coolant, see tab F Technical data.
2 Drain the cooling system after 1-2 days of operation.
NOTE
Drainage should be performed quickly, within 10 minutes,
without the engine being at a standstill for a long time to prevent
dissolved material from re-entering the cooling system.
Remove the filler cap from the expansion tank and possibly a
lower radiator hose to increase the draining speed.
3 Immediately rinse the system very carefully with clean warm water
to prevent dirt from depositing again on the internal surfaces.
Rinse until the outflowing water is completely clean. Check that
the water valve is fully open when cleaning.
4 Should impurities remain after flushing for a long time, it's possible
to clean with coolant, contact Cargotec Service.
NOTE
Only use cleaning agents approved by the engine manufacturer.
Follow the instructions on the packaging carefully.

1:36 1 Engine – Coolant
Filling point
1 When the cooling system is completely free from impurities, close
the drain valves.
CAUTION
Different types of coolant may not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, the same type
of coolant must be used as was used before.
NOTE
Only use recommended coolant.
2 Fill with the recommended coolant so the level is visible in the

sight glass.
3 Start the engine.

Check that the water valve is fully open in order to bleed the
heating system.
4 Stop the engine after approx. one hour and check the coolant
level, top up if needed.

1 Engine – Coolant level sensor 1:37
1.7.8 Coolant level sensor

Sensor coolant level, description
The cooling system is equipped with an sensor (level switch) that
1
activates an alarm on the display if the coolant level is to low.
The sensor is located in the expansion tank.
The sensor (B759) sends voltage signal to Control unit, engine

(ECU794).
014889
1. Coolant level sensor
Sensor coolant level, replacement

2 Open the hood.
3 Drain the coolant out of the expansion tank.
4 Unplug the connector for the switch.
5 Unscrew the sensor from the expansion tank.
6 Fit in reverse order. Seal with "Loxeal adhesive 18.10".
7 Fill the system with coolant. Check the level.
1.7.10 Engine heater

Engine heater, description
The engine heater is connected via an external power connector. The

connector is located above the left-hand footstep. The engine heater
used to warm up the engine and facilitate starting when the machine
has been switched off for a long time or in a cold climate.

1:38 1 Engine – Control system, engine
1.9 Control system, engine

1.9.1 Engine control unit
Engine control system, description
The engine is controlled by a control system whose central unit is a
control unit.
The system consists of sensors, control unit and electric injectors,

amongst other things. The sensors provide input signals to the control
unit, which in turn controls the injectors.
The control unit receives input signals about the engine's operating
condition from the following components:
• sensor camshaft rpm
• sensor flywheel speed
• sensor coolant temperature
• sensor charge air pressure and temperature
• sensor oil pressure
• sensor water in fuel
• sensor fuel pressure
• sensor fuel pressure, distribution pipe
• sensor coolant level (B757)
• accelerator pedal (B690)
• control unit SCR (UDS)
• control breaker
• sensor level and temperature AdBlue
• sensor exhaust gas temperature
• NOx sensor
Based on input signals, the control unit controls:

• main relay
• preheating relay
• starter motor (M654)
• injectors diesel
• injectors AdBlue
• accelerator pedal actuator
• fuel pump (MPROP)
• control unit SCR (UDS)
If serious malfunctions are detected by the control system on the

engine, then engine power is limited to protect the engine from further
damage.
The data from the sensors provides exact information about the
operating conditions and makes it possible for the processor in the
control unit to, for example, calculate the correct fuel volume and to
check the condition of the engine.
For more information about the engine control unit, see section
11 Common electrics, group 11.5.3 Control units and supplier
documentation engine.
Control unit, engine, general

See section 11 Common electrics, group 11.5.3.10 Control unit, engine
and supplier documentation, engine.

1 Engine – Start/stop 1:39
1.11 Start/stop
Start/stop, general
The electrical system works with 24 volts voltage.
The plus terminal is connected to a battery disconnect switch (A).

1. When starting the gear selector must be in neutral position.
2. Turn the ignition key lock to position 1, preheating is activated
if the engine senses the requirement. The display shows the
preheating symbol down on the left-hand edge.
3. Turn the ignition key lock to position 3, the ECU790 sends a
signal to the engine via the CAN bus.
A-D NOTE
A D The starter motor can be activated for 20-30 seconds and then
the circuit is broken for 1.5 - 2 minutes for the starter motor to
cool down. This is in order to protect the starter motor
4. The engine is stopped by the ignition key lock being turned to

position 0.
C
NOTE
B
The battery disconnector must not be used for emergency stop!
NOTE
Wait about a minute before switching off the system voltage
with the battery disconnector so the SCR system has time to be
emptied, this is particularly important during cold weather.
There is a stop button on the engine that can be used in an

emergency to stop the engine, e.g. if the engine cannot be stopped
014409
by other means.
A Battery disconnector
B Knob for opening the battery cover
C Position for main current on
D Position for main current off
1.11.1 Starter motor

Starter motor, description
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
batteries. A relay on the starter motor (solenoid) is activated by Control
unit, engine (ECU794).
NOTE
The starter motor can be activated for 20-30 seconds and then the
circuit is broken for 1.5 - 2 minutes for the starter motor to cool down.
This is in order to protect the starter motor

1:40 1 Engine – Stopping device
1.11.2 Stopping device

Stopping device, description
The engines have electrically regulated injectors that stop delivering
fuel when the voltage is cut off, which means that the engine stops.
The engine is stopped by switching off the ignition with the ignition
key lock.
There is a stop button on the engine that can be used in an emergency

to stop the engine, e.g. if the engine cannot be stopped by other
means.
NOTE
The battery disconnector must not be used for emergency stop!
NOTE
Wait about a minute before switching off the system voltage with the
battery disconnector so the SCR system has time to be emptied, this
is particularly important during cold weather.
1.11.3 Automatic engine stop 5 minutes after

driver's seat is empty
Automatic engine stop 5 minutes after driver's seat is
empty, description
The machine is equipped with a function that turn the engine off if the
driver leaves the cab for more than five minutes.
(Five minutes is the normal standard setting, the time can however be
altered by a Cargotec industries authorised service technician).
1.11.5 Warning and engine power limitation

Warning and engine power limitation, description
Control unit, engine (ECU794) monitors engine function. The control
unit is equipped with a protection function that in the event of engine
malfunction issues a warning and can limit engine power by down to
50% of nominal power.

2:1
2 Transmission
Contents 2 Transmission
2 Transmission ......................................................................................................2:3
2.1 Controls and instruments ...............................................................................2:13
2.1.6 Gear and direction of travel selector .........................................................2:13
2.1.7 Inching.......................................................................................................2:13
2.2 Torque converter/Clutch system ....................................................................2:15
2.2.1 Flex plates .................................................................................................2:15
2.2.6 Break contact (opening switch) declutch...................................................2:15
2.6 Lubrication system .........................................................................................2:16
2.7 Cooling system ..............................................................................................2:17
2.7.3 Oil cooler ...................................................................................................2:17
2.8 Control system, transmission.........................................................................2:18
2.8.1 Transmission control unit (ECU 793) ........................................................2:19
2.8.2 Transmission cable harness......................................................................2:23
2.8.3 Display and menus....................................................................................2:23
2.8.4 Reversing lock...........................................................................................2:24
2.8.5 Manual gear changing...............................................................................2:25
2.8.6 Automatic gearing .....................................................................................2:25
2.8.7 Inching.......................................................................................................2:26
2.8.9 Diagnostics................................................................................................2:27
2.8.10 Calibration .................................................................................................2:27
2.8.11 Service menus ..........................................................................................2:30

2:2

2 Transmission – Transmission 2:3
2 Transmission
Transmission, general
The forklift trucks use Powershift transmission as standard. This is
electrically controlled via ECU 793, which controls gear changes in an
intelligent way.
The machine is equipped with ZF 3WG171.

and instructions regarding the transmission's components and
systems, refer to the relevant supplier documentation.


2:4 2 Transmission – Transmission
Transmission, function description
3 F
1
R F
°< D7 N
25 R
D25 <° D1 R
7 1
4 5
D24 24
D23 2,8,21,26 ECU790

23 Pa
EDU795
20
22
17,19,27
ECU794 ECU793
9,10 12,13,14,15,16
11 SENSORS
6
5
18
014900
1 The gear selector (S160) sends Forward: K1:12=24V Gear and direction of travel selector,
a voltage signal to the general description, page 2:13
Reverse: K1:13=24V
control unit (ECU790).
Gear 1: K1:9=24V, K1:10=24V.
Gear 2: K1:9=24V, K1:10=0V. ECU790 input K1:9-K1:13.
Gear 3: K1:9=0V, K1:10=0V.
2 The general control unit Checked by control system, See Section 11 Common electrics, group 11.6
(ECU790) transmits selected error shown with error code. communication
travel direction (forward, reverse
or gear 1-3) on the CAN bus
to Control unit, transmission
(ECU793).
3 If the parking brake switch Parking brake applied: 0 V See section 4 Brakes, group 4.5 Parking brake
(S107) is activated, the parking system
Parking brake released: 24 V
brake relay (K314) closes
and sends a signal to Control
unit, general (ECU790), and
then neutral is selected in the
transmission.
4 The transmission's oil pump - -
pumps oil when the engine is
running.
5 The transmission's oil filter - -
cleans the oil from impurities.


6 The oil filter differential pressure Normal = 510 Ohm -
sensor sends a signal to
Contaminated = Open circuit
ECU793 if the oil filter is
contaminated.
7 The accelerator pedal sends a U = 0.5-4.5 V See section 1 Engine, group 1.1.2 Accelerator
signal to the general control unit pedal
(ECU790).
ECU790 input K1:26.
(ECU790) transmits desired error shown with error code. communication
throttle application to the engine
control unit ECU794 via the
CAN bus.
(ECU790) sends selected error shown with error code. communication
shifting program the gearbox
control unit ECU793 on the CAN
bus.
10 The transmission control unit Checked by Control unit, Transmission control unit (ECU 793),
(ECU793) supplies voltage to transmission, error shown with description, page 2:19
the transmission control valve error code.
block to obtain desired function.
11 Solenoid valves for travel Checked by Control unit, -
direction and gear position transmission, error shown with
in valve block transmission error code.
control activate gears in the
Forward = KV (B)
transmission and the engine's
power is transmitted to the Reverse = KR (E)
transmission's output shaft.
First gear = K1 (D)
Second gear = K2 (A)
Third gear = K3 (C)
12 The turbine speed sensor (B751) Checked by Control unit, -
sends the transmission control transmission, error shown with
unit (ECU793) a pulse signal error code.
with frequency proportional to
turbine speed.
13 Sensor, engine speed (B753) Checked by Control unit, -
sends a pulse signal with transmission, error shown with
frequency proportional to the error code.
engine speed to Control unit,
transmission (ECU793).
14 The drum speed sensor (B752) Checked by Control unit, -
sends the a pulse signal with transmission, error shown with
frequency proportional to error code.
drum speed to Control unit,
transmission (ECU793).
15 The output shaft speed sensor Checked by Control unit, -
(B758) sends the transmission transmission, error shown with
control unit (ECU793) a error code.
pulse signal with frequency
proportional to output shaft
speed.
16 Sensor, oil temperature Checked by Control unit -
transmission (B766) sends transmission and sent to
a voltage signal proportional to ECU795 for display. Error code
the oil temperature to Control is sent if the oil temperature is
unit, transmission (ECU793). too high.


(ECU793) controls gear shifting transmission, error shown with description, page 2:19
based on the selected shifting error code.
program.
18 The oil cooler cools the - Oil cooler, description, page 2:17
transmission oil.
19 Control unit, transmission Checked by Control unit, See Section 11 Common electrics, group 11.6
(ECU793) sends temperature transmission, error shown with communication
information on the CAN bus. error code.
20 The terminal control unit Checked by Control unit, -
(EDU795) shows transmission transmission, error shown with
information in operating menus. error code.
21 If the signal from the output - -
speed sensor (B758) indicates
that the ground speed of the
machine exceeds the speed
limitation, the Control unit,
general (ECU790) sends a
request for reduced engine
speed on the CAN bus.
22 The engine control unit - See section 1 Engine, group 11.9.1 Engine
(ECU794) reduces engine control unit
rpm.
23 Break contact (opening switch) U = 24 V D23: Diagnostic menu, see section 8 Control
(S220) opens the circuit if the system, group 8.4.1.1 View inputs, menu 1,
brake pressure is above 2 MPa ECU790 input K1:15.
and sends a signal to Control
unit, general (ECU 790).
24 The inching switch (S1039) U = 24 V D24: Diagnostic menu, see section 8 Control
on the steering panel sends a system, group 8.4.1.1 View inputs, menu 1,
Inching on/off = K1:15,
voltage signal to the general ECU790 input K1:15.
ECU790.
control unit (ECU790) to activate
inching.
25 Potentiometer in brake pedal D25: Diagnostic menu, see section 8 Control
(R690) sends signal to Control system, group 8.4.1.1 View inputs, menu 1,
unit general (ECU790). ECU790 input K1:15.
26 Control unit general (ECU790) Checked by Control unit, See Section 11 Common electrics, group 11.6
sends inching on/off and the transmission, error shown with communication
inching value on the CAN bus. error code.
(ECU793) supplies voltage to transmission, error shown with description, page 2:19
the transmission control valve error code.
block to disengage the drive.

Transmission, replacement
DANGER
The transmission is very heavy.
Risk of crushing!
It is forbidden to go under the transmission when it
has been lifted by a jack or similar.
NOTE
Safety.
2 Detach the universal drive shaft from the transmission.

014863
3 Disconnect the requisite hoses and cables before separating engine

and transmission.
NOTE

a) Detach the accumulator on one side without removing the hoses.
008294
b) Detach the hoses for the bypass valve on the transmission's
left-hand side without detaching the hoses from the valve.
NOTE
from impurities.
015465
4 Attach hoisting equipment to the transmission.

009499

5 Remove the plugs in front of the flywheel on the right-hand side

of the engine.
Use the outer hole to turn the engine round.
6 Remove the flex plate's fastening bolts (x4). Rotate the engine
(use Volvo special tool 999 3590), until the flex plate's screws are
visible in the inner hole. The flex plate has four attachment points
to be loosened.
NOTE
7 Use a jack to secure the engine.
NOTE
Secure the diesel engine so that it does not tip over when the
transmission is removed.
014343
8 Detach the transmission brackets from both sides of the

transmission.
014864

9 Remove the bolts (x12) between engine and transmission.

10 Carefully separate the transmission and engine.
NOTE
If the flex plates are damaged during transmission replacement,
they must be replaced.
11 Lift away the transmission.
Assembly
12 Move the transmission bracket from the removed transmission to
the new one. Torque tighten the screws to 390 Nm.
13 Move the hydraulic oil pumps from the old transmission to the new
one, see section 10 Common hydraulics, group 10.4 Hydraulic
oil pumps.
014865
14 Insert two studs into the flywheel housing as a guide when the
transmission is installed.

15 Apply lubricating grease to the converter connection - both on the

engine and the transmission.
16 Check that the clips are aligned directly over the holes in the flex
plate.
17 Lift the new transmission into place. Make sure that the studs
on the flywheel are aligned in the right position so that they do
not damage the flex plate.
NOTE
If the flex plates are damaged during transmission replacement,
they must be replaced.
18 Align one of the holes on the flywheel so that it is centred in the

inner hole in the flywheel housing.
19 Install the bolts that affix the transmission and engine, but do
not tighten the bolts fully. Leave about a millimetre between the
engine and transmission to facilitate installation of the nuts for the
flex plate/flywheel.

20 Fit the nuts that fix the flex plates at the flywheel in two steps. First
fit the nuts without tightening. Then rotate the flywheel one more
revolution and torque tighten the nuts to 40 Nm (oiled screw).
NOTE
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.
21 Tighten the bolts that attach the transmission and engine.

22 Measure and check that the transmission is centred in the frame.
23 Screw the transmission into the transmission brackets. (Tighten to

a torque of 169 Nm). Refit the universal drive shaft.
24 Remove the hoisting equipment from the transmission.
25 Remove the jack from underneath the engine.
26 Connect the requisite hoses and cables for the transmission.
Check and fill fluids as required.
27 Calibrate the transmission; see Calibration, description, page 2:27.
CAUTION
014866
The transmission's clutch pack is destroyed if the

machine is operated without calibration having been
performed.

2 Transmission – Controls and instruments 2:13

2.1.6 Gear and direction of travel selector
Gear and direction of travel selector, description
The main communication with the machine takes place via the gear
1 2 F selector. It is used to select the direction of travel and gear changing
3 range. The gear selector's output signals are coupled to ECU790
which in turn gives information on selected gear via the CAN bus to
Control unit, transmission ECU793.
R
L 0
R
1 4 5
2 3
008599
Gear and direction of travel selector
2.1.7 Inching
Inching, description
The brake pedal (11) can be combined with an inching switch (46),
which is located on the steering panel.
The brake pedal has a declutch function if it is depressed approx.

F
55%.
4 3 2 1
N
L 0
Inching involves a slipping mode which makes it possible to use the

R
4 3 hydraulic functions with a gear engaged.
010056
12 46 11 10
10. Accelerator pedal

11. Brake pedal
12. Brake pedal
46. Inching switch (S1039)

2:14 2 Transmission – Inching
When inching is activated and the brake pedal is depressed, the

(Nm, %) gearbox changes over to inching mode. Speed can be controlled
100 by moving the brake pedal up and down in connection with high
engine speed. This allows the driver to manoeuvre the vehicle at low
1 speed with precision operation while power is available for working
80 hydraulics.
2
60
40
4
3
20
003788
25 50 75 100 (%)
0
Torque depends on pedal position
1. No inching
2. Variable speed
3. Lowest speed
4. Declutch
Inching potentiometer, replacing

2 Remove the two screws securing the bracket and potentiometer to

the pedal bracket.
3 Unplug the connector from the potentiometer.
4 Remove the two screws securing the potentiometer to the bracket.
5 Replace the potentiometer.
010248

1
7 Calibrate the new potentiometer, see section 8 Command system,
1. Inching potentiometer (R690) (behind brake group 8.5.2 Automatic gearing.
pedal) .

2 Transmission – Torque converter/Clutch system 2:15
2.2 Torque converter/Clutch system

2.2.1 Flex plates
Flex plates, changing
2 Remove the gearbox; see Transmission, replacement, page 2:7.
3 Remove the bolts holding the flex plate to the transmission.

4 Replace the flex plate, fit washers between the torque converter
and flex plate under the screws.
NOTE
Lock the screws with Loctite (type number 262).
Tighten the screws that hold the flex plate to the transmission to a
torque of 115 Nm.
5 Reinstall the gearbox; see Transmission, replacement, page 2:7.
6 Before the machine is put into operation, the transmission must be
calibrated; see Calibration, description, page 2:27.
009497
Flex plate attachment
2.2.6 Break contact (opening switch) declutch

Break contact (opening switch) declutch, description
See section 4 Brakes, group 4.3.7 Normally closed (NC) switch,
disengagement.

2:16 2 Transmission – Lubrication system
2.6 Lubrication system

Lubrication system, description
The transmission lubrication system has the following function:
• Lubricate gear wheels and bearings
• Apply the clutches in the gearbox
• Cool down the torque converter and gearbox
• Clean the oil of any impurities with oil filter.
During engine operation, the oil pump draws oil from the gearbox oil
sump through a strainer, and then pumps it through the oil filter to a
control valve.
The control valve provides oil at the correct pressure to the gearbox
valve housing to activate the clutch plates for FORWARD or REVERSE
and gear 1, 2 or 3. The clutch plates require just a small amount of
the oil flow supplied by the pump. The remaining oil flow is pumped
through the torque converter circuit to the oil cooler and returns to
the gearbox for lubrication.

2 Transmission – Cooling system 2:17
2.7 Cooling system

2.7.3 Oil cooler
Oil cooler, description
The transmission's oil is cooled in the cooling unit.
1
A temperature-controlled bypass valve, which only acts on the
transmission oil cooling circuit, is located in a pipe on the underside of
the cooler (engine side). The bypass valve is initially open in order
that the oil should reach operating temperature more quickly. When
the oil approaches the operating temperature the bypass valve closes
and the oil starts to circulate through the transmission oil cooler. When
the transmission oil reaches 80 °C the bypass valve is fully closed.
4
014826
3
2
Cooling unit
1. Expansion tank
2. Intercooler
3. Condenser
4. Transmission oil cooler
5. Radiator, engine

2:18 2 Transmission – Control system, transmission
2.8 Control system, transmission

Transmission control system, description
The ZF 3WG171 is an electronic Powershift gearbox with three gears in
each direction and electronically controlled clutch plates. The gearbox
has functions for manual gear changing as standard, and automatic
gear changing and electronic inching via the brake pedal as options.
Monitoring and reversing lock are standard.

2 Transmission – Transmission control unit (ECU 793) 2:19
2.8.1 Transmission control unit (ECU 793)

Transmission control unit (ECU 793), description
ECU 793 is an electronic unit for the ZF transmission, which controls
and monitors the shifting function.
The ECU 793 is mounted in the arch over the transmission. The
cables are connected to the gearbox sensors and the control valve
and wiring that is routed straight up to the cab and the electronic box.
Since signal transmission mostly travels via the CAN bus the wiring is
quite small, with few cables. A diagnostic socket is fitted in the wiring
for programming the ECU 793 if the need arises.
• The control unit has the following inputs and outputs:
• 13 digital inputs, active high (ED)
015482
• 2 digital inputs, active high (EV)
• 2 frequency inputs for active sensors (EF)
ECU 793
• 3 frequency inputs for inductive sensors (EF)
• 2 voltage inputs for power supply (EU)
• 2 resistance / temperature inputs (ER)
• 2 digital inputs, prepared for diagnostics (ER)
• 8 digital outputs, lowering (ADM)
• 8 current outputs, PWM, lowering (AIP)
• 1 sensor, power supply (AU)
• 2 central valve feed outputs (VPS)
• 1 diagnostic channel ISO (SDDI)
• 2 CAN bus channels 2.0B (CAN1/2)
• 2 high-speed communication buses (SD1-2)
• 1 speed output for instruments (SD4)
• 1 programming input, voltage (EUPR)
• The control unit
• has been developed for work vehicles with a 24 V electrical
system.
• has all of its inputs, outputs and interfaces short-circuit proofed
to both earth and battery voltage.
• has a safety and monitoring module with a microprocessor
and "watchdog" circuit.
• has a diagnostic function (ISO compatible) for all inputs,
outputs and power supplies, as per the system description.
• has a non-volatile memory for diagnostics and adaptive
functions.
• Programming of data sets in a sealed control unit with
encapsulation class IP66K, where the non-connected
terminals in the connector are sealed.
The control unit receives control values from:

1. Gear selector.
2. The vehicle's configuration on the CAN bus from EDU795.
3. Brake pedal with analogue position sensor (potentiometer) supplies
control value (V) to the analogue input on ECU790 sending to
ECU793 on the CAN bus. The position sensor is active in inching
mode for slow speed manoeuvring and when the inching switch is
off for declutch function at approx. 35% depressed brake pedal.

2:20 2 Transmission – Transmission control unit (ECU 793)
Installation in machine
90˚ 90˚ 90˚ 90˚
009383
ECU793 installation position
100
A
50
209
B
100
009382
ECU793 installation dimensions

A. ZF type plate
B. Minimum distance for disconnecting connector
ECU793, replacement
2 Remove the ECU as follows:

2 Transmission – Transmission control unit (ECU 793) 2:21
a) Disconnect the connector from the ECU.
015482
b) Unscrew the 4 screws securing the ECU and lift the ECU away.
015483
3 Install the new ECU in the reverse order, following steps 1-2.
NOTE
Make sure that the replacement ECU has the correct part
number.
2.8.1.1 Connectors
Connectors, description
2 22
1 23
24 45 009380
46 68
Connectors, seen from the cable side.
Terminal Function Description Machine connection

1 Feed, ground 1 VM1 Battery 0 V
2 Feed, ground 2 VM2 Battery 0 V
3 Feed, ground sensor 1 VMG1 Speed sensor B2 and B3, 0 V
4 Feed, ground sensor 2 VMG2 Speed sensor B4, 0V
5 Output signal, digital sink 4 ADM4
8 Feed, switchable peripherals 2 VPS2
9 Output current 5, active low AIP5 Current valve KR, reverse, max 532 mA

2:22 2 Transmission – Transmission control unit (ECU 793)

10 Output current 2, active low AIP2 Current valve KB, gear 2, max 532 mA
12 Feed, switchable peripherals 1 VPS1 Digital out valves, max 5.5 A
13 Feed, switchable peripherals 1 VPS1 Digital out valves, max 5.5 A
14 Communication interface 1 SD1 ZF display communication
15 Diagnostic interface communication SDDK Diagnostics switch
16 Input frequency 5 EF4
17 Input resistance / switch diagn. 3 ER3
18 Input programming voltage EUPR Programming/calibration
19 Input frequency 1 EF1
20 Input digital 3 ED3
23 Positive feed "Term. 30" 1 VPE1 Battery 24V, "30" voltage
24 Ground feed analogue sensor 1 VMGA1
25 Full CAN1 high CAN1-H CAN-H
26 Full CAN1 low CAN1-I CAN-I
27 Full CAN1 circuit termination resist. CAN1-T
28 Shield VGS
32 Output current 3 AIP3
35 Input digital EV1 EV1
36 Output speed signal SD4
37 Output sensor feed 1 AU1
38 Input voltage 1 EU1
39 Input resistance/temperature sensor 1 ER1
40 Input resistance / switch diagn. 4 ER4
41 Input frequency 2 EF2 Turbine speed
42 Input frequency 3 EF3 Internal gear ratio rpm
45 Positive feed "Terminal 15" VPI 24V ignition key lock, "15" voltage
46 Ground feed analogue sensor 2 VMGA2 Temperature sensor 0 V
47 Full CAN2 high CAN2-H
48 Full CAN2 low CAN2-L
49 Input resistance/temperature sensor 2 ER2 Temperature sensor signal
50 Output current 7, active low AIP7 Brake valve current, max. 1.2 A

2 Transmission – Transmission cable harness 2:23

53 Feed, switchable peripherals 2 VPS2 Digital output, brake valve, max 5.5 A
55 Output current 4 AIP4 Current valve KV, forward, max 532 mA
56 Output current 1 AIP1 Current valve KA, gear 1, max 532 mA
58 Feed, switchable peripherals 1 VPS1
59 Input digital EV2 EV2
60 Communication interface 2 SD2
61 Input voltage 2 EU2
62 Input frequency 4 EF4 Output shaft speed
68 Positive feed, "Terminal 30" 2 VPE2 Battery 24V, "30" voltage
2.8.2 Transmission cable harness

Transmission cable harness, description
The sensors fitted on the transmission send signals to the ECU 793
control unit via wiring. The wiring is routed through a cable duct where
the transmission and engine are secured together and then on to ECU
793.
See section E Schematics.
2.8.3 Display and menus

Display and menus, description
Operation information and menus are shown in the display on the
steering panel.
Conditions, description
There are five different conditions for the transmission: Normal,
and four conditions with reduced functionality in order to protect the
transmission in the event of serious faults: Substitute clutch control,
Limp-home, Transmission-shutdown and ECU793 shutdown.
Troubleshooting and error codes, description

See section 8 Control system; D Error codes group 2.8 Control system
transmission.
Calibration, description
See Calibration, description, page 2:27.

2:24 2 Transmission – Reversing lock
2.8.4 Reversing lock

Reversing lock, description
Forward to reverse, or vice versa
Transmission behaviour is very dependent on what speed the machine
is travelling at when travel direction is changed.
If the machine's speed is too high (approx. 3-4 km/h), then the change
of travel direction will be delayed and neutral selected.
If the engine speed is below 1600 rpm and the speed of the machine
is low enough then travel direction is changed without the gear being
changed.
Neutral to forward or reverse (from stationary)

Transmission turbine speed must be below 1600 rpm in order to
authorise change of travel direction from neutral to forward or reverse.
Machine speed must be below 3 km/h.
Forward to neutral to forward

When driving in a certain direction and the gear selector is moved
into neutral and back in same direction then the direction will be
re-engaged, provided that engine speed has fallen below the limit for
change of travel direction (if this is used).
Functional test, reversing lock

Forward to reverse, or vice versa
Accelerate the machine forward to 10-15 km/h and select reverse with
the gear selector.
Allow the machine to freewheel until the gear for travel direction reverse
is engaged. This should occur at about 3 km/h, depending on the
setting. In order to test the engine's speed limitation, rev up the engine
to approx. 1900 rpm and then allow the engine speed to decrease until
the gear is engaged. This should take place at approx. 1600 rpm.
Neutral to forward or reverse (after being stationary)

In order to test the engine's speed limitation when selecting gear, rev
up the engine to approx. 1900 rpm and then select forward or reverse.
Reduce engine speed gradually until the gear is engaged. This should
take place at approx. 1600 rpm.
Forward to neutral to forward

While driving forward or in reverse, when neutral is selected and then
returning to the same travel direction, the gearbox is set in the gear for
the same travel direction if engine speed is below 1600 rpm.

2 Transmission – Manual gear changing 2:25
2.8.5 Manual gear changing

Manual gear changing, description
Selected gear position normally follows gear selector position. If the
operator tries to change to a gear that will damage the machine then
the gear change is delayed until it can be made safely and without
damage. This means that if the operator starts in first gear, accelerates
at the same time and selects third gear, then the gear change will take
place in the same way as with automatic gear changing. On the other
hand, if the operator is driving at high speed in third gear and selects
first gear, then the gearbox will not change gear until the vehicle has
reached the appropriate speed.
Protection for selection of travel direction, so-called reversing lock, see

Reversing lock, description, page 2:24, is also activated for manual
gear changing.
Functional test, manual gear changing

It is a prerequisite that the gear selector is working properly.
Start by selecting the F1 gear and then accelerating the machine. Then
select 2nd gear, followed by 3rd later on. These should be engaged
without delay. If top gear is engaged immediately after starting in 1st
gear, then there should be an automatic upshift into top gear in the
same way as with automatic gear changing.
If the machine is driven in 3rd gear at a higher speed and 1st gear is
selected, then downshift should take place in the same way as with
automatic gear changing.
2.8.6 Automatic gearing

Automatic gearing, description
Automatic gearing is designed for gearboxes with torque converter.
The function takes care of changing up and down, which facilitates
driving and extends the service life of the drive equipment.
Automatic gearing comprises the following:

• Soft engagement, changing gear at the right time based on engine
speed, vehicle speed and current gear.
• Current gear is shown continuously on the display.
The following signals are monitored:

• gear selector (S160)
• sensor turbine speed (B751)
• sensor drum speed (B752)
• sensor engine speed (B753)
• sensor output shaft speed (B758)
• sensor oil temperature transmission (B766)
• sensor oil temperature transmission
• solenoid valves for travel direction and gear position
• sensor oil filter

2:26 2 Transmission – Inching
D ECU 793 controls the gear changes in an electronically modulated

gearbox. ECU 793 handles all gearbox related functions in order to
ensure good gear changing characteristics and high reliability. ECU
A E 793 can also control engine speed via the CAN bus. There are built-in
self tests and diagnostics to quickly identify any faults. Installation of
ECU793 the unit in the truck includes gear selector, speed sensor, valve block
B F on the gearbox and, where required, different pedal assemblies with
position sensors.
The gear selector limits the highest gear that can be selected for
C G
automatic gear changing. Lever control signals can be obtained
on the CAN bus in accordance with Kalmar's CAN protocol (or via
messages in accordance with the SAE/J1939 standard).
The standard algorithm uses all the available intervals for automatic
009624
gear changing.
CAN Bus Automatic upshift takes place when the pulling power in the higher
gear is greater than the pulling power in lower gear. Automatic
A Gear selector
downshift takes place when the lower gear's pulling power is greater
B Gas than in the higher gear.
C Brake
D Control unit
E ECM, Electronic Controlled
F Speed sensor (4 units)
G Engine speed via CAN-bus
Function test, automatic gear changing

Select 3rd gear and select forward or reverse. The gears will be
engaged during acceleration, depending on accelerator pedal position,
turbine speed and slipping in the torque converter.
If the machine is driven in top gear and the accelerator pedal is

released completely, then a downshift will take place using the same
principles as an upshift, but in the opposite way.
As with manual gear changing, an upshift can take place manually by

moving the gear selector, the gearbox checks if it is appropriate to
engage the selected gear.
2.8.7 Inching
Inching, description
Inching is a function that temporarily reserves engine power for load
handling while the machine is being operated. The machine can be
driven at low speed with the engine at high engine speed.
ECU793 controls the function by slipping the direction clutches, which

limits the power that can be drawn from the engine.
Inching run can be used in both forward and reverse and in all gears,
but is most effective in 1st gear.
Automatic gear changing is normally deactivated during inching.
Inching is controlled by the left-hand brake pedal. The output obtained

depends on how far the brake pedal is depressed.
Activating inching
The conditions below must be fulfilled at the same time in order to
start the inching function:
• Left-hand brake pedal depressed.
• Switch for inching on the steering panel activated.

2 Transmission – Diagnostics 2:27
In some cases a minimum engine speed is required for the requisite

torque. Engine speed does not affect vehicle speed - the engine can
run at full throttle in order to speed up hydraulics and steering.
ECU793 will try to match the desired inching speed as far as possible.
Deactivating inching
If any of the following conditions are fulfilled, the inching function will
be switched off:
• Release the brake pedal
Note that the deactivation of the inching switch does not stop the
inching function.
• Select neutral or opposite direction and deactivate the inching
switch.
Note that if the change is made when the inching switch is still
activated then the inching function will be reactivated in the
opposite direction.
• When inching torque reaches the maximum permissible value.
When inching is stopped, the direction clutch gradually closes and
the inching function is deactivated until the brake pedal is fully
released.
Brake pedal function in connection with inching

Brake pedal position gives inching the following function modes:
1. Inching deactivated (brake pedal not depressed).
2. Continuous speed control for inching - the machine is not braked.
3. Transmission disengaged - further increased braking force.
Function test, electronic inching

Activate the inching function with the inching switch, accelerate the
machine and slowly depress the left-hand brake pedal halfway. At the
same time, depress the accelerator pedal and rev up the engine to
maximum speed. It should now be possible to check machine speed
with the left-hand brake pedal by raising and lowering the brake pedal.
If the brake pedal is fully depressed then the machine should stop and
engage neutral with minimal slipping in the transmission.
2.8.9 Diagnostics
Diagnostics, description
Tools for advanced diagnostics are available from ZF’s dealer, for more
information contact Cargotec Sweden AB.
2.8.10 Calibration
Calibration, description
After changing oil in the transmission, it is recommended to calibrate
the clutches for optimum driving comfort. The transmission must first
be warmed up to least 70 °C and then a clutch calibration performed
using the display in the vehicle. If the inching function is available
on the machine and the system has been changed, or if the inching
sensor has been replaced, then the sensor must be calibrated using
the display in the vehicle, see section 8 Control system, group 8.5.2.2
Calibrating automatic gearing for additional information.

2:28 2 Transmission – Calibration
Transmission, calibration
DANGER
Do not leave the machine during calibration. The
machine may start to move.
1 Stop the machine on level ground, change to neutral, apply the

parking brake. Allow the engine to run at idling speed and check
the oil level and that the transmission oil temperature is between
70 - 90 ºC.
2 To select function to calibrate, first navigate to the service menu.

Now press Enter.
000056
3 Enter the code for calibration.

Code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060
The code determines which service menu is activated (Service,

Diagnostic test, Initiation or Calibration).
4 Select AUTOMATIC GEAR SHIFT ECU 793 by scrolling with the

arrow keys (1 and 2) and confirming with Enter.
AUTOMATIC GEAR SHIFT
007741
ECU793
5 Select CALIBRATION by scrolling with the arrow keys (1 and 2)

AUTOMATIC 2(2) and confirming with Enter.
GEAR SHIFT ECU793
007742
CALIBRATION
6 Only shown when the engine is running.

CALIBRATION 1(2)
The signals for parking brake and declutch have been temporarily
disengaged to make it possible to operate "Heat mode", the
009098
GEARBOX HEAT MODE highest possible gear is always selected.

ACTIVATE P-BRAKE!

2 Transmission – Calibration 2:29
CALIBRATION 7 "Heat Mode" is a function for heating the transmission when the
machine is stationary by using the parking brake to slow the
machine and allowing the converter to heat the gearbox oil.
FWD<->NTRL 15S CYCLE! Increase the oil temperature in the transmission as follows:
SELECTED GEAR F3
009541
A. Apply the parking brake so that the machine is stationary.
TEMPERATURE 70”C
B. Select travel direction forward or reverse and apply half to full
throttle for 30 seconds.
C. Engage neutral position, apply half throttle for 15 seconds and
then run the engine at idling speed.
D. Repeat steps B and C until the oil is above 70 °C or maximum
90 °C. The temperature display starts to flash when calibration
of the clutches can be started.
NOTE
During this heating procedure it is possible that the temperature
from the converter exceeds the limit value. This is a
consequence of heating the transmission with this rapid
procedure.
Set the transmission in neutral and rev the engine to approx.
1300 rpm for approx. one minute in order to cool the
transmission. This allows the heat in the converter to be
evacuated.
After one or two minutes the heating procedure can be resumed,
if the transmission's temperature has not yet reached 70 °C.
IMPORTANT
Calibration can be interrupted at any time by moving
the gear selector to the opposite travel direction. At
which point the transmission's control unit will be reset
and ignore the calibration results obtained so far.
CALIBRATION 2(2) 8 Only shown when the engine is running. Press "Enter" to access
the next menu.
AUTOMATIC CLUTCH
FILLING PARAMETER
009100
ADJUSTMENTS (AEB)
CALIBRATION 9 The following requirements must be fulfilled in order to start

calibration: Transmission in neutral position and parking brake
>SELECT NEUTRAL activated. Check that all requirements are fulfilled and that the
>P-BRAKE ACTIVE oil temperature is 70 ºC before proceeding to the next menu by
009101
>TEMP >70grC pressing Enter.
CALIBRATION 10 When the TCU has started the calibration the display shows
information about the calibration process in clear text. Any error
STATUS messages are also shown here.
009103
11 During calibration, engine speed is automatically regulated to a

K1 ADJUST! preset value which suits each transmission.
After completion of calibration the following text is shown in the
display: "ADJUSTMENT FINISHED SWITCH OFF IGNITION
FOR 5 SECONDS!"
CALIBRATION 2(2) 12 Only shown when the engine is switched off and inching is
installed, this is an option.
009104
INCH PEDAL To able to see "CALIBRATION INCH PEDAL" requires that the
engine is already switched off, otherwise this is not shown at all.

2:30 2 Transmission – Service menus
CALIBRATION 13 When the TCU has started the calibration the display shows
information about the calibration process in clear text. Any error
STATUS messages are also shown here.
009105
14 Depress the pedal slowly and hold until the information in the
PRESS PEDAL SLOW! display changes to "Release pedal slow!". Release the pedal
slowly.
If everything has worked the following is shown: ADJUSTMENT
FINISHED SWITCH OFF IGNITION FOR 5 SECONDS!"
15 Switch off the ignition for 5 seconds in order to store the values.
2.8.11 Service menus

Setup and calibration
Level 3, automatic gear changing ECU 793
Level 3, automatic gear changing ECU 793
A U T O M A T IC G E A R S H IF T
Select AUTOMATIC GEAR SHIFT ECU 793 by scrolling with the
008455
E C U 793
arrow keys (1 and 2) and confirming with Enter.
This display and the following are only shown if ECU 793 is selected.
Level 4, automatic gear changing ECU793
Level 4, automatic gear changing ECU793
A U T O M A T IC 1 (2 )
G E A R S H IF T E C U 7 9 3 Select AUTOMATIC GEAR SHIFT ECU 793 INITIATION by scrolling
IN IT IA T IO N
008456
with the arrow keys (1 and 2) and confirming with Enter.
This display and the following are only shown if A_GEAR_SHIFT_793

is selected.
Select AUTOMATIC GEAR SHIFT ECU 793 CALIBRATION by
A U T O M A T IC 2 (2 )
scrolling with the arrow keys (1 and 2) and confirming with Enter.
G E A R S H IF T E C U 7 9 3
C A L IB R A T IO N
008457
This display and the following are only shown if ECU 793 is selected.
Level 4, initiation automatic gear changing ECU793
IN IT 1 (3 ) Level 4, initiation automatic gear changing ECU793

N D
S T A R T IN 2 ####
Only shown if automatic gearing is selected in the machine's
008458
G E A R $$$$
S T
0=1 G E A R 1=2
N D
G E A R configuration.
IN IT 2 (3 ) Only shown if automatic gearing is selected in the machine's Setup.

A U T O M A T IC ####
008459
G E A R S H IF T O F F $$$$
0=A U TO 1=M A N U A L
IN IT 3 (3 ) Only shown if automatic gearing and NOT inching is selected in Setup.

D E C LU TC H ####
008460
(C C O ) O F F $$$$
0=O N 1=O FF

3:1
Contents 3 Power transmission

3 Power transmission ...........................................................................................3:3
3.2 Propeller shaft..................................................................................................3:4
3.3 Drive axle .........................................................................................................3:6

3:2

3 Power transmission – Power transmission 3:3
Driveline/axle, general
and instructions regarding the driveline/axle's components and
systems, refer to the relevant supplier documentation.


3:4 3 Power transmission – Propeller shaft
3.2 Propeller shaft

Propeller shaft, description
1 2 3 The propeller shaft transfers engine power from the gearbox to the
drive axle. Both universal joints on the propeller shaft make power
transmission possible despite movements of transmission/engine
and jolts due to road conditions (distance between transmission and
drive axle varies).
It is possible to change the length of the propeller shaft since its

divided in two parts, connected with a bolted joint and splines, as well
as the universal joints, so-called spiders, at both ends. The universal
drive shaft connection is the cross-tooth type in order to unload the
connection (the bolts). The spindles are pre-lubricated and thus
maintenance free.
5 4 001058
Principle figure, universal joint

1. Lock ring
2. Needle bearing
3. Drive flange fork
4. Spindle
5. Drive flange
008836
Cross-tooth universal drive shaft connection

3 Power transmission – Propeller shaft 3:5
Propeller shaft, replacement

2 Remove the propeller shaft attaching bolts.

Remove the propeller shaft.
014778
1
1. Propeller shaft
3 Clean the contact surfaces (cross-toothed) on the drive axle and

transmission.
4 Fit the propeller shaft's attaching bolts.
Tightening torque: 98 Nm (oiled bolt).
Retighten the attaching bolts after 50 operating hours.
015464

3:6 3 Power transmission – Drive axle
3.3 Drive axle

Drive axle, replacement
DANGER
Drive axle and machine are very heavy.
Risk of crushing!
It is forbidden to go under a machine which has been
lifted by a jack etc. For machine weight, see section F
Technical data.
1 Park the machine with blocks behind the steering wheels.
2 Stop the engine and turn the start key to position I.
3 Depressurise the hydraulic system, see B Safety.
4 Turn the start key to position 0 and switch off the system voltage.
5 Insert suitable support between steering axle and frame on both

sides.
008905
6 Detach the hydraulic hoses from the distribution block.
NOTE
from impurities.
014903

3 Power transmission – Drive axle 3:7
7 Remove the cover (1) over the parking brake.
014901
8 Loosen the lock nut (1) and screw in the screw (2). This
compresses the brake spring. Screw until the brake pads release
1 from the brake disc. Refit the cover over the parking brake.
2
008834
9 Detach the hydraulic hose from the parking brake.
NOTE
from impurities.
014902
10 Detach the propeller shaft from the drive axle. Secure the propeller
shaft, otherwise there is a risk that it will be pulled apart.
008906

11 Attach hoisting equipment to the lifting lugs on the mast in a safe

manner and raise the machine so that the drive wheels are lifted
off the ground.
12 Remove the drive wheels from the drive axle.
008907
Raise the machine
13 Support the drive axle under the hubs.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away
uncontrollably.
008915
Raise the machine
14 Undo the screws which fix the drive axle to the frame.
008919

3 Power transmission – Drive axle 3:9
15 Lift the machine up so that the frame is lifted away from the axle.
NOTE
If the distribution block is detached from the bracket then the
frame does not need to be lifted so high in order to lift the drive
axle.
008907
Raise the machine
16 Lift out the drive axle.
CAUTION
Crushing injury!
uncontrollably.
008916
17 Transfer the equipment from the old axle to the new axle.
18 Clean contact surfaces on drive axle and frame. Also clean the
washers' contact surface on the underside of the drive axle.
19 Lift the drive axle in under the frame.
CAUTION
Crushing injury!
008917
uncontrollably.
20 Lower the frame down onto the drive axle. Check that the guides
align and that the drive axle is centred in the frame.
008909

21 Fix the new screws which fix the drive axle to the frame.
NOTE
Check that the threads are not damaged and that all dirt is
removed. It is important to obtain the correct tightening torque.
008921
22 Start by tightening all nuts in numerical order (position 1-8) tight

enough to give metal contact between the drive axle and the frame.
7
NOTE
5
6 Check that there is full contact between the drive axle and the
2 frame for all bolts.
8
3
4 Continue to tighten all nuts in numerical order (position 1-8) to half
tightening torque 675 Nm (oiled bolt).
008835
1 Finish by tightening all nuts in numerical order (position 1-8) to full

tightening torque 1350 Nm (oiled bolt). Re-tighten the attaching
bolts after 50 hours of operation.
23 Rust proof the new screws with suitable paint.
24 Connect the hydraulic hoses to the distribution block.

25 Connect the hydraulic hose to the parking brake. Adjust the
parking brake, see section 4 Brakes, group 4.5.4 Parking brake
unit.
26 Connect the universal drive shaft to the drive axle, tighten the
bolts to a tightening torque of 98 Nm. Re-tighten the bolts after 50
hours of operation.
27 Check the oil level in the drive axle.
28 Start the machine and bleed the brakes, see section 4 Brakes,
group 4.3.10 Wheel brake.
014903
29 Check carefully that no leakage occurs.

4:1
4 Brakes
Contents 4 Brakes
4 Brakes..................................................................................................................4:3
4.1 Controls and instruments .................................................................................4:3
4.1.1 Brake pedal .................................................................................................4:3
4.3 Power-assisted brake system ..........................................................................4:7
4.3.1 Hydraulic oil pump.......................................................................................4:8
4.3.2 High-pressure filter ......................................................................................4:8
4.3.4 Accumulator ................................................................................................4:9
4.3.5 Brake valve .................................................................................................4:9
4.3.6 Distribution block .......................................................................................4:13
4.3.7 Break contact (opening switch) declutch...................................................4:14
4.3.8 Switch normally closed (NC), low brake pressure.....................................4:16
4.3.9 Make-contact (closing switch) brake lights................................................4:17
4.3.10 Wheel brakes ............................................................................................4:18
4.3.11 Pipes and hoses........................................................................................4:20
4.3.13 Accumulator charging valve ......................................................................4:21
4.3.14 Shuttle valve dual brake pedals ................................................................4:25
4.5 Parking brake system ....................................................................................4:27
4.5.1 Hydraulic oil pump.....................................................................................4:28
4.5.2 High-pressure filter ....................................................................................4:28
4.5.3 Solenoid valve parking brake ....................................................................4:29
4.5.4 Parking brake unit .....................................................................................4:30
4.5.5 Normally closed (NC) switch, parking brake .............................................4:33
4.5.6 Pipes and hoses........................................................................................4:34
4.8 Temperature control, cleaning and oil brake system......................................4:35
4.8.1 Hydraulic oil tank .......................................................................................4:35
4.8.2 Tank heater ...............................................................................................4:35
4.8.4 Accumulator charging valve ......................................................................4:36
4.8.5 Distribution block .......................................................................................4:36
4.8.6 Wheel brakes ............................................................................................4:36
4.8.7 Oil cooler ...................................................................................................4:36
4.8.12 High-pressure filter ....................................................................................4:36
4.8.13 Pipes and hoses........................................................................................4:36
4.8.14 Hydraulic oil...............................................................................................4:36

4:2

4 Brakes – Brakes 4:3
4 Brakes
4.1.1 Brake pedal
Brake pedal, description
The brake pedal (1) acts on the brake valve via a lever. A spring
1 1 causes the pedal to automatically return to rest position. It is important
to keep the area around the pedal clean. Dust and dirt can cause the
pedal to jam or not become fully depressed.
If the inching function is used ( ), a potentiometer (R690) shows

brake pedal position. This signal travels to ECU790 and is forwarded
unchanged to ECU795 and on to ECU793.
009557
1. Brake pedal
Brake pedal, turnable driver's seat, description
There are two sets of brake pedals if a turnable driver's seat is fitted.
Customer specification determines the functions which are activated.
See also section 9 Frame, cab, body and accessories, group 9.3.9
Turnable driver's seat.
Inching potentiometer, replacement

2 Disconnect the electrical connection to the potentiometer.

015757

4:4 4 Brakes – Brake pedal
3 Detach the link arm from the potentiometer.
015754
4 Loosen the screws holding the potentiometer.

015755

6 Fit the screws holding the potentiometer.
Connect the link arm and electrical connection to the potentiometer.
7 Switch on the system voltage and turn the ignition key lock to
position I.
015756

4 Brakes – Brake pedal 4:5
8 Depress the brake pedal and check that the potentiometer's signal
range is between the angle Δ30° to 40° or voltage min 0.83 V -
max 4.17 V for the sensor's output signal 1. The signal must have
a range of at least 2 V in order for Control unit, transmission (ECU
793) to receive the calibration of the sensor's output signal.
Check the signal with Diagnostic menu, see section 8 Control
system, group 8.4.1.1 View inputs, menu 4, ECU790 input K1:27
9 If the signal is outside the limit values then the link arm for the
potentiometer must be adjusted.
Brake pedal, replacement

2 Depressurise the hydraulic systems, See section B Safety.
3 Secure the brake valve and the steering valve on the cab\qs
underside.
4 Screw down the set screw (position 1) for the brake pedal all the
way to facilitate access.
5 Detach the steering valve from the pedal assembly.
Remove the steering valve's attaching bolts (2). Pull the valve
down slightly so that it detaches from the steering wheel shaft.
6 Detach the brake valve from the brake pedal
Remove the brake valve attaching bolts (position 3) securing the
brake valve to the cab floor.
2 7 Remove the four screws (position 4) securing the bracket to the
3 cab floor.
1
8 Undo the splint pins and drive the shaft out.
005741
4 9 Replace the brake pedal.

10 Fit in the reverse order.

4:6 4 Brakes – Brake pedal
Brake pedal, checking and adjustment
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 necessary, adjust the brake pedal's stop screw to the correct
clearance.
3 Check that the pedal moves smoothly.
Stop screw for adjusting clearance between brake pedal

and brake valve. (The illustration shows a loose brake
pedal.)
4 Lubricate the pedal hinge with "EP2" universal grease.

5 Check that the rubber pad on the brake pedal is intact and that the
tread pattern is not worn away. Replace if necessary.
Lubrication points, brake pedal. (The illustration shows

a loose brake pedal.)

4 Brakes – Power-assisted brake system 4:7
4.3 Power-assisted brake system

Power-assisted brake system, function
description
ECU790
12,14
D11 <° 13b D13

5
B
Pa P 10
T
11 D13
16
13a Pa Pa
9
4 8
C C 7
B 6
ACC
X
3 15 T
P
P B
2 C
015648
1 The hydraulic oil pump pumps oil from P (when the accumulator is Section 10 Common hydraulics,
the hydraulic oil tank. charged) = 13.0-16.5 MPa group 10.3.1 Tank
P (during cooling) = < 0.1 MPa Section 10 Common hydraulics,
group 10.4.1 Gear pump with fixed
displacement
2 The high pressure filter cleans the oil. - Section 10 Common hydraulics,
group 10.6.8 High pressure filter
3 The accumulator charging valve directs P (when the accumulator is Accumulator charging valve,
oil to accumulator charging or through charged) = 13.0-16.5 MPa description, page 4:21
the brake system's cooling circuit.
P (during cooling) = < 0.1 MPa
4 The accumulator store oil pressure. See pressure plate on left-hand Section 10 Common hydraulics,
front mudguard. group 10.3.2 Accumulator
5 The brake valve directs pressure from - Brake valve, description, page 4:9
the accumulator to the brake cylinders
proportional to pressing of the pedal.
6 The distribution block guides the oil to - Distribution block, description, page
the brake cylinders. 4:13
7 The brake cylinders compress the discs See pressure plate on left-hand Wheel brakes, description, page
in the brake unit. front mudguard. 4:18
8 The wheel brakes brake the machine. - Wheel brakes, description, page
4:18

4:8 4 Brakes – Hydraulic oil pump

9 Make-contact (closing switch), brake Brake pressure above 0.2 MPa: Make-contact (closing switch) brake
light (S216) closes the circuit when the lights, description, page 4:17
Conn 1, U = 24 V
brake cylinders are pressurised.
Conn 2, U = 24 V
Brake pressure below 0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
10 Relay brake light (K308-1) supplies U = 24 V Section 9 Frame, body, cab and
voltage to the brake lights (E411L and accessories, group 9.6.4 Brake lights
E411R).
11 Make-contact (closing switch) (S204) Brake pressure above 11.5 MPa: Switch normally closed (NC), low
opens the circuit if the pressure in the brake pressure, description, page
Conn 1, U = 24 V
accumulators is low. 4:16
Conn 2, U = 24 V
D11: Diagnostic menu, see section 8
Brake pressure below 11.5 MPa: Control system, group 8.4.1.1 View
inputs, menu 2, ECU 790 input K1:22
Conn 1, U = 24 V
Conn 2, U = 0 V
12 If the hydraulic brake pressure is too low Checked by control system, error Section 11 Common electrics, group
general control unit (ECU790) transmits shown with error code. 11.5.3.2 ECU control unit 790
a low brake pressure warning on the
CAN bus.
13a The disengagement (NC) switch (S220) U = 24 V Break contact (opening switch)
opens the circuit if the brake pressure is declutch, description, page 4:14
above 2 MPa and transmits a signal to
D13: Diagnostic menu, see section
the general control unit (ECU 790) and
8 Control system, group 8.4.1.1 View
further to ECU793 via ECU795.
13b On machines with inching the inching U = 0.5-4.5 V Section 2 Transmission, group 2.1.7
potentiometer in the brake pedal (R690) Inching.
sends signals to Control unit, general
D13: Diagnostic menu, see section
(ECU 790) and on to ECU793 via
8 Control system, group 8.4.1.1 View
ECU795 if the brake pedal is depressed
more than approx. 55%.
14 The transmission control unit (ECU 793) - Section 11 Common electrics, group
disengages the engine drive. 11.5.3.2 ECU control unit 790
15 When one of the brake pedals is - Shuttle valve dual brake pedals,
activated on a machine with turnable description, page 4:25
operator's station the pressure signal
runs to the shuttle valve, dual brake
pedals.
16 Shuttle valve, dual brake pedals, sends - Shuttle valve dual brake pedals,
the pressure signal on to the wheel description, page 4:25
brakes which are applied in the same
way as in point 6-10.
Hydraulic diagram, see section E Schematics, group 10 Common

hydraulics
4.3.1 Hydraulic oil pump

Hydraulic oil pump, description
The brake system has a gear pump with fixed displacement, see
section 10 Common hydraulics, group 10.4.1 Gear pump with fixed
displacement.
4.3.2 High-pressure filter

High-pressure filter, description
See High-pressure filter, description, page 4:36.

4 Brakes – Accumulator 4:9
4.3.4 Accumulator
Accumulator, description
See section 10 Common Hydraulics, group 10.3.2 Accumulator.
4.3.5 Brake valve

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

valve. With the brake pedal depressed halfway the brake pressure is
around 27 bar, then pedal resistance increases more steeply. When
the pedal is fully depressed the brake pressure is 100 bar. This
2 provides optimum pedal responsiveness as well as increased safety
as the operator can easily sense if no brake pressure is being built
4 up (no resistance in the pedal).
1
001903
1. Brake valve
2. Break contact (opening switch), low brake
pressure (S204) (white)
3. Normally closed switch, disengagement (S220)
(green)
4. Make-contact (closing switch) brake lights
(S216) (red)

4:10 4 Brakes – Brake valve
Braking
Braking
1 2
1. Position III
In unactuated position the valve slide (position 1 in the illustration)
is held in place by springs (2 and 3). The inlet from the
accumulator (P) is closed and the connection between brake
circuit and tank is open.
2. Position I
The pedal is depressed and the valve slide (1) opens the
connection between the inlet from the accumulator (P) and the
brake circuit (A).
3. Pressure is built up in the brake circuit. The pressure in the brake
B circuit is used as counterpressure on the valve slide (1) underside
3 and acts against the main pressure spring (2).
4. The valve slide (1) is pressed upward until balance is obtained
between pedal force and brake pressure.
5. Position II
In the equilibrium position the valve slide closes the connection
PT between accumulator and brake circuit. The brake pressure
is held constant. This means that the brake pressure rises
I II III proportionally to the force on the brake pedal.
6. The brake pedal is released, the return spring (3) and the control
pressure on the underside of the piston press up the valve slide
(1).
7. Position III
The valve slide (1) opens the connection between the brake
circuit (B) and the tank (T). The brake pressure is discharged
001190
to the tank.
8. The control pressure on the underside of the valve slide (1) is
1. Valve slide reduced and the main pressure spring (2) presses the valve slide
(1) downward.
2. Main pressure spring
9. The valve slide (pos. 1) closes the outlet to the tank (T).
3. Return spring
Brake valve, checking
NOTE
Safety.
1 Operate and warm up the machine so that the hydraulic oil

reaches operating temperature, at least 50 ºC.

4 Brakes – Brake valve 4:11
3 Connect a pressure gauge (0-25 MPa) to the measuring outlet for

brake pressure on the distribution block.
4 Start the machine and run it at idling speed until the accumulator is
charged and the accumulator charging valve changes to cooling.
5 Press down the pedal completely and read off the pressure.
Compare with the pressure plate on the left-hand front mudguard.
6 Turn off engine.
7 Depress the pedal fully and keep it pressed down, check the
pressure.
015457
The brake pressure must correspond with the value specified on
the pressure plate and must not decrease from this value for 15
Measuring outlet for brake pressure on the distribution seconds.
block
8 Release the pedal. The brake pressure must decrease to 0 MPa
immediately.
If the brake pressure does not go down all the way to 0 MPa then
the pedal's zero position may have to be adjusted. The pedal's
zero position is adjusted with the screw under the pedal, see
Brake pedal, checking and adjustment, page 4:6.
If the brake pedal is correctly adjusted and the pressure does not
fall to 0 MPa, the brake valve is not sealed and can cause the
brakes to remain applied and then overheat during operation.
Replace the brake valve if it is not sealed.
9 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
Brake valve, replacement
NOTE
Safety.
1 Machine in service position, see section B Safety
3 Remove the horn from the brake valve. Fit the horn on the new
brake valve.
015458
Bracket for horn.

4:12 4 Brakes – Brake valve
4 Mark up and detach the hydraulic hoses from the brake valve.
NOTE
from impurities.
5 Secure the brake valve under the cab.
6 Remove the brake valve attaching bolts.

7 Remove the brake valve by pulling it downward.
8 Transfer the connection adapters to the new brake valve.
9 Fit the new brake valve.
NOTE
Remember the spacer ring.
10 Connect the hydraulic hoses to the brake valve in accordance

with the marking.
NOTE
position.
11 Lubricate and adjust the brake pedal, see Brake pedal, checking
and adjustment, page 4:6.
12 Turn on the main electric power and start the engine. Let the
engine run at idle speed.
13 Test the brakes a couple of times.
14 Check that the brake valve's connections are sealed tightly.
15 Bleed the wheel brakes' brake cylinders, see Wheel brakes,
bleeding, page 4:18.

4 Brakes – Distribution block 4:13
4.3.6 Distribution block

Distribution block, description
A distribution block situated on top of the drive axle divides oil flow
and brake pressure between the right and left wheel brake.
The distribution block has a measuring outlet for brake pressure.
The distribution block has a bypass valve (opens at pressures above

1 bar) leading oil directly from the cooling circuit input to the cooling
circuit return (oil back to tank) if the resistance in the axle is too great.
This protects the wheel brake seals, e.g. when oil is viscous in cold
conditions or at the wrong viscosity.
9 1
2
8
7 4
014953
5
6
1. Cooling circuit left brake

2. Brake pressure to left-hand brake
3. Return to tank
4. Cooling circuit in, from valve block, port cool
5. Brake pressure from brake valve, port B
6. Brake pressure to right-hand wheel housing
7. Cooling circuit right brake
8. Measuring nipple brake pressure
9. Bypass valve (1 bar)
Distribution block, replacement
NOTE
Safety.
3 Mark up and detach the hydraulic hoses from the distribution block.
NOTE
from impurities.

4:14 4 Brakes – Break contact (opening switch) declutch
4 Remove the bolts which secure the distribution block.
008401 5 Transfer the connection adapters to the new distribution block.

6 Fit the new distribution block.
7 Connect the hydraulic hoses to the distribution block in accordance
with the marking.
NOTE
position.
8 Switch on the system voltage and start the engine. Let the engine
008402
run at idle speed.

9 Test the brakes a couple of times.
10 Check that the distribution block\qs connections are sealed tightly.
4.3.7 Break contact (opening switch) declutch

Break contact (opening switch) declutch, description
The normally closed (NC) switch for disengagement (S220) opens the
circuit if the brake pressure is above 2 MPa and sends a signal to the
general control unit (ECU 790) to disengage engine drive (makes
additional power available for working hydraulics).
See also Brake valve, description, page 4:9.
On machines equipped with inching, the inching potentiometers in

2
the brake pedal is used to detect pedal position. When 55% of full
pedal angle is reached, forward drive is interrupted, see section 2
4 Transmission, group 2.1.7 Inching.
1
008889
1. Brake valve
(green)
(S216) (red)

4 Brakes – Break contact (opening switch) declutch 4:15
Normally closed (NC) switch, disengagement,

replacement
NOTE
Safety.
3 Detach the electrical connectors (position 1) from the contact.

4 Replace the contact (position 2).
2 5 Fit in the reverse order.
1
008434

4:16 4 Brakes – Switch normally closed (NC), low brake pressure
4.3.8 Switch normally closed (NC), low brake

pressure
Switch normally closed (NC), low brake pressure,
description
Break contact (opening switch) for low brake pressure (S204) issues
a warning if there is a pressure drop in the brake system. The switch
is connected to KCS and an error code appears on the display if
brake pressure is low (the trigger pressure of the sensor is set to
ensure pressure for another 6-8 brake applications without feed from
the pump from the time the lamp illuminates).
2 See also Brake valve, description, page 4:9.
1
008889
1. Brake valve
(green)
(S216) (red)
Switch normally closed (NC), low brake pressure,

replacement
NOTE
Safety.

4 Replace the contact (position 2).
1
008435

4 Brakes – Make-contact (closing switch) brake lights 4:17
4.3.9 Make-contact (closing switch) brake lights

Make-contact (closing switch) brake lights,
description
Make-contact (closing switch), brake lights (S216) activates the brake
lights by closing the electric circuit for brake lights when the brake
valve opens and pressurises the wheel brake circuit.
See also Brake valve, description, page 4:9.
1
008889
3
1. Brake valve
(green)
(S216) (red)
Make-contact (closing switch), brake lights,

replacement
NOTE
Safety.

4 Replace the switch (position 2).
1
008436

4:18 4 Brakes – Wheel brakes
4.3.10 Wheel brakes

Wheel brakes, description
The wheel brake, consisting of disc pack and brake cylinder, is
mounted between axle and hub reduction. The wheel brake's housing
is screwed in the axle and the inner part is interconnected with the hub
reduction. The wheels are fastened in the hub reduction's housing.
The wheel brake uses so-called wet disc brakes (WDB). Wet disc
brakes require minimal maintenance and have a long service life due
to efficient cooling. Maintenance requirements are minimised since oil
circulates in the brake system and prevents corrosion.
008987
Wheel brakes, bleeding
NOTE
Safety.
IMPORTANT
Both the brake cylinder and disc brake must be bled
after work which involves the brake system being
opened or after work on the wheel brake.

4 Brakes – Wheel brakes 4:19
Disc brake
2 Position a ring spanner on the bleed nipple and connect a

transparent hose to the bleed nipple.
Direct the other end of the hose down into a receptacle.
3 Start the machine and depress the brake pedal, keep the pedal
depressed.
4 Open the bleed nipple and allow oil to run out of it until the oil is
free of air bubbles.
NOTE
The hydraulic hose between the brake pedal and brake is long.
So allow at least two litres of oil to pass through the bleed
nipple when bleeding to ensure that no air pockets remain in
008975
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 1-5 on the other side.
4.3.10.1 Disc pack
Disc pack, description

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

the discs. This creates friction between the discs that are fixed to the
axle and those that are fixed to the hub reduction.
008988

4:20 4 Brakes – Pipes and hoses
4.3.10.2 Brake cylinder
Brake cylinder, description

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

in the wheel brake housing. The pressure moves the metal ring
sideways and compresses the disc pack.
008989
Brake cylinder

See section 10 Common hydraulics, group 10.5.1 Pipes and hoses.

4 Brakes – Accumulator charging valve 4:21
4.3.13 Accumulator charging valve

Accumulator charging valve, description
The accumulator charging valve distributes the oil from the hydraulic
10 1 11
oil pump between pressure storage and cooling of the wheel brakes.
The accumulator charging valve is located to the left of the plate in
12 the area in front of the transmission.
The accumulator charging valve stores pressure by directing the oil to

the accumulators. The wheel brakes are cooled by oil being directed
13
to the drive axle cooling circuit and then on to the brake system cooler.
The accumulator charging valve prioritises charging of the

accumulator above cooling. A restriction of the charging means
that a small quantity of oil also flows to cooling during accumulator
charging. At idle the flow from the pump is so small that all oil flows
5 to pressure storage.
4
The drain valve (position 11) is used to relieve the pressure in the
accumulator to the tank. The valve opens a connection between the
accumulator and the wheel brake's cooling circuit. The oil is drained
3 through the wheel brake to the tank.
There is a measuring outlet to measure the accumulator pressure

2 (position 5) and pump pressure (position 4) on the accumulator
7
charging valve. The pressures are individual to each machine and
are on the pressure plate on the left-hand frame member, see section
10 Common hydraulics. Also fitted on the accumulator charging valve
8 are: Solenoid valve parking brake (position 6) and Break contact
(opening switch) parking brake (position 7).
• Solenoid valve parking brake, description, page 4:29
6 • Make-contact (closing switch) brake lights, description, page 4:17
• Normally closed (NC) switch, parking brake, description, page
014906
9 4:33
1. Safety valve
2. Connection from pump (P)
3. Connection, wheel brake (T)
4. Measuring outlet, pump pressure (M)
5. Measuring outlet, accumulator pressure (M)
6. Solenoid valve parking brake (Y642)
7. Switch (NO), parking brake (S200)
8. Connection, accumulators (ACC)
9. Connection to brake valve (B)
10. Connection, parking brake caliper (H)
11. Drain valve
12. Main valve, charging
13. Pressure limiting valve

4:22 4 Brakes – Accumulator charging valve
Accumulator charging, checking and adjustment
NOTE
Safety.
1 Run the machine warm the machine so that the oil reaches an
operating temperature of at least 50 ºC.
3 Depressurise the brake and hydraulic systems, see section B

Safety.
4 Connect a pressure gauge (0-25 MPa) to the accumulator

pressure measuring outlet on the accumulator charging valve.
5 Start the engine and run it at idle.
6 Close the drain valve on the accumulator charging valve.
014478
7 Check that the maximum pressure corresponds with the

accumulator pressure on the pressure plate on the left frame
beam.
015833
MPa

4 Brakes – Accumulator charging valve 4:23
8 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.
Anticlockwise: reduce pressure.
Clockwise: increase pressure.
9 Open the drain valve on the accumulator charging valve so that
the accumulators are drained and the valve switches to charging.
Close the valve and check the max. pressure again.
10 Repeat steps 8-10 until the accumulator pressure matches the
015649
data on the pressure plate.
Safety.
measuring outlet.
14 Fit the cover plates over the area on the gearbox.
Accumulator charging valve, replacement
NOTE
Safety.

Safety.
1 3 Mark the hydraulic hoses and electric cables as illustrated.

A 4 Detach the wiring from the accumulator charging valve.
5 Detach and plug all hydraulic hoses from the accumulator charging
valve.
2
B Remove the parking brake valve (C) for easier access.
NOTE
3 Plug all connections immediately to protect the brake system
5 from impurities.
C
6 Remove the accumulator charging valve.
015651
7 Transfer the connection adapters and sensors to the new

4 accumulator charging valve.
8 Fit the new valve.

1 9 Connect the hoses to the accumulator charging valve in

A accordance with the marking.
NOTE
2 Check that the O-rings are intact, clean and in the correct
B position.
10 Fit the parking brake valve and parking brake NO switch.

3 11 Connect the wiring to the accumulator charging valve.
5
C
015651
4

13 Turn on the main electric power and start the engine.
Check that the hydraulic connections are sealed tightly.
14 Check the charging and switching function, see Accumulator
charging, checking and adjustment, page 4:22.
015653

4 Brakes – Shuttle valve dual brake pedals 4:25
4.3.14 Shuttle valve dual brake pedals

Shuttle valve dual brake pedals, description
On machines with turnable operator's station there is an extra

brake pedal and brake valve for driving with the driver's seat facing
backward. The shuttle valve selects the strongest brake signal and
sends it on to the wheel brakes. The shuttle valve is located on the
underside of the cab floor.
2
1
4 3
008890
1. Shuttle valve
2. Brake pressure from brake valve (driving
forward)
3. Brake pressure from brake valve (driving
backward)
4. Brake pressure to wheel brake

4:26 4 Brakes – Shuttle valve dual brake pedals
Shuttle valve dual brake pedals, replacement
NOTE
Safety.
3 Mark up and detach the hydraulic hoses and the couplings from
the shuttle valve (position 1).
NOTE
from impurities.
4 Transfer the connection adapters to the new shuttle valve.

5 Fit the new shuttle valve.
6 Connect the hydraulic hose and the fittings to the shuttle valve in
accordance with the marking.
008441
1. Shuttle valve
NOTE
position.
7 Turn on the main electric power and start the engine. Let the
engine run at idle speed.
8 Test the brakes with both pedals a few times.
9 Check that the shuttle valve\qs connections are sealed tightly.

4 Brakes – Parking brake system 4:27
4.5 Parking brake system

Parking brake system, function description
800 rpm N
0 km/h
15
F
N
EDU795
R
R
1
4 5
D9 ECU790
6,12,14 D5 5,13
11
4
C
9,10 Pa
7
ACC
C 3 D6
8
P H
2 T
015654
1 The hydraulic oil pump pumps oil P (when the accumulator is Section 10 Common hydraulics, group 10.3.1
from the hydraulic oil tank. charged) = 13.0-16.5 MPa Tank
P (during cooling) = < 0.1 Section 10 Common hydraulics, group 10.4.1
MPa Gear pump with fixed displacement
2 The high pressure filter cleans the - Section 10 Common hydraulics, group 10.6.8
oil. High pressure filter
3 The accumulator charging valve P (when the accumulator is Accumulator charging valve, description, page
directs oil to charging of accumulator charged) = 13.0-16.5 MPa 4:21
or through the brake system\qs
P (during cooling) = < 0.1
cooling circuit.
MPa
4 The accumulator store oil pressure. See pressure plate on Section 10 Common hydraulics, group 10.3.2
left-hand front mudguard. Accumulator
5 Switch, parking brake (S107) Switch activated: Section 9 Frame, body, cab and accessories,
activates the parking brake by group 9.1 Controls and instruments.
Conn. 1, U = 22-28 V
sending a voltage signal to Control
unit, general (ECU 790). Conn. 7, U = 0 V
system, group 8.4.1.2 View Inputs, menu 2,
The switch uses a signal with two Switch in home position: ECU 790 output K1:23
levels, 24 V and 0 V, one for applied,
Conn. 1, U = 0 V
one for released parking brake. Both
levels must be correct for the parking Conn. 7, U = 22-28 V
brake to be released.
6 Control unit, general (ECU 790) U = 24 V D6: Diagnostic menu, see section 8 Control
activates Solenoid valve, parking system, group 8.4.1.2 View Outputs, menu 3,
brake (Y642) ECU 790 output K2:14
7 Solenoid valve parking brake (Y642) Pump pressure
acts on the valve slide which drains
pressure in the parking brake's brake
caliper to tank.

4:28 4 Brakes – Hydraulic oil pump

8 The brake caliper is drained of 0 MPa Parking brake unit, description, page 4:30
pressure and the spring applies the
parking brake.
9 Break contact (opening switch), Applied parking brake: Normally closed (NC) switch, parking brake,
parking brake, (S200) closes the description, page 4:33
Conn. 1, U = 24 V
circuit when the pressure increases
and sends a voltage signal to Control Conn. 2, U = 0 V
system, group 8.4.1.1 View Inputs, menu 1,
unit, general (ECU790).
Released parking brake: ECU 790 output K1:14
Conn. 1, U = 24 V
Conn. 2, U = 24 V
10 Break contact (opening switch), U = 24 V
parking brake (S200) also sends
a voltage signal to Relay, parking
brake (K314).
11 Relay parking brake (K314) connects U = 24 V Section 9 Frame, body, cab and accessories,
the indicator light in switch parking group
brake (S107) to ground and sends a
signal to Control unit, general (ECU
790).
12 Control unit general (ECU 790) U = 24 V Section 11 Common electrics, group 11.5.3.2
sends a signal over CAN-bus to ECU control unit 790
allow activating of inching /
declutch.
13 Indicating lamp in switch parking U = 24 V Section 9 Frame, body, cab and accessories,
brake (S107) is activated and a group 9.1 Controls and instruments.
signal is sent to Control unit general
(ECU 790).
14 Control unit general (ECU 790) Checked by control system, Section 11 Common electrics, group 11.5.3.2
sends information over CAN-bus to error shown with error ECU control unit 790
Control unit terminal (EDU795). code.
15 Control unit terminal (EDU795) U = 24 V Section 11 Common electrics, group 11.5.3.1
shows parking brake activated with Control unit EDU 795
a symbol in the display.

hydraulics

displacement.

See High-pressure filter, description, page 4:36.

4 Brakes – Solenoid valve parking brake 4:29
4.5.3 Solenoid valve parking brake

Solenoid valve parking brake, description
Solenoid valve parking brake (Y642) activates the parking brake. The
solenoid valve is fitted on the accumulator charging valve, which is
located to the left on the panel in the area in front of the transmission,
see Accumulator charging valve, description, page 4:21.
The solenoid valve opens a connection between the accumulators

and the parking brake caliper on activation. This means that the
parking brake caliper is pressurised and the parking brake is released.
When the voltage feed to the solenoid valve is cut off, the connection
between the accumulators and parking brake caliper is closed.
Instead, a connection between the parking brake caliper and tank is
opened and the parking brake is applied. This means that the parking
brake is applied if the machine becomes de-energised or if the brake
system becomes depressurised.
The solenoid valve is supplied with voltage by Control unit, general

(ECU790) on activation.
014961
Solenoid valve parking brake, checking
DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to
roll when the parking brake is released.
1 Start the engine and run it at idling speed until the accumulator
charging valve changes to cooling.
2 Switch off the engine and turn the start key to position I.
3 Release the parking brake with the switch for the parking brake
and check that the parking brake's brake caliper releases. The
brake caliper should be able to move.
4 Activate the parking brake with the switch for the parking brake
and check that the parking brake's brake caliper is applied.

4:30 4 Brakes – Parking brake unit
4.5.4 Parking brake unit

Parking brake unit, description
A The parking brake unit keeps the machine stationary when parked.
The parking brake unit is fitted on the drive axle input shaft between
B the propeller shaft and drive axle.
The parking brake acts on the propeller shaft via a disc mounted on
C the drive axle input shaft and a brake caliper with dry brake pads
mounted in a bracket on the drive axle.
NOTE
If the hydraulic pressure in the feed circuit drops, a warning is
activated before the pressure drops so low that the parking brake
is applied. If the parking brake is applied while the machine is in
motion, the brake disc and brake pads must be replaced.
014955
A Brake disc of parking brake

B Parking brake unit
C Protective cap over adjusting screw
Parking brake unit, replacement
NOTE
Safety.
3 Detach the hydraulic hose from the parking brake unit.
NOTE
from impurities.
014902

4 Brakes – Parking brake unit 4:31
4 Remove the parking brake unit attaching bolts (position 1).

1
5 Remove the parking brake unit.
014958
6 Transfer the connection adapter (1) to the new parking brake unit.
1
7 Fit the new parking brake unit.
8 Connect the hydraulic hose to the parking brake unit.
NOTE
position.
run at idle speed.
10 Release the parking brake.
014957
11 Adjust the adjusting screw so that the brakes are applied.

12 Unscrew the adjustment screw 0.5±0.1 mm.
13 Tighten the lock nut.
NOTE
To avoid turning the adjusting screw as well it must be held still
when tightening the lock nut.
14 Refit the cover to the calliper.

15 Test the parking brake a couple of times.
16 Check that the hydraulic connections are sealed tightly.

4:32 4 Brakes – Parking brake unit
4.5.4.1 Parking brake caliper
Parking brake calliper, description

The brake caliper has a spring section and a hydraulic section. The
1 2 3 4 spring section applies the brake while the hydraulic section is used to
release the brake. This allows the parking brake to be applied if the
brake system loses pressure, which in turn means that the machine is
slowed down if a serious fault occurs.
001198
1. Brake pads
2. Release cylinder
3. Thrust spring
4. Release screw
4.5.4.2 Parking brake pads
Parking brake pads, description

The brake pads consist of a metal plate with friction material (lining).
4.5.4.3 Parking brake disc
Parking brake disc, description

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

4 Brakes – Normally closed (NC) switch, parking brake 4:33
4.5.5 Normally closed (NC) switch, parking brake

Normally closed (NC) switch, parking brake,
description
Break contact (opening switch) parking brake (S200) detects whether
the parking brake is applied or released.
Break contact (opening switch) parking brake (S200) senses the

pressure in the parking brake circuit. When the pressure is so high
that the parking brake is released, the sensor closes an electric
circuit. This is used to indicate that the parking brake is released.
When the pressure exceeds the activation pressure, the break contact
(opening switch) parking brake (S200) sends a voltage signal to relay,
parking brake (K314) and Control unit, general (ECU790).
1
NOTE
014956 Gears cannot be engaged when the parking brake is applied.
1. Break contact (opening switch) parking brake

(S200)
Switch normally open (NO), parking brake,

replacement
NOTE
Safety.
3 Detach the connector from break contact (opening switch), parking

brake (position 1).
4 Remove break contact (opening switch), parking brake (position
1), from the parking brake unit.
5 Replace break contact (opening switch), parking brake.
1
014956
1. Break contact (opening switch) parking brake

(S200)

4:34 4 Brakes – Pipes and hoses


4 Brakes – Temperature control, cleaning and oil brake system 4:35
4.8 Temperature control, cleaning

and oil brake system
Temperature control, cleaning and oil brake
system, function description
C C
4
P T
2 5
3
002611
1 The hydraulic oil pump pumps oil from P (when the accumulator is Section 10 Common hydraulics, group
the hydraulic oil tank. charged) = 13.0-16.5 MPa 10.3.1 Tank
P (during cooling) = < 0.1 Section 10 Common hydraulics, group
MPa 10.4.1 Gear pump with fixed displacement
2 The high pressure filter cleans the oil. - Section 10 Common hydraulics, group
10.6.8 High pressure filter
3 The accumulator charging valve directs P (when the accumulator is Accumulator charging valve, description,
oil to charging of accumulators or charged) = 13.0-16.5 MPa page 4:21
through the brake system's cooling
P (during cooling) = < 0.1
circuit.
MPa
4 The oil cools the wheel brake. - Wheel brakes, description, page 4:18
5 The bypass valve in the distribution - Distribution block, description, page 4:36
block leads oil past the drive axle if the
back pressure through the wheel brake
is too great.

hydraulics
4.8.1 Hydraulic oil tank

Hydraulic oil tank, description
See section 10 Common Hydraulics, group 10.3.1 Tank.
4.8.2 Tank heater

Tank heater, description
See section 10 Common Hydraulics, group 10.6.1 Tank heater.

displacement.

4.8.4 Accumulator charging valve

Accumulator charging valve, description
See Accumulator charging valve, description, page 4:21

See Distribution block, description, page 4:13.
4.8.6 Wheel brakes

Wheel brakes, description
See Wheel brakes, description, page 4:18.
4.8.7 Oil cooler

Oil cooler, description
See section 10 Common Hydraulics, group 10.6.2 Hydraulic oil cooler.

See section 10 Common hydraulics, group 10.6.8 High-pressure filter.

4.8.14 Hydraulic oil

Hydraulic oil, description
The brake system uses the same hydraulic oil as the machine\qs other
hydraulic systems, see section 10 Common hydraulics, group 10.6.9
Hydraulic oil.

5:1
5 Steering
Contents 5 Steering
5 Steering ...............................................................................................................5:3
5.1.1 Steering wheel and steering wheel shaft.....................................................5:3
5.1.2 Mini-wheel ...................................................................................................5:3
5.1.3 Joystick control............................................................................................5:7
5.2 Power assisted system .................................................................................. 5:11
5.2.2 Priority valve..............................................................................................5:16
5.2.3 Steering valve ...........................................................................................5:16
5.2.4 Steering cylinder .......................................................................................5:19
5.2.5 Steering axle cradle ..................................................................................5:20
5.2.6 Link arm ....................................................................................................5:20
5.2.7 Wheel spindle............................................................................................5:21
5.2.8 Wheel hub .................................................................................................5:22
5.2.11 Sensor, steering wheel movement ............................................................5:22
5.2.14 Control valve steering ...............................................................................5:23
5.2.15 Directional control valve, turnable driver's seat.........................................5:27
5.2.16 Sensor turnable driver's seat.....................................................................5:27
5.2.17 Pipes and hoses........................................................................................5:27

5:2

5 Steering – Steering 5:3
5 Steering
5.1.1 Steering wheel and steering wheel shaft
Steering wheel and steering wheel shaft, replacement
2 Remove the steering wheel, steering panel covers, direction

indicators and the covers for the steering wheel shaft, see section
lever, replacement.
3 Remove the six bolts securing the steering wheel shaft.

4 Replace the steering wheel shaft.
NOTE
Torque tighten the socket cap screws that hold the multi-function
lever to the steering wheel shaft to 2.5-3.0 Nm.
Torque tighten the nut in the centre of the steering wheel to
40 Nm (5 Nm).
5.1.2 Mini-wheel
Mini-wheel, description
The mini-wheel is an electro-hydraulic function for comfortable steering

with the arm resting on the left-hand arm rest. The wheels always
follow the position of the mini-wheel. If the mini-wheel is released then
both steering wheel and wheels remain in the set position.
Otherwise, the same characteristics and settings apply as for joystick

control, see Joystick control, description, page 5:7. Amplification factor
setting in main loop, see Joystick control, description, page 5:7.
The control valve is electrically controlled by an electric steering

module (Y615). It controls the flow of oil to the steering cylinder via
the control valve. The solenoid valves receive analogue signals from
Control unit, steering (ECU 792).
The standard steering wheel is equipped with a sensor that checks all
steering wheel movements in an emergency situation. As soon as
steering with the standard steering wheel is started the mini-wheel is
disconnected and the lamp in the switch for forward/reverse goes out.

5:4 5 Steering – Mini-wheel

• 2-channel, 2-axis potentiometer in left-hand arm rest
• steering valve (impedance and current)
See also Joystick control/mini-wheel, function description, page 5:14.
Function test
See Function test, page 5:8.
Troubleshooting
See Troubleshooting, page 5:8.
Mini-wheel, replacement
2 Remove the mini-wheel by undoing the socket cap screw.

3 Replace the mini-wheel.

5 Steering – Mini-wheel 5:5
Mini-wheel travel direction selector, replacement

2 Remove the screws securing the top of the plastic panel for the
mini-wheel.
3 Unplug the connector from the travel direction selector.

4 Replace the switch.

5:6 5 Steering – Mini-wheel
Mini-wheel potentiometer, replacement

2 Remove the steering wheel by undoing the Allen screw.
3 Remove the Allen screw and nut.
mini-wheel.

5 Steering – Joystick control 5:7
5 Unplug the connectors from the potentiometer.

5.1.3 Joystick control

Joystick control, description
Joystick control is an electrically controlled function for steering the

% machine with a joystick on the left-hand arm rest. The steering angle
is inversely proportional to the machine's speed, i.e. low speed gives
large angle and vice versa.
V
001631
(km/h)
The steering angle can also be set in 10 steps from linear (step 0)
in to maximum exponential (step 10). In this way better response is
achieved with small steering angles.
out
001630
The operating menus in the main loop have a setting for the
amplification factor from 1 to 9 that the operator can set. It is possible
to set which factor the system should start up with.
-/+
001348
The control valve is electrically controlled by an electric steering

module (Y615). It controls the flow of oil to the steering cylinder via
the control valve. The solenoid valves receive analogue signals from
Control unit, steering (ECU 792).
The standard steering wheel is equipped with an inductive sensor that

recognises any steering wheel movements. The sensor is used to
disconnect the joystick control if the operator encounters an emergency
situation. As soon as the standard steering wheel is used the joystick
control is disconnected and the lamp in the switch for forward/reverse
goes out. The arrangement fulfils the safety requirements for a
feedback system.

5:8 5 Steering – Joystick control

• joystick in left-hand arm rest
• steering valve (impedance and current). Switches off steering in
the event of open circuit or short-circuit. Error code activated.
See also Joystick control/mini-wheel, function description, page 5:14
Function test
All test-running with the joystick control or mini-wheel must be
performed without load. It is when the steering axle is loaded that most
problems are felt distinctly.
Check that the joystick control/mini-wheel disengages when the

steering wheel is turned. If the steering wheel is turned slowly then
steering should not be disengaged. Internal leakage in the steering
valve can turn the steering wheel.
The mini-wheel should have 6-8 turns from one lock (end-position)
to the other. This must be tested when the machine is rolling slowly
(below 5 km/h) and applies when "Sensitivity" is set to 9.
If the machine is operated slowly (below 5 km/h), a small angling of

the lever (or slow turning of the steering wheel) should result in the
steering axle changing position slowly, without jerking or delay. Test
both to the right and left.
Test-run in a realistic work operation, for example:

1. Run at full speed forward.
2. Slow down and turn 90 degrees left.
3. Stop and reverse with 90 degree right turn.
1 2 3
4. Run back in the direction you came from.
004198
4 Does the machine follow the intended path? Position cones to

indicate the intended path.
Troubleshooting
All alarms are saved and can be read out according to "Last alarms",
see section 8 Control system, group 8.4.5 Last alarms. This may be
very useful when troubleshooting a machine that, according to the
operator or test, has had problems, but ones that are not triggered
when troubleshooting.
For error code tables, see section D Error codes.
A number of fault tracing examples are shown below.
Steering feels good at low speed, but uncontrollable at

high speed
Check the following:
1. Setting the start current. See section 8 Control system, group
8.5.4.1 Initiating joystick control, Adjusting joystick control.
2. Setting of linearity (only applies to joystick control). Can be set in
10 steps from linear (step 0) to maximum gear down sensitivity of
lever movements (step 10). This gives improved feel for small
steering movements. See section 8 Control system, group 8.5.4.1
Initiating joystick control.
3. Setting of speed dependence. See section 8 Control system,
group 8.5.4.1 Initiating joystick control, Adjusting joystick control.

5 Steering – Joystick control 5:9
Steering is shut off while operating

This occurs if any of the alarms for joystick control/mini-wheel is
generated. The steering is disengaged for safety reasons.
Steering can also be shut off by the inductive sensor that senses
movements of the standard steering wheel.

1. Cause of alarm, see section D Error codes.
2. Cabling and inductive sensor for standard steering wheel.
Steering is not shut off when the standard steering wheel

is turned
Use diagnostic menus to view input K1:3. Shall give signal 4
times/steering wheel turn.
Steering shall be shut off by the inductive sensor that senses

movements of the standard steering wheel.

1. The inductive sensor for standard steering wheel may be squeezed
too hard in its bracket. Replace sensor.
2. The steering wheel bracket is fitted too loosely on the steering
wheel shaft. It slides down, at which the sensors are incorrectly
positioned on the steering wheel shaft.
Steering cannot be turned on

Conditions for turning on steering:
1. No alarms active
2. Speed below 3 km/h
Wheels steer in opposite direction of the joystick.

1. Joystick has been deflected in the wrong direction when calibrating.
2. Electrical connection right - left valve incorrect. K1:6 shall be for
steering right. K1:7 shall be for steering left.
3. Valve - steering cylinder, faulty hydraulic connection. Switch hoses.
4. For turnable driver's seat: If steering steers to lock (end-position)
only when the seat is reversed. The settings (see section 8 Control
system, group 8.6 Software) state whether the steering should
switch right/left when the seat is reversed. This depends on
whether the steering valve is located before or after the valve that
changes the steering valve's flow to the steering cylinder. Different
for DCE50-90 and DCE100-180/DCF180-250.
Steering feels jerky or slow (harsh)

1. Setting of min. current for steering valve. If steering is jerky, min.
current is too high. If steering is slow (large angle before anything
happens), min. current is too low. For adjusting, see section 8
Control system, group 8.5.4.1 Initiating joystick control, Adjusting
joystick control.
2. Valve binds. Impurities in hydraulic system?
Start-up of new steering

1. Download program and setup.
2. Set basic values for "Initiation". Can be done with PC or menu.
3. Calibrate steering.
4. Fine-tune start currents for right and left, respectively.
5. Test-run and adjust. See section 8 Control system, group 8.5.4.1
Initiating joystick control, Adjusting joystick control.

5:10 5 Steering – Joystick control
Joystick, replacement
mini-wheel.
3 Unplug the connector from the joystick.

4 Replace the joystick.
6 Calibrate the joystick. See section 8 Control system, group 8.5.4.2
Calibration joystick control.

5 Steering – Power assisted system 5:11
5.2 Power assisted system

Power assisted system, function description
2
PP P
C
CF LS
T
6
P
LS T L R
3
4 7
1
014418
1 The hydraulic oil pump pumps oil to the See the pressure plate on Section 10 Common hydraulics, group 10.4.2
priority valve. the left-hand frame beam. Axial piston pump with variable displacement
2 The priority valve prioritises pressure Checked by control See section 10 Common hydraulics, group
feed to the control valve over working system, error shown with 10.5.3 Priority valve.
hydraulics. The priority valve also sends error code.
control signals to the hydraulic oil pump.
3 Shuttle valve control selects the Checked by control Section 10 Common hydraulics, group
strongest load signal to the hydraulic oil system, error shown with 10.5.4 Shuttle valve
pump if hydraulic functions are activated error code.
at the same time as the steering wheel
is turned.
4 Shuttle valve lift/tilt selects the strongest Checked by control Section 10 Common hydraulics, group
load signal to the hydraulic oil pump if system, error shown with 10.5.4 Shuttle valve
lift/tilt is activated at the same time as error code.
the steering wheel is turned.
5 The steering wheel is turned and acts on - Section 9 Frame, body, cab and accessories,
the steering valve\qs input shaft. group 9.1 Controls and instruments
6 The steering valve pumps pressurised - Steering valve, description, page 5:16
oil to the steering cylinder and transmits
a load signal to the main pump.
7 The steering cylinder turns the wheels. - Steering cylinder, description, page 5:19

hydraulics.

5:12 5 Steering – Power assisted system
Power assisted steering system, turnable

operator's station, function description
7 7
5
R
D7
2
PP
C C ECU790
P 6 8
CF
P
LS
LS T
3 T
L R
4
9
1 12 D8
10 10
11
014963
1 The hydraulic oil pump pumps oil to the See the pressure plate on Section 10 Common hydraulics, group 10.4.2
priority valve. the left-hand frame beam. Axial piston pump with variable displacement
2 The priority valve prioritises pressure Checked by control Section 10 Common hydraulics, group
feed to the control valve over working system, error shown with 10.5.3 Priority valve.
hydraulics. The priority valve also sends error code.
control signals to the hydraulic oil pump.
3 Shuttle valve control selects the Checked by control Section 10 Common hydraulics, group
strongest load signal to the hydraulic oil system, error shown with 10.5.4 Shuttle valve
pump if hydraulic functions are activated error code.
at the same time as the steering wheel
is turned.
the steering valve\qs input shaft. group 9.1 Controls and instruments
6 The steering valve pumps oil to the - Steering valve, description, page 5:16
directional control valve.
7 Sensor, turnable operator's station Forward = 0.5 V Sensor, turnable driver's seat, description,
forward (S720-1) or sensor, turnable page 5:27
Middle = 2.5 V
operator's station backward (S720-2)
controls a resistor network which Backward = 4.5 V
generates various voltages to the
ECU 790 input K1:37
Control unit, general (ECU 790)
depending on which direction the
operator's station is turned.


8 The Control unit general (ECU 790), - Section 11 Common electrics, group 11.5.3.2
sends a current signal to the solenoid General control unit ECU 790
valve, steering forward (Y636-1), or
solenoid valve, steering backward
system, group 8.4.1.2 View outputs, menu
(Y636-2).
1, ECU 790 output K2:38 (steering forward)
and menu 2, ECU 790 output K2:41 (steering
rearward).
9 Directional control valve, turnable - Directional control valve, turnable driver's
operator's station, controls pressure to seat, description, page 5:27
the steering cylinder.
10 Solenoid valve, steering forward - Directional control valve, turnable driver's
(Y636-1), or solenoid valve, steering seat, description, page 5:27
rearward (Y636-2), pressurise the valve
slide in directional control valve, turnable
operator's station.
11 Oil is forced into that side of the - Steering cylinder, description, page 5:19
cylinder that gives the desired change of
direction. Oil from the other side of the
cylinder flows to the steering valve.
12 The steering valve ensures that - Steering valve, description, page 5:16
returned oil from the steering cylinder is
transported back to the hydraulic tank.

hydraulics

5:14 5 Steering – Power assisted system
Joystick control/mini-wheel, function description

Joystick control/mini-wheel Voltage signal from Mini-wheel, description, page 5:3
activated mini-wheel/joystick control
Joystick control, description, page 5:7
switch.
Steering wheel stationary No signal from the steering angle Sensor, steering wheel movement, description, page 5:22
sensor.
Speed Below 3 km/h (at engagement) Section 2 Transmission.
Control breaker Not activated Section 9 Frame, body, cab and accessories, group 9.2.1
Control switch.
ECU790 2, 13
1
ECU792 11
EDU795
D1
D12
12
D2
C
4, 8 3 9
EF
P Ps P
LS Ts T
T
5 CL CR L R
7
10
014964


1 Joystick control Signal 1, U = 0.5 - 4.5 V Joystick control, description, page 5:7
The potentiometer in the switch joystick D1: Diagnostic menu, see section 8 Control
(R825) sends a voltage signal to Control system, group 8.4.2.1 View inputs, menu 4,
unit steering (ECU 792). ECU792 input K1:31
Mini-wheel Signal 1, U = 0.5 - 4.5 V Mini-wheel, description, page 5:3

The 2-channel potentiometer in the Signal 2, U = 0.5 - 4.5 V D1: Diagnostic menu, see section 8 Control
mini-wheel switch (R825) sends a system, group 8.4.2.1 View inputs, menu 4,
voltage signal to the steering control unit ECU 792 input K1:35 and K1:36.
(ECU 792), which calculates the rotation
speed of the joystick.
2 Control unit, steering (ECU792) supplies U = 0 V to battery voltage. Section 11 Common electrics, group
voltage to the electric steering module 11.5.3.14 Control unit, steering.
Steering takes place
(Y615). When the voltage is 50% of the
as set out below as a D2: Diagnostic menu, see section 8 Control
battery voltage the valve is in the neutral
percentage of the battery system, group 8.4.2.2 View outputs, menu
position. Lower voltage gives steering to
voltage: 2, ECU 792 output K1:06.
the left and higher voltage gives steering
to the right. 0-15% = error indication
25% = full steering left
approx. 45% = start
steering left
50% = neutral position
approx. 56% = start
steering right
76% = full steering right
85-100% = error indication
In the event of signal
error or internal fault in
the valve a signal is sent
from the steering valve
to Control unit, steering
(ECU792) (24V).
3 Electric steering module (Y615) - Control valve steering, description, page
pressurises the steering slide in Control 5:23
valve, steering.
On machines with turnable operator's

station, right is changed to left when the
driver's station is turned to the back.
4 The priority valve sends a load signal to - Section 10 Common hydraulics, group
the shuttle valve for steering. 10.5.3 Priority valve.
5 Shuttle valve steering selects the Checked by control Section 10 Common hydraulics, group
strongest load signal to the hydraulic system, error shown with 10.5.4 Shuttle valve
oil pump for steering and load handling error code.
if hydraulic functions are activated at
the same time as the steering wheel is
turned.

5:16 5 Steering – Hydraulic oil pump

7 The hydraulic oil pump for steering See the pressure plate on Section 10 Common hydraulics, group
and load handling pumps oil from the the left-hand frame beam. 10.4.2 Axial piston pump with variable
hydraulic oil tank. displacement.
8 The priority valve prioritises pressure See the pressure plate on Section 10 Common hydraulics, group
supply to the steering valve over the the left-hand frame beam. 10.5.3 Priority valve.
working hydraulics.
9 The steering spool changes position and -
pressurises the steering cylinder.
10 The steering cylinder turns the wheels. - Steering cylinder, description, page 5:19
the steering valve\qs input shaft. group 9.1 Controls and instruments.
12 The steering angle sensor (B770) sends U = 24 V Sensor, steering wheel movement,
a voltage signal to the KIT cab control description, page 5:22
unit (D790-2).
D12: Diagnostic menu, see section 8
Control system, group 8.4.2.1 View inputs,
menu 1, ECU792 input K1:03
13 Control unit, steering (ECU792) sends Checked by the control -
abort steering on the CAN-bus. system, error indicated
with error code.

hydraulics

Hydraulic oil pump, general
See section 10 Common hydraulics, group 10.4.2 Axial piston pump
with variable displacement.
5.2.2 Priority valve

Priority valve, description
See section 10 Common hydraulics, group 10.5.3 Priority valve.
5.2.3 Steering valve

Steering valve, description
The steering valve is the load sensing type with load signal connection
to the valve block. The load signal provides load dependent regulation
of the oil pressure from the valve block to the steering valve.
The steering valve consists of a gear pump and a distribution valve.

When the steering wheel is turned, oil is fed from the valve block over
the gear pump to the distribution valve which ensures that the oil flow
is supplied to the port that corresponds to the direction of rotation.
The gear pump ensures the oil flow fed to the cylinder is proportional
T to the steering wheel's turning angle.
L
P The control valve contains built-in shock and anti-cavitation valves.
R
The shock valves, which open at 200 bar, prevent high pressures
spikes being propagated to the steering valve through impact against
the steering wheels. Underpressure on opposite side of the piston,
which can lead to cavitation (cavity in which steam can form), is
008848
prevented by means of the anti-cavitation valves (non-return valves)

opening.
Steering valve with connections

5 Steering – Steering valve 5:17
1
2 Applies to machines with joystick control/mini-wheel.
3
The control system consists of a pilot control valve that gives a signal
with low pressure and low flow (load signal) to the control valve
steering. Control valve, steering acts as a pilot-operated directional
control valve with an electric steering module (Y615).
The control valve steering also has a built-in priority valve that gives
priority to oil to the steering function. For control valve steering, see
5
Control valve steering, description, page 5:23.
4
015656
Steering valve with connections, machine with joystick

control/mini-wheel
1. Steering valve
2. Load signal steering left (L)
3. Tank return (T)
4. Pressure feed (P)
5. Load signal steering right (R)

5:18 5 Steering – Steering valve
Steering valve, replacement
NOTE
Safety.
3 Remove the six screws securing the lower plastic steering wheel
shaft cover.
Remove the plastic cover.
4 Mark up and detach the hydraulic hoses from the steering valve.
NOTE
from impurities.
5 Secure the steering valve.

5 Steering – Steering cylinder 5:19
6 Remove the four screws securing the steering valve to the cab
floor.
7 Remove the steering valve by pulling it downward.
8 Transfer the connection adapters to the new steering valve.
9 Fit the new steering valve.
10 Connect the hydraulic hoses to the steering valve in accordance
with the marking.
NOTE
position.
run at idle speed.
Attachment of steering valve.
12 Test the steering a couple of times.
13 Check that the steering valve\qs connections are sealed tightly.
5.2.4 Steering cylinder

Steering cylinder, description
The steering cylinder is a double-acting hydraulic cylinder with a piston
1
rod running all the way through, acting on the wheels via link arms.
3
008852
Steering cylinder, replacement
NOTE
Safety.
3 Remove the wheels (steering).
4 Detach the link arms from the steering cylinder as described under
Link arm, replacement, page 5:21.
5 Mark up and detach the hydraulic hoses from the steering cylinder.
NOTE
from impurities.
008853

5:20 5 Steering – Steering axle cradle
6 Remove the four screws securing the steering cylinder to the

steering axle cradle.
7 Transfer the connection adapters to the new steering cylinder.
8 Fit the new steering cylinder. Tightening torque: 940 Nm (oil).
9 Connect the hydraulic hoses to the steering cylinder in accordance
with the marking.
NOTE
014973
position.
10 Fit the link arms to the steering cylinder.

11 Fit the wheels (steering).
run at idle speed.
13 Test the steering a couple of times.
14 Check that the steering cylinder\qs connections are sealed tightly.
Hydraulic cylinders, repairs

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

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

Link arm, description
The link arm transfers the lateral movement of the steering cylinder to
turning the wheel spindles.
The setting of the steering wheels cannot be adjusted. If the link arms
are deformed in a way that changes the setting of the steering wheels
then they must be replaced.
The link arms must be turned to the right direction, otherwise they can
be damaged by the rims with large wheel angles.
1
008854
1. Link arm

5 Steering – Wheel spindle 5:21
Link arm, replacement

2 Remove the wheels (steering).
3 Remove the screw and locking plate that hold the stub axle.
008857
4 Remove the stub axles.

008858
5 Replace the link arm.
NOTE
Check that the bearings in the link arm are correctly aligned
before the link arm is installed.

008859
5.2.7 Wheel spindle

Wheel spindle, general
See section 6 Suspension, group 6.2.2 Wheel spindle.
Wheel spindle, replacement

See section 6 Suspension, group 6.2.2 Wheel spindle.

5:22 5 Steering – Wheel hub
5.2.8 Wheel hub

Wheel hub, general
See section 6 Suspension, group 6.2.3 Wheel hub.
Wheel hub, replacement

See section 6 Suspension, group 6.2.3 Wheel hub.
5.2.11 Sensor, steering wheel movement

Sensor, steering wheel movement, description
1
The steering wheel movement sensor (B770) detects whether the

steering wheel has been turned and sends a signal to Control unit,
steering (ECU 792). This is used to disengage joystick control or
mini-wheel. The sensor is located by the steering shaft inside the
panels.
2 The sensor is activated by a metal plate on the steering shaft with four
cams. The location of the sensor and the spacing between the cams
means that small movements on the steering wheel can be detected.
014420
1. Metal plate (with four teeth)

2. Sensor steering wheel movement
Sensor steering wheel movement, replacement

2 Remove the steering wheel and the steering panel covers, section
lever, replacement.
3 Undo the screw securing the sensor.

4 Unplug the connector from the sensor.
5 Replace the sensor.
NOTE
Do not tighten the screws that hold the sensor too tightly. The
sensor could then break.
NOTE
The distance between the sensor and metal plate must not be
008447
more than 1.5 mm.
Attachment of steering wheel movement sensor.

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

Control valve steering, description
Valve slide, steering
1
2 Applies to machines with joystick control/mini-wheel.
11
The control valve is a proportional valve controlled by load signals
from the steering valve. This means that both volume and direction of
the flow from the valve can be adjusted and that the valve also sends
a control signal to the hydraulic oil pump. The load signals control a
spring-centred valve slide that controls the pressure and flow for the
existing direction.
3
The electric steering module (Y615) is fitted on the control valve for
4 steering. The steering module is an electrically-operated pressure
reducing valve that converts electric current from the joystick
10 control/mini-wheel to servo pressure. The servo pressure then
controls the spring-centred valve slide, which controls the pressure
9 and flow for the current direction. The steering module controls the
8 control valve for steering via signals from the Control unit steering
(ECU792).
5 6 7
Valve slide, steering
The valve slide controls the direction and steering angle by controlling
the hydraulic pressure to the steering cylinder.
The valve slide is controlled by the steering Servo valve.

Servo valve steering
014974
The steering servo valve controls the servo pressure to valve slide
steering, so that it controls the oil pressure for steering right or left.
1. Electric steering module (Y615)
The steering servo valve is controlled electrically with the electric
2. Control valve steering
steering module (Y615) which is activated by Control unit, steering
3. Load signal to shuttle valve load handling and (ECU792).
steering (LS)
4. Tank return (T)
5. Pressure feed to steering valve (PS)
6. Tank return from steering valve (TS)
7. Load signal steering right (R)
8. Connection steering cylinder (CR)
9. Connection steering cylinder (CL)
10. Load signal steering left (L)
11. Priority valve

5:24 5 Steering – Control valve steering
Control valve steering, replacement
NOTE
Safety.
3 Mark and disconnect the hydraulic hoses from the control valve.
NOTE
from impurities.
015673 4 Mark and disconnect the cable harness from the control valve.
5 Remove the priority valve from the control valve.

015674

5 Steering – Control valve steering 5:25
6 Loosen the screw and remove the control valve from the mounting
plate. Place the valve on a clean and protected surface.
7 Transfer parts to the new control valve.
NOTE
position.
NOTE
Transfer one connection at a time so that the marking is not
mixed up.
8 Fit the new valve.

9 Connect the cable harness to the control valve according to the
marking.
015675
10 Connect the hydraulic hoses to the control valve in according to
the marking.
NOTE
position.
11 Connect the priority valve.
NOTE
Check that the accumulator drain valve is fully closed and
13 Start the engine and check for leaks.

14 Check the function.
CAUTION
Air in the hydraulic system may cavitate and result in
014476
product damage.
Activate the steering carefully and operate at the lowest
possible speed a couple of times to avoid cavitation.
15 Check the oil level in the hydraulic system, fill if necessary.
CAUTION
Do not overfill!
Leakage and environmental damage!
Check the hydraulic oil level with all hydraulic cylinders
fully retracted.

5:26 5 Steering – Control valve steering
Electric steering module, joystick control or

mini-wheel, replacement
NOTE
Safety.
3 Mark and disconnect the cable harness from the solenoid valve.
4 Loosen the screws and remove the solenoid valve from the control
valve.
5 Fit the new solenoid valve.
6 Connect the cable harness to the solenoid valve according to the
marking.
015676
NOTE

CAUTION
014476
product damage.

5 Steering – Directional control valve, turnable driver's seat 5:27
5.2.15 Directional control valve, turnable driver's

seat
Directional control valve, turnable driver's seat,
description
On machines with turnable operator's station there is an additional

directional control valve (reversing valve) between the steering valve
and the steering cylinder. The directional control valve shifts the
connections between the steering valve and the steering cylinder
1 2 when the operator is turned to drive in reverse so that the steering
wheel and wheel angles correspond.
The directional control valve is actuated by solenoid valve, steering

forward (Y636-1) or solenoid valve, steering rearward (Y636-2).
See also section 9 Frame, body, cab and accessories, group 9.3.9
3 Turnable driver's seat.
005710
6 5 4
1. Pressure to steering cylinder (A)

2. Pressure from steering valve (T)
3. Pressure to steering cylinder (B)
4. Solenoid valve, steering forward (Y636-1)
5. Pressure from steering valve (P)
6. Solenoid valve, steering rearward (Y636-2)
5.2.16 Sensor turnable driver's seat

Sensor, turnable driver's seat, description
Machines with a turnable operator's station have two make-contact

closing switches that detect whether the driver's station is facing
forward or backward.
Sensor, turnable driver's seat, forward (S720-1) and Sensor, turnable

driver's seat, reverse (S720-2) send a voltage signal via a resistor
1
network to Control Unit Steering (ECU 792).
See also section 9 Frame, body, cab and accessories, group 9.3.9
Turnable driver's seat.
002629
2
1. Sensor, turnable operator's station, reverse
(S720-2)
2. Sensor, reversible driver\qs position, forward
(S720-1)


5:28

6:1
6 Suspension
Contents 6 Suspension
6 Suspension .........................................................................................................6:3
6.2 Suspension ......................................................................................................6:4
6.2.1 Steering axle cradle ....................................................................................6:5
6.2.2 Wheel spindle..............................................................................................6:7
6.2.3 Wheel hub ...................................................................................................6:9
6.3 Tyres and rims ...............................................................................................6:15
6.3.1 Tyres .........................................................................................................6:16
6.3.2 Rim ............................................................................................................6:17
6.3.3 Nut, washer and clamp .............................................................................6:18

6:2

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

6:4 6 Suspension – Suspension
6.2 Suspension
Suspension, description
The steering axle cradle is secured in frame with two bushings, one at
the front edge and one at the rear edge of the steering axle cradle. The
steering axle cradle contains two wheel spindles mounted on king pins
which are bearing-mounted in the steering axle cradle. The machine is
steered by means of the wheel spindles rotating. The wheel spindles
have bearings for the wheel hubs, to which the wheels are attached.
Suspension, component location

4 Suspension refers to:
• Steering axle cradle
• Wheel spindle
5
1 • Wheel hub
2
3
007811
11 10 9 8 7 6
1. Steering axle cradle
2. Fixing lug on steering axle cradle
3. Rubber bushing
4. Tyres
5. Rim
6. Steering cylinder
7. Piston rod
8. Link arm
9. Wheel spindle
10. Hub
11. Bolts

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

Steering axle cradle, description
The steering axle is pendulum suspended with a double-acting steering
cylinder. The design comprises a minimum of moving parts to minimise
service points and simplify maintenance.
The frame suspension comprises maintenance-free parts. The rear

suspension is designed with a fixed bolted joint.
Steering axle cradle, replacement
DANGER
Steering axle and machine are very heavy.
Risk of crushing!
It is forbidden to go under a machine which has been
lifted by a jack etc. For machine weight, see section F
Technical data.
NOTE
Safety.
2 Support the machine under the counterweight.

3 Remove the steering wheels.
008967

6:6 6 Suspension – Steering axle cradle
4 Raise the steering axle cradle slightly.

5 Release the cables from the steering angle sensor (only refers to
machines with joystick control).
6 Position a receptacle under the steering cylinder's hydraulic hoses.
7
NOTE
from impurities.
8 Remove the circlip that is fitted on the stub axle at the front and
rear mounting points.
9 Tap out the stub axle with a sledgehammer.
10 Move the steering axle cradle aside in a suitable way.
CAUTION
The steering axle may start to roll.
Crushing injury!
Make sure that the steering axle does not roll away
uncontrollably.
11 Lift the new steering axle into place under the frame.
12 Fit the axles in the front and rear mounting points. Fit circlips onto
the stub axles.
NOTE
Lubricate mounting points and axle with copper paste or Similar
to prevent corrosion.
13 Connect the hydraulic hoses to the steering cylinder in accordance

with the marking.
NOTE
position.
14 Connect the cables to the steering angle sensor (only refers to

machines with joystick control).
15 Remove the lifting equipment from the machine.

6 Suspension – Wheel spindle 6:7
6.2.2 Wheel spindle

Wheel spindle, description
The wheel spindle is the link between steering axle and wheel hubs
which means that the wheels can be turned.
The wheel spindle is bearing-mounted with a roller bearing (lower

bearing) and a taper roller bearing (upper bearing).
3
2
4
5
1 6
8 7
9
009780
11 10
1. Wheel spindle
2. Seal ring
3. Bearing (upper)
4. Protective ring
5. Seal ring
6. Bearing (lower)
7. Circlip
8. Shim
9. Bearing cage
10. Screws
11. Grease nipple
Wheel spindle and bearing for king pin, replacement
DANGER
Tyres should be regarded as pressure reservoirs. If
handled incorrectly, they constitute fatal danger.
Parts could be thrown out with explosive force and
cause severe injuries.
Never repair damaged tyres, wheel rims or lock rings.
Tyre changes must be performed by authorised
personnel.
2 Raise the machine under the steering axle at the wheel in

question. Support the steering axle in a safe way.

6:8 6 Suspension – Wheel spindle
3 Remove the steering wheel in question.
4 Clean the wheel spindle and its surrounding area.
5 Detach the link arm from the wheel spindle, see section 5 Steering,
group 5.2.6 Link arm.
6 Remove the wheel hub and wheel bearing; see Wheel hub and
wheel bearings, replacement, page 6:10.
7 Remove the six screws holding the bearing cage to the wheel
spindle.
8 Detach the bearing cage by screwing a screw into the removal

hole.
9 Remove the bearing cage and shim from the wheel spindle.
10 Remove the wheel spindle.
11 Remove the three screws on the top of the steering axle cradle.
Press out the upper bearing's outer bearing race by screwing three
screws (about 90 mm long) into the holes.
12 Remove the inner bearing races of the upper and lower bearings
from the wheel spindle.
13 Remove the outer bearing race of the lower bearing from the
bearing cage.
14 From underneath, tap in the outer bearing race of the upper
002419
bearing into the steering axle cradle. Use a pipe of a suitable

diameter so as not to damage the bearing race.
15 Refit the three screws on the top of the steering axle cradle.
16 Fit upper bearing's inner bearing race, seal ring, guard ring and
seal ring as well as the lower bearing's inner bearing race and
circlip on the wheel spindle.
17 Fit the wheel spindle.
18 Tap the lower bearing's outer bearing race into the bearing cage.
Use a pipe of a suitable diameter so as not to damage the bearing
race.
19 Fit the bearing cage and tighten it with adjusting shims, tighten the
six screws to a tightening torque of 70 Nm.
20 Check that the wheel spindle rotates smoothly, with a maximum
clearance of 0.25 mm. If necessary, correct with shims.
21 Lubricate the wheel spindle bearings via the grease nipples.
22 Fit the wheel hub and wheel bearing; see Wheel hub and wheel
bearings, replacement, page 6:10.

6 Suspension – Wheel hub 6:9
23 Attach the link arm to the wheel spindle, see section 5 Steering,
group 5.2.6 Link arm.
24 Fit the wheel.
25 Remove the support and lower the steering wheel.
26 Test-operate the machine and test the steering. Check also that
the machine feels stable when driving straight ahead.
6.2.3 Wheel hub

Wheel hub, description
The wheel hub holds the wheel in place and allows the wheel to
3 2
rotate. The hub is bearing-mounted with two taper roller bearings.
1
4
5
6
7
8
9
10 11
008595
1. Wheel hub
2. Wheel bolt
3. Wheel nut
4. Hub cap
5. Spacer
6. Nut
7. Washer
8. Bearing
9. Screw
10. Bearing
11. Seal ring

6:10 6 Suspension – Wheel hub
Wheel hub and wheel bearings, replacement

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

4 Remove the hub cover.
5 Wipe away grease from hub cover and hub nut. Handle it as
environmentally hazardous waste.
6 Bend up the locking washer's tabs.
7 Remove the lock nut, locking washer and the bearing nut.

8 Remove the protecting washer from the hub.
9 Remove the entire wheel hub including the outer bearing.
10 Remove the inner bearing race from the wheel spindle.

11 Remove the bearings' outer races from the hub.
Use a drift and tap out the bearing races.
12 Remove the seal from the hub.
13 Clean the hub and line the inside with universal grease "EP2".
14 Fit new outer bearing races in the hub.
Use a drift and tap in the bearing races. Never use directly on
the bearings.
NOTE
Fit the outer races with the larger diameter outward.

15 Fit the inner bearing's inner race and rollers on the wheel spindle.
Pack the bearing with universal grease "EP2".
16 Fill the empty space in the hub with universal grease "EP2".
17 Fit the hub on the wheel spindle.

18 Install the outer bearing, protecting washer, and bearing nut.

Pack the bearing with grease and fit the bearing.
Fit the washer and hub nut with the smooth surface in towards
the hub.
009177 19 Tighten the bearing nut in the following stages.
a) Lubricate the thread and the side of the nut facing the bearing
with oil (SAE 80W/140).
b) Tighten the nut while turning the hub.
c) Rotate the hub at least 10 revolutions.
d) Tighten the nut while turning the hub.
e) Repeat the procedure b-d until the nut does not move during
tightening.
f) Check the upper limit of the friction torque in accordance with
the following:
The upper limit can be checked using a spring balance. Max.
friction torque should be approx. 19 Nm.
Max 8 kg
Wrap a wire a couple of times around the wheel nuts before the
wheel is fitted and suspend with spring scales.
510 mm
009580
g) Read from the scale when the hub begins to rotate.

20 Fit the lock nut and tighten to at least 250 Nm or then more to
engage the locking washer in the closest groove. Lock the bearing
nut and lock nut with the locking washer.
21 Fill the bearing casing with grease and fit it.

22 Grease the wheel bearing with grease through the lubricant nipple.
Rotate the hub to distribute the grease. Lift the seal ring's lip with
a small screwdriver to facilitate the escape of air. Lubricate until
grease comes out at the seal.
23 Fit the wheel.
24 Remove the support and lower the steering wheel.
007862

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

Tyres and rims, safety
DANGER
Always block the wheels on the side of the axle that
is not going to be worked on before positioning the
jack. Always secure the jack to prevent it from sliding
out of position.
Fully deflate the tyre before removal. Otherwise the
conical ring and locking clips can loosen and shoot
out when the pressure is changed. With double wheel
fitting both tyres must be fully deflated!
The air should always be released via the valve. If this
is not possible - loosen the valve in the wheel rim and
deflate. If this is not possible then break, cut or saw
off the valve stem. If it is not possible to release the
air through the valve connection then the tyre must be
deflated by drilling a hole in the tyre tread. Use a drill
bit with max. Ø 5 mm. Damaged tyres may explode.
Never stand directly in front of the wheel when
013940
deflating or inflating. The conical ring and locking

clips can loosen and shoot out when the pressure is
changed.
Never fit damaged tyres or rims.
Example: The figure shows inflating the drive wheels.
It is prohibited to repair rims with welding.
It is prohibited to operate the machine if one of the
tyres is flat.
Wheels, tyres and rims are dimensioned and selected
for each machine type so that maximum wheel loads
and travel speeds are not exceeded. For this reason it
is not permitted to change tyre dimension, tyre make,
tyre type, rim type, or rim make without approval from
Cargotec.

6:16 6 Suspension – Tyres
CAUTION
When removing wheels, the wheel nuts should be left
in place after loosening. If the wheel nuts are removed
immediately, the wheel may release from the hub.
When removing drive wheels, make sure that the
wheels are secured in position when the spacer rings
are removed. If the wheels move they may displace the
spacer rings, with crushing injuries as a result.
When fitting drive wheels, ensure that the clamps clamp
straight on the spacer ring.
Wheel nuts should be check-tightened after 4-5
operating hours.
Always follow the tyre manufacturer's or other approved
instructions when changing tyres.
Never use a steel hammer to fit or remove rim
components. Instead, use a lead, brass or plastic
mallet.
Keep the tyre pressures at the prescribed level.
Insufficient tyre pressure impairs stability and reduces
the machine's capacity.
Remove stuck objects such as crushed glass, pieces
of wood, metal filings, etc.
Check if tyre wear is abnormal. This could indicate a
mechanical fault. Rectify faults immediately and change
damaged tyres.
6.3.1 Tyres
Tyres, description
The tyres are the point of contact between the machine and the
ground, and they absorb unevenness and provide suspension.
The drive axle is subject to major forces during operation. If each

tyre's rolling circumference differs, the stresses on the drive axle
increase. For this reason it is important that the tyres on the drive
axle have equal wear and correct air pressure.
Spare and replacement tyres must be from a manufacturer approved

by Cargotec.
001544
Rear wheels

6 Suspension – Rim 6:17
001545
Front wheels
Tyres, changing
DANGER
Changing tyres is complicated and dangerous work.
EXTREME DANGER!
Leave tyre work to authorised personnel/tyre company.
The rims must be checked when tyres are changed. See Maintenance
manual.
6.3.2 Rim
Rim, description
The rim is split to make it possible to fit a tyre. The rim consists of
1 2
the following parts.
3 4 1. Inner rim
2. Outer rim
3. Inner spacer ring
4. Outer spacer ring
5. Clamp
6 6. Nut
5
007892

6:18 6 Suspension – Nut, washer and clamp
6.3.3 Nut, washer and clamp

Nut, washer and clamp, description
The rim is attached to the wheel hub with nuts and clamps.
There are 22 nuts and clamps that attach each front wheel to the drive
axle with hub reduction.
Each rear wheel is attached with 12 nuts and clamps on the steering
axle.
Bolt equipment, replacement

2 Raise the machine under the counterweight.
008967
3 Remove the wheel.
4 Knock out the bolt with a sledge hammer.

5 Install the new bolt.

7:1
7 Load handling
Contents 7 Load handling

7 Load handling .....................................................................................................7:3
7.1.1 Control lever ................................................................................................7:3
7.2 Lift and lower....................................................................................................7:8
7.2.1 Hydraulic oil pump..................................................................................... 7:11
7.2.3 Control valve load handling ....................................................................... 7:11
7.2.4 Lift cylinder ................................................................................................7:14
7.2.5 Accumulator damping ...............................................................................7:14
7.2.6 Mast ..........................................................................................................7:16
7.2.7 Mast wheels ..............................................................................................7:23
7.2.8 Chains .......................................................................................................7:24
7.2.9 Chain wheels and hose wheels.................................................................7:25
7.2.10 Trolley........................................................................................................7:26
7.2.11 Load control valve .....................................................................................7:29
7.2.12 Pipes and hoses........................................................................................7:30
7.2.14 Support roller.............................................................................................7:30
7.2.15 Top support roller ......................................................................................7:32
7.4 Side shift ........................................................................................................7:33
7.4.3 Control valve load handling .......................................................................7:36
7.4.4 Side shift cylinder ......................................................................................7:37
7.4.6 Trolley........................................................................................................7:38
7.4.7 Pipes and hoses........................................................................................7:38
7.5 Spreading (positioning) ..................................................................................7:39
7.5.4 Flow divider ...............................................................................................7:48
7.5.5 Spreading cylinder ....................................................................................7:48
7.5.6 Trolley........................................................................................................7:49
7.5.7 Pipes and hoses........................................................................................7:49
7.7 Tilt ..................................................................................................................7:50
7.7.4 Load holding valve (over-centre valve) .....................................................7:54
7.7.5 Tilt cylinder ................................................................................................7:55
7.7.6 Mast ..........................................................................................................7:58
7.7.7 Pipes and hoses........................................................................................7:58
7.9 Load carrier....................................................................................................7:59
7.9.1 Lift forks.....................................................................................................7:59
7.10 Other functions...............................................................................................7:61
7.10.1 Scale .........................................................................................................7:61

7:2

7 Load handling – Load handling 7:3
7 Load handling
7.1.1 Control lever
Control lever, replacement
NOTE
Safety.
3 Remove the cover from the control levers (six screws).
4 Detach the control levers from the bracket (four screws).

7:4 7 Load handling – Control lever
5 Cut the cable tie and fold down the gaiter to expose the control
levers\q connections.
6 Lift the control levers off the bracket.
7 Remove the hose connections.

7 Load handling – Control lever 7:5
8 Unscrew the control levers.

9 Replace the relevant control lever. Also replace the O-ring in the
event of leakage.
10 Check that there are no leaks when the levers are refitted.
Electro-hydraulic servo, description

The electrical servo makes possible the use of small fingertip controlled
linear levers, or a "joystick", for the different functions of the working
hydraulics.
The control levers contain potentiometers. The output signals

from these are handled in ECU 796 and then used for control of
electro-hydraulic proportional valves (see section 10 Common
hydraulics, group 10.5.5 Proportional valves). These convert the output
signals from ECU 796 to hydraulic servo pressure which then controls
the adjustment slides in the hydraulic system's main valve.
During operation, the output signals are changed via two break points
in proportion to the lever deflections, which gives direct control of the
main valves. An IIR type filter and a ramp for lifting/lowering have
been added in order to dampen high frequency interference from the
surroundings and to obtain smooth hydraulic movements but with
maintained speed. The lowering movement has a longer ramp time
than lifting.
There is a control switch next to the electrical control levers or joystick.

When it is depressed, the voltage supply is closed to the PWM output
signals in ECU 796. At which point, no hydraulic functions can be
moved. A red LED in the end of ECU 796 flashes if the control switch
has been depressed. A green LED is activated with a constant glow if
the supply voltage is between 22-28 V, it flashes at a high frequency
if the voltage is above 28 V, and flashes at a lower frequency if the
voltage is below 22 V. A yellow LED is activated with a constant glow if
the communication on the CAN bus is working. The output signal is
broken at two points for improved detailed sensitivity. Breakpoint 1
(BP1) is preset so that at 40% of lever movement the ECU gives 20%
of max. output signal. Breakpoint 2 (BP2) is set so that at 80% of lever
movement the ECU gives 60% of max. output signal. Hence the ECU
gives 100% output signal at 100% lever movement.
The control of the main valve (diagram y-axis) is not proportional to
out the lever angle (diagram x-axis). This gives a better response with
small lever angles.

• control levers or joystick
in • proportional valves (impedance and current)
001632

7:6 7 Load handling – Control lever
Function test
In general, test all hydraulic functions to make sure that they react and
move in the correct direction. The speed of the movements may need
to be adjusted individually for each machine. For example, side shift
may be too fast at times, then max. current should be set to a lower
value for the respective solenoid valve.
1. Dead zone. Check if the dead zone is sufficient by test-running the
machine on an uneven surface and note if any hydraulic function
moves. If it does, increase the dead zone, for example, 10 steps.
2. Lift/lower movement. Check smoothness of movement at idle and
max. rpm.
3. Tilt in/out. Same as lift/lower.
4. Side shift. Same as lift/lower.
5. Spreading (positioning). Same as lift/lower.
Separate spreading. Same as lift/lower.
Troubleshooting
For error code tables, see section D Error codes.
A number of fault tracing examples are shown below.
Symptom: Lifting/lowering not working!

• Error code 610. No signal or incorrect signal from the
lifting/lowering lever. If the signal is outside the calibrated values
for more than 100 ms then the alarm is generated. Try to calibrate
the lever again. If the problem persists, replace the lever.
• Error code 615 or 616. Short circuit or open circuit in the solenoid
valve for lifting/lowering. Check whether the connector to the valve
block is pushed in far enough. Otherwise, measure the resistance
in the solenoid valve's coil. It should be approx. 20 ohm, not less
than 15 ohm.
Symptom: Tilt in/out not working!

• Error code 611. See lift/lower above.
• Error code 617 or 618. See lift/lower above.
Symptom: Side shift not working!

Symptom: Spreading not working!

Symptom: Levelling or 5th function not working!


7 Load handling – Control lever 7:7
Symptom: No response in any hydraulic function.

• Error code 604. No voltage supply 24 V to PWM output signals.
Check whether the control switch at the electric servo levers is
depressed. If the electric servo still does not work, check fuse
F58-4 no. 7 (10 A). Otherwise, the internal supply in the ECU is
faulty and it must be replaced.
• Error code 603. No voltage supply 10 V in relation to the electric
servo levers. Measure 10 V in relation to the ECU between pins
X46.7 (0 V) and X46.6 (10 V). If there is no 10 V supply, or if the
voltage is below 9 V or above 11 V, then the supply from the ECU
is incorrect and it must be replaced.
• Error code 601. Voltage supply to ECU 796 below 14 V or above
33 V or not available. Check fuse F58-4 no. 7 (10 A).
• Error code 602, 605 or 606. Hardware fault on ECU 796. Try to
restart the system with the ignition key lock. If it does not work
then the ECU must be replaced.

7:8 7 Load handling – Lift and lower
7.2 Lift and lower

Lifting/lowering, function description (hydraulic
servo)
12
8 11
1
10
9
2, 7
C C
6 PS B2
T EF P 10
P 9
P
LS T A2
12
4 8 11
C C
5 3 13
015241
1 Control lever, lifting/lowering, controls 3.5 MPa Section 9 Frame, body, cab and accessories,
servo pressure in proportion to lever group 9.1 Controls and instruments
movement to control valve load handling.
2 The control valve's lift slide changes - Load handling control valve, description
position and pressurises the lift cylinders (hydraulic servo), page 7:12
and sends a load signal to the hydraulic
oil pump for lifting/lowering and tilt and
the shuttle valve for lift/tilt.
3 Hydraulic oil pump, lifting/lowering and See pressure plate on Section 10 Common hydraulics, group
tilt, pumps oil from the hydraulic oil tank left-hand front mudguard. 10.4.2 Axial piston pump with variable
to the control valve for load handling. displacement
4 Shuttle valve, lift/tilt, sends a lift signal - Section 10 Common hydraulics, group
onward to the hydraulic oil pump for 10.5.4 Shuttle valve
steering and load handling.
5 The steering hydraulic oil pump and load See pressure plate on Section 10 Common hydraulics, group
handling pump oil from the hydraulic oil left-hand front mudguard. 10.4.2 Axial piston pump with variable
tank to the priority valve and pressure displacement
reducer.
6 The priority valve leads supply pressure See pressure plate on Section 10 Common hydraulics, group
to the control valve for load handling. left-hand front mudguard. 10.5.3 Priority valve
7 Pressurised oil passes via control valve, See pressure plate on Section 10 Common hydraulics, group
load handling, to the load control valves. left-hand front mudguard. 10.3.2 Accumulator

7 Load handling – Lift and lower 7:9

8 Lifting or lowering the carriage (free - Load control valve, description, page 7:29
lift)
The load control valve opens and leads
pressure onward to the free lift cylinders
and lift cylinders.
9 During lifting the load control valve is - Load control valve, description, page 7:29
opened and forwards pressure to the lift
cylinders. The free lift cylinders start to
move at a lower pressure, because their
area is 15-20% larger than that of the
lift cylinders.
During lowering, the load control valve
is closed and directs limited flow from
the free lift cylinder.
10 The freelift cylinder raises or lowers the - Lift cylinder, description, page 7:14
trolley in relation to the inner mast.
Mast, description, page 7:16
11 Lift or lower mast - Load control valve, description, page 7:29
The load control valve opens and directs
pressure on to the lift cylinders.
12 The lift cylinders raises or lowers the - Lift cylinder, description, page 7:14
inner mast in relation to the outer mast.
13 Hydraulic oil filters clean the oil. - -

hydraulics.

7:10 7 Load handling – Lift and lower
Lifting/lowering, function description (electrical

servo)

Control breaker Disengaged Section 11 Common electrics, group 11.5.1.4
Emergency stop switch voltage (15E)
14
2 ECU796 10 13
1
D
D 12
11
3
4, 9
8 C
B2
T EF P
12
P 11
P
A2
LS T
14
6 10 13
C C
7 5 15
015242
1 The control lever, lifting and lowering U = 0-10 V DC Section 9 Frame, body, cab and accessories,
(R8071), sends a voltage signal which group 9.1 Controls and instruments.
is proportional to the lever movement to
the Control unit hydraulics (ECU 796).
ECU 796 input K1:9
2 The hydraulics control unit (ECU 796) - Load handling control valve, description
sends a current signal to the solenoid (electric servo), page 7:13
valve for mast lifting (Y6005) or the
solenoid valve for mast lowering
system, group 8.4.4.2 View outputs, menu 1,
(Y6004).
ECU 796 input K2:3 (lower), input K2:4 (lift)
3 Solenoid valve, mast lifting (Y6005) or - Load handling control valve, description
the solenoid valve for mast lowering (electric servo), page 7:13
(Y6004) allocates servo pressure in
proportion to the control current in the lift
slide in the load handling control valve.
position and pressurises the lift cylinders (electric servo), page 7:13

7 Load handling – Hydraulic oil pump 7:11

7 The steering hydraulic oil pump and load See pressure plate on Section 10 Common hydraulics, group
handling pump oil from the hydraulic oil left-hand front mudguard. 10.4.2 Axial piston pump with variable
tank to the priority valve and pressure displacement
reducer.
9 Pressurised oil passes via control valve, See pressure plate on Section 10 Common hydraulics, group
load handling, to the load control valves. left-hand front mudguard. 10.3.2 Accumulator
10 Lifting or lowering the carriage (free - Load control valve, description, page 7:29
lift)
The load control valve opens and leads
pressure onward to the free lift cylinders
and lift cylinders.
11 During lifting the load control valve is - Load control valve, description, page 7:29
opened and forwards pressure to the lift
cylinders. The free lift cylinders start to
move at a lower pressure, because their
area is 15-20% larger than that of the
lift cylinders.
During lowering, the load control valve
is closed and directs limited flow from
the free lift cylinder.
12 The freelift cylinder raises or lowers the - Lift cylinder, description, page 7:14
trolley in relation to the inner mast.
13 Lift or lower mast - Load control valve, description, page 7:29
The load control valve opens and directs
pressure on to the lift cylinders.
14 The lift cylinders raises or lowers the - Lift cylinder, description, page 7:14
inner mast in relation to the outer mast.
15 Hydraulic oil filters clean the oil. - -

hydraulics.

7.2.3 Control valve load handling

Load handling control valve, general
There are two types of load handling control valve: hydraulic servo
and electrical servo.
Control valve load handling controls all load handling functions. The
control valve is fitted on the plate in the area in front of the transmission.
The control valve is controlled hydraulically or with electric servo valves.

7:12 7 Load handling – Control valve load handling
The control valve has the following sections:

• Lift
• Tilt
• Side shift
• Spreading (positioning)
Load handling control valve, description (hydraulic

servo)
Lift slide
For more information on load handling with hydraulic servo, see
Lifting/lowering, function description (hydraulic servo), page 7:8, Side
shift, function description (hydraulic servo), page 7:33, Spreading,
function description (hydraulic servo), page 7:39, Tilt, function
description (hydraulic servo), page 7:50 and .
Actuation of the control valve is proportional to servo pressure. This

means that the magnitude and direction of the flow from the valve can
be controlled by adjusting the servo pressure to the control valve.
A small hydraulic pressure toward the so-called servo pressure from

1 the control levers actuates the spring-centred control spools in the
control valve. The control spool for each function controls the main
2
flow from the hydraulic oil pumps to the hydraulic cylinders for the
3 function in question. The speed of the function is controlled by the
11 flow, which is proportional to the movement of the control lever.
4
Lift slide
5 10 If the lift control lever is activated when the mast is in the position for
6 lifting, the lift spool is pressurised and controls the direction and flow
7 of the oil from the hydraulic oil pumps to the lift cylinder.
9
015343
1. Spreading, left fork out

2. Spreading, left fork in
3. Spreading in
Spreading, right fork in
4. Spreading out
Spreading, right fork out
5. Side shift, right
6. Side shift, left
7. Feed from hydraulic oil pump
8. Lift
9. Tilt out
10. Tilt in
11. Lower

7 Load handling – Control valve load handling 7:13
Load handling control valve, description (electric

servo)
Lift slide
For more information on load handling with electric servo, see

Lifting/lowering, function description (electrical servo), page 7:10, Side
shift, function description (electrical servo), page 7:35, Spreading,
function description (electrical servo), page 7:41 and Tilt, function
description (electrical servo), page 7:52.
Actuation of the control valve is proportional to servo valves. This

means that the magnitude and direction of the flow from the valve
can be adjusted.
1 10
9 Electrically controlled pressure reducing valves (servo valves) convert
2 electric current into a low hydraulic pressure that is proportional to the
8 current, so-called servo pressure. The servo pressure acts on the
3 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 the flow, which is

proportional to the movement of the control lever.
Lift slide
The lift slide controls the direction and flow of the oil to the lift cylinder.
Servo valve, lift
Servo valve lift is controlled electrically with Solenoid valve, lift
(Y6005) which is activated by Control unit, hydraulics (ECU 796). The
4
servo valve directs servo pressure to the lift slide which is proportional
7 to the control current to the solenoid valve.
015344
5
6 Servo valve, lower
1. Solenoid valve, spreading left fork out (Y6022) Servo valve lifting/lowering is controlled electrically with Solenoid
2. Solenoid valve, spreading in (Y6019) valve, lower (Y6004) which is activated by Control unit, hydraulics
(ECU 796). The servo valve directs servo pressure to the lift slide
Solenoid valve, spreading right fork in (Y6018)
which is proportional to the control current to the solenoid valve.
3. Solenoid valve, side shift right (Y6021)
4. Solenoid valve, lift (Y6005)
5. Solenoid valve, tilt out (Y6010)
6. Solenoid valve, tilt in (Y6011)
7. Solenoid valve, lower (Y6004)
8. Solenoid valve, side shift left (6020)
9. Solenoid valve, spreading out (Y6018)
Solenoid valve, spreading right fork out (Y6018)
10. Solenoid valve, spreading left fork in (Y6023)

7:14 7 Load handling – Lift cylinder
7.2.4 Lift cylinder

Lift cylinder, description
The lift cylinders lift and lower the inner mast which runs in the outer
mast. The lower parts of the lift cylinders are fixed to the outer mast,
while their upper parts are fixed to the inner mast - one on the right
and one on the left of the mast.
The lift cylinders are connected in parallel and fed from control valve
load handling, see Load handling control valve, description (hydraulic
servo), page 7:12 or Load handling control valve, description (electric
servo), page 7:13.
The cylinder head is threaded in the cylinder barrel (and can be

removed using a hook wrench if needed). When it is time to refit the
cylinder head after a cylinder overhaul, it is extremely important that
the piston rod is unloaded precisely so as not to damage the threads.
There are double piston rod seals on the cylinders (applies to all
cylinders for load handling). The bearing assembly consists of guide
bushings that hold the piston rod in the centre of the cylinder.
For images of the lift cylinders, see Mast, description, page 7:16.
The lift cylinders for the Duplex freelift mast have end position
damping. This function means that when the cylinders approach their
bottom position during lowering, the oil flow out from the cylinders is
restricted. In this position the oil flow is forced through a gap between
the piston end and the cylinder bottom. To ensure the cylinders' lift
movement from the bottom position, a non-return valve directs oil past
the restrictor.

7.2.5 Accumulator damping

Accumulator damping, description
This accumulator, which is only intended for the lifting/lowering

function, is the piston accumulator type (not to be confused with
the diaphragm accumulator in group 10 Common hydraulics). It is
an option that significantly improves damping performance when
lifting/lowering loads.
The piston accumulator is connected to the lift cylinders and provides

a damping function in the cylinder, e.g. when driving on an uneven
surface, which can create pressure spikes in the hydraulic system.
NOTE
Handling the accumulator requires special equipment and training.
015250
Piston accumulator

7 Load handling – Accumulator damping 7:15
Accumulator damping, replacement
NOTE
Safety.
3 Mark up and detach the hydraulic hoses from the accumulator.

2
1 NOTE
from impurities.
4 Remove the accumulator attaching bolts.

3 008929 5 Remove the accumulator.
6 Charge the new accumulator. As standard, it must be charged
with 4 MPa preload pressure. The pressure can be lowered to
1. Piston accumulator achieve the desired functionality.
2. Attaching bolt and clamp 7 Transfer the connection adapters to the new accumulator.
3. Connection adapter
8 Fit the new accumulator.
9 Connect the hydraulic hoses to the accumulator in accordance
with the marking.
NOTE
position.
run at idle speed.
11 Test the lifting and lower a couple of times.
12 Check that the accumulator\qs connections are sealed tightly.

7:16 7 Load handling – Mast
7.2.6 Mast
Lift masts, general
The lift masts that are available are: Duplex Standard, Duplex Freelift
and Triplex freelift. The Duplex alternatives have an outer mast and
inner mast while the Triplex Freelift also has a centre mast.
Mast, description
The mast lifts the load. The trolley runs on the mast, and in turn holds
the forks, attachment or coil ram.
The lower part of the mast is fixed to the frame by two shafts in the
two lugs on the front part of the driving axle. The mast is also fixed
into the frame with two tilt cylinders.
1 2 The masts, both duplex as well as triplex, are based on a free-visibility

concept. The number of welds has been reduced to a minimum for
maximum strength, and stresses on the mast parts are low. All of the
mast wheels are mounted on high-quality bearings.
3
The inner mast (inner and centre on Triplex) is moved laterally via
plastic slide blocks in the outer end of the outer mast and the lower
end of the inner mast.
4
007785
1. Inner mast
2. Lift cylinders
3. Chains
4. Outer mast
Duplex standard, description

Oil is forced into the lift cylinders. The lift cylinders' piston rod is
attached to the inner mast, which is lifted. The chain, which is attached
to the trolley (and in the outer frame), runs over chain wheels in the top
of the inner mast. In this way even the trolley is lifted at the same time
as the inner mast.
Duplex free lift, description

Oil is forced into the lift cylinders. The lift cylinders have a hollow piston
rod that is connected to the free lift cylinders. Through area control
(free lift cylinders require lower oil pressure than the lift cylinders to be
lifted) the free lift cylinders' piston rod is forced out before that of the
lift cylinders. At the end of the piston rod on the free lift cylinders is a
chain wheel over which a chain runs. The chain is attached to the
carriage (and in the inner mast) which means that this is lifted at the
same time as the free lift cylinders' piston rod is extended.
When the free lift cylinders have reached their end position, the
pressure in the lift cylinders increases and their piston rod lifts the
inner mast.
The lift cylinders for the Duplex freelift mast have end position damping;
see Lift cylinder, description, page 7:14.

7 Load handling – Mast 7:17
Triplex free lift, description

Oil is forced into the lift cylinders. Through area control (free lift
cylinders require lower oil pressure than the lift cylinders to be lifted)
the free lift cylinders' piston rod is forced out before that of the lift
cylinders. At the end of the piston rod on the free lift cylinders is a
chain wheel over which a chain runs. The chain is attached to the
carriage, and in the inner mast, which means that the carriage is lifted
at the same time as the free lift cylinders' piston rod is extended.
When the free lift cylinders have reached their end position, the
pressure in the lift cylinders increases and their piston rod lifts the
middle mast.
The chain attached to the inner mast and outer mast runs over a chain
wheel at the top of the middle mast, which means that the inner mast is
raised at the same time as the middle mast.
The lift cylinders for the Triplex freelift mast have end position damping;
see Lift cylinder, description, page 7:14.
Mast, removing
NOTE
Safety.
1 Remove the trolley; see Trolley, removing, page 7:27.
4 Connect lifting equipment to the lifting lugs on the mast in a secure

manner.
5 Start the engine and tilt the mast forwards as far as possible.
6 Turn off engine.
7 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
8 Turn the start key to position 0 and switch off the main power.
008907
9 Position a receptacle under the hydraulic connections of the mast

to collect any spilled oil.
10 Mark up and disconnect the hydraulic connections of the lift
cylinders.
NOTE
from impurities.
015657

11 Position a receptacle under the hydraulic connections for the front

2 plate to collect any spilled oil.
12 Mark up and release the hydraulic connections on the front plate
1 on the mast. Let the oil drain out.
NOTE
from impurities.
015658
1. Connections for spreading

2. Connections for side shifting
13 Detach the connector and disconnect the cable for the mast
lighting
14 Mark up and undo other electrical connectors if there are any.
Undo the connectors and protect the terminals by lubricating them
with contact grease. Then loosely insert the connectors.
008413
15 Release the tilt cylinder from the mast.

Remove the cylinder shaft. If necessary, use the threaded hole
and a puller to pull the shaft out.
Start the engine and retract the cylinder so that it comes loose
from the mounting in the mast. Turn off engine.
Save the circlips. Refit the shaft in the tilt cylinder.
Lower the cylinder onto a block of wood. Then slacken and
remove the lifting equipment (overhead crane).
Repeat the procedure for the other cylinder.
16 Tension the lifting equipment. Do not lift the mast.
008807

17 Detach the connection to central lubrication.

Detach the mast from the machine by loosening the screw and
remove the shaft that holds the mast in the frame, use two screws
3 (M24) in the threaded holes as pullers.
WARNING
2
The mast can swing out when it is released from the
machine.
1 Risk of personal injury!
015263
1. Screw
2. Connection, central lubrication
3. Threaded holes (M24)
18 Lift aside the mast.

19 Place the mast on the ground and detach the lifting equipment
(overhead crane).
Mast, installing
NOTE
Safety.
3 The shafts and bearing surfaces must be checked before the mast
is refitted for deep grooves/scratches, fibres must not protrude
above the bearing surface. If there are signs of damage, the
shaft/bearing must be replacement.


manner.
5 Lift the mast into place.
008907 6 Fit the shafts and secure them with screws.

Connect central lubrication.
3 7 Grease the mast anchorage.
1
015263
1. Screw
2. Connection, central lubrication
3. Threaded holes (M24)
8 Lift the tilt cylinders into place.

9 Start the engine and tilt the mast forwards as far as possible.
10 Turn off engine.
11 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
12 Turn the start key to position 0 and switch off the main power.

13 Connect the tilt cylinder to the mast.

Align the tilt cylinder and fit the spacers. Fit the lock rings.
14 Grease the cylinder anchorages.
008807
15 Remove the plugs and connect the hydraulic hoses to the lift
cylinders in accordance with the marking.
NOTE
position.
015657
16 Remove the plugs and connect the mast's hydraulic connections

2 on the front plate.
1
015658
1. Connections for spreading

2. Connections for side shifting

17 Affix the mast lighting cable and connect the mast lighting
connector.
008413
18 Undo the lifting equipment (travelling crane).
19 Switch on the system voltage and start the engine.
20 Check that the hydraulic connections are sealed tightly.
21 For the duplex free lift mast: release air from the air cylinders.
a. Lift the carriage about 0.5 m.
b. Connect a hose to the air vent valve. Insert the other end
of the hose into a receptacle.
c. Open the valve and let the oil flow until clear oil with no air
flows out of the hose.
008907
WARNING
The trolley lowers.
Risk of crushing.
22 Check the mast functions. If necessary, adjust the tilt cylinders,

see Tilt cylinder, adjustment, page 7:58.
23 Check the oil level in the hydraulic system with all cylinders in
retracted position. Top up if necessary.

7 Load handling – Mast wheels 7:23
7.2.7 Mast wheels

Mast wheels, description
The mast wheels consist of a wheel race with two rolling bearings.
4 7
6
5
4
3
2
1
008808
1. Pin
2. Set screw
3. Seal washer
4. Bearing
5. Mast wheels
6. Circlip
7. Grease nipple
Mast wheels, checking and replacement

1 Remove the trolley; see Trolley, removing, page 7:27.
2 If possible, dismantle the mast when it is installed on the machine.

If this is not possible, see Mast, removing, page 7:17 and
dismantle the mast on the ground.
3 Applies to Duplex Standard

1
Separate the outer mast and inner mast.
a. Detach the cables, chains and hoses as required to dismantle
the mast. Detach the circlips holding the lift cylinders to the
inner mast.
b. Attach hoisting equipment (overhead crane) to the inner mast
and lift the inner mast away from the outer mast.
c. Place the inner mast on the ground in a safe manner.
4 Check the mast wheels and replace as necessary.
008817
1. Circlip holding the lift cylinders

7:24 7 Load handling – Chains
7.2.8 Chains
Chains, description
The chains are of the Fleyer chains type.
Chains, replacement
WARNING
The lifting chain is heavy.
Risk of crushing. The chain is difficult to handle.
Handle with caution and be very careful when the chain
is removed from the chain wheel. Serious personal
injury and damage to the vehicle can result from
carelessness.
2 Lower the trolley to the lowest position.
3 Release the lifting chain from the load unit.

Remove the cotter pin and shaft from each side of the load carrier.
4 Connect lifting equipment to the chain in a secure manner.
Undo the chain anchorage from the chain tensioner and lay the
chain down.
5 Fit a new chain.
008801
6 Tension the chain with the chain tensioner. Check that the chains
are tensioned equally.
7 Adjust the trolley's lower position so that the carriage sides cannot
run against the bottom plate of the outer mast. Then measure the
ground clearance of the trolley. The distance must be equal on the
right and left-hand sides, with a tolerance of 5 mm. Adjust further
with the chain tensioner if necessary.
008802

7 Load handling – Chain wheels and hose wheels 7:25
7.2.9 Chain wheels and hose wheels

Chain wheels and hose wheels, description
The chain wheels and hose wheels are provided with two roller
bearings.
Chain wheels, replacement

2 Raise the mast.
3 Position a support under the trolley and lower the mast again.
Chains and hoses are now slackened.
4 Connect lifting equipment to the chain in a secure manner.

Undo the chain anchorage from the chain tensioner and lay the
chain down.
008801
1 5 Remove the screws for the lock plate that locks the shaft.
6 Pull the shaft out and remove the sprocket.
NOTE
2
The sprocket will fall down when the shaft is loosened!
7 Install a new sprocket and re-install the shaft.
NOTE
3
Lubricate the shaft with sliding grease.
008803
4
8 Lock the shaft with the lock plate and screws.
1. Lock plate 9 Grease the sprocket.
2. Screws
10 Re-install the chain.
3. Shaft
4. Chain wheel

7:26 7 Load handling – Trolley
Hose wheels, replacement

2 Raise the mast.
3 Position a support under the trolley and lower the mast again.
Chains and hoses are now slackened.
4 Remove the hose guide that prevents the hoses from becoming
1 derailed.
5 Remove the screws for the lock plate and remove the hose
wheel's shaft.
NOTE
Lubricate the shaft with sliding grease.
2
3 6 Install a new hose wheel.
7 Fit the shaft and lock with the lock plate and screws.
8 Put the hoses back and install the hose guide. Secure the hose
4
008804
guide with cotter pins.
1. Hose guide locked with cotter pin

2. Shaft locked with lock plate and screws
3. Hose wheel
4. Hoses
7.2.10 Trolley
Trolley, description
1 6 3 4 5 The trolley holds the fork mountings and lift forks and runs in the inner
mast with bearing-mounted support rollers and mast wheels. During
lifting, the lift cylinders' piston rods are pushed out and the inner mast
is lifted. The chain, which is attached to the trolley (and in the outer
frame), runs over chain wheels in the top of the inner mast. In this
way even the trolley is lifted at the same time as the inner mast.
During freelift, the freelift cylinder raises the trolley in relation

to the mast.
The spreading-side shift carriage and centre levelling carriage have

6
the same forks, while the carriage for manually adjusted forks and
2 1
side shift carriage have forks with different mountings, see Lift forks,
7 description, page 7:59.
3
4
5
6
015753
1. Fork mounting
2. Support rollers
3. Side shift and spreading cylinders
4. Trolley
5. Lift fork
6. Fork rollers
7. Mast wheels

7 Load handling – Trolley 7:27
Trolley, removing
NOTE
Safety.
1 Start the machine and set the mast vertical. Lower the mast.
NOTE
The trolley must be placed on a flat surface and secured. It
could otherwise tip over when the machine is reversed away.
3 Remove the lift forks.
5 Position a receptacle under the hose connections of the trolley

6 Mark up and detach the hydraulic hoses from the trolley.
NOTE
from impurities.
007718
7 Detach the lifting chains on the machine.

8 Fasten weights in or secure the chains with rope to prevent them
from travelling across the chain wheel when the mast is raised.
008801

9 Start the machine and lift the mast, lift and lower the trolley with
the lifting equipment if necessary, so that the carriage is free from
the mast. Reverse away from the mast, or move the trolley.
WARNING
The trolley can swing out when it releases from the
mast.
Risk of personal injury!
008809
Make sure to secure it with the lifting equipment.
Trolley, installing
NOTE
Safety.
1 Start the machine and set the mast vertical.
2 Raise the mast so high that there is room for the trolley.
3 Connect the lifting equipment to the trolley in a secure manner and

run the machine toward or position the trolley in the mast with the
lifting equipment.
4 Lower the mast.
008809
7 Fasten the lifting chain tensioners in the trolley.

Fit the shaft and secure it with a cotter pin.
8 Tension the chain with the chain tensioner. Check that the chains
are tensioned equally.
9 Measure the ground clearance of the trolley. The distance must be
equal on the right and left-hand sides, with a tolerance of 5 mm.
Adjust with the chain tensioner if necessary.
008801

7 Load handling – Load control valve 7:29
10 Connect the hydraulic hoses to the trolley in accordance with the

markings.
NOTE
position.

12 Turn on the power supply and start the engine.
13 Activate the load handling functions. Check the hydraulic
connections for leaks.
14 Check the oil level in the hydraulic oil tank when all hydraulic
007718
pistons are fully retracted; top up as necessary.
7.2.11 Load control valve

Load control valve, description
The load control valve is fitted on the piston side's connection for
the lift cylinders and on the rod side for the lift and free lift cylinders
for the free lift mast.
The valve contains a spring-loaded guide piston and a moveable

1 throttle plate that work together to give a constant through-flow,
2
regardless of size of the load. The maximum lowering speed is
constant and independent of the weight of the load.
For lifting, the throttle plate and the guide piston are in the through-flow
position, allowing the unobstructed passage of the oil. For lowering,
the throttle plate assumes a throttle position. The internal pressure
drop in the valve and the pre-load force of the guide piston's spring
counteract each other, balancing the position of the guide piston, with
a corresponding size of restriction gap. Big load - small gap, small
load - big gap.
015288
1. Lift cylinder
2. Load control valve

7:30 7 Load handling – Pipes and hoses
Load control valve, replacement
NOTE
Safety.
3 Detach the hydraulic hose from the load control valve.
NOTE
1 from impurities.
2
4 Remove the connection adapter.
5 Detach the old load control valve and remove it.
6 Fit the new load control valve, (torque tighten a 1" valve to 20 Nm).
7 Fit the connection adapter.
8 Connect the hydraulic hose to the adapter.
NOTE
position.
015288
1. Lift cylinder run at idle speed.
2. Load control valve 10 Test the lifting and lower a couple of times checking max. lowering
speed with max load.
11 Check that the connections are sealed tightly.

7.2.14 Support roller

Support rollers, inspection, adjustment and possible
replacement
NOTE
Safety.
1 Remove the mast, see Mast, removing, page 7:17.
2 Divide the inner and outer mast.

7 Load handling – Support roller 7:31
3 Check the spacing between the mast beams with inside calipers in
the centre of the beam. Move the inside calipers along the width
of the beams to register the shortest distance.
007787
4 Use a Vernier callipers to measure the inside callipers and note
the value.
Vernier callipers with measurement length 1500 mm and

inside callipers
5 Measure the spacing between the support rollers' highest point

with the Vernier calipers. Compare with the previously noted
measurement.
The spacing between the support rollers should be 2-3 mm larger
than the smallest spacing measured between the mast beams
with the inside calipers and Vernier calipers. If necessary, adjust
the spacing using 1 mm shims.
6 Loosen the four screws holding the support roller (use Loctite
when the screws are refitted). Clean the support roller's contact
surface against the mast. Fit 1 mm shims in pairs between the
mast beam and the support roller.
NOTE
Distribute the shims so that they are not all on the same side of
the inner mast (or carriage when adjusting its support rollers).
7 Secure the support roller and remeasure with the Vernier calipers.
Lock the screws with Loctite.
NOTE
Replace the support roller if necessary.
8 Slide the inner and outer masts together.

9 Repeat steps 3-7 to check and adjust the carriage's support rollers.
a. Measure the inner measurement in the inner mast.
b. Measure the spacing across the support rollers on the
carriage.
005247

7:32 7 Load handling – Top support roller
7.2.15 Top support roller

Top support roller, inspection and possible
replacement
See Support rollers, inspection, adjustment and possible replacement,
page 7:30.

7 Load handling – Side shift 7:33
7.4 Side shift

Side shift, function description (hydraulic servo)
C C 2, 7, 10
6 PS B
T EF P
LS T A
9
3
C 4
5 11
015289
1 Control lever, side shift, controls servo 3.5 MPa Section 9 Frame, body, cab and accessories,
pressure in proportion to lever movement group 9.1 Controls and instruments
to control valve load handling.
2 The control valve's side shift slide - Load handling control valve, description
changes position and pressurises the (hydraulic servo), page 7:36
side shift cylinders and sends a load
signal to the shuttle valve for steering
and load handling.
3 Shuttle valve, steering and load - Section 10 Common hydraulics, group
handling, sends a load signal to the 10.5.4 Shuttle valve
shuttle valve for lift/tilt.
4 Shuttle valve lift/tilt sends a load signal - Section 10 Common hydraulics, group
5 Hydraulic oil pump, steering and load See pressure plate on Section 10 Common hydraulics, group
handling, pumps oil from the hydraulic left-hand front mudguard. 10.4.2 Axial piston pump with variable
oil tank to the priority valve. displacement
7 Pressurised oil passes via control valve, - Load handling control valve, description
load handling, to the side shift cylinders. (hydraulic servo), page 7:36
8 The oil pressurises the rod side on one - Side shift cylinder, description, page 7:37
of the side shift cylinders. Oil is forced
out on the piston side.

7:34 7 Load handling – Side shift

9 Oil is led to the piston side of the second - Side shift cylinder, description, page 7:37
side shift cylinder. Oil is then forced out
on its rod side and the forks are moved
in parallel laterally. Oil from the side shift
cylinder is returned to control valve, load
handling.
10 Control valve, load handling, leads - Load handling control valve, description
return oil to the hydraulic oil filter. (hydraulic servo), page 7:36
11 The hydraulic oil filter cleans the return - -
oil that is routed back to the hydraulic
oil tank.

hydraulics.

7 Load handling – Side shift 7:35
Side shift, function description (electrical servo)

Control breaker Disengaged Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage (15E)
2 ECU796
D2
1
D1 10
3
4, 9, 12
8 C
B
T EF P
LS T
A
5 11
6
C
7 13
015290
1 The control lever, side shift, (R8073) U = 0-10 V DC Section 9 Frame, body, cab and accessories,
voltage signal to Control unit hydraulics group 9.1 Controls and instruments.
(ECU 796).
ECU 796 input K1:11
valve for left-hand side shift (Y6020) or
the solenoid valve for right-hand side
shift (Y6021).
ECU 796 input K2:7 (left), output K2:8 (right)
3 Solenoid valve side shift left (Y6020) or - Load handling control valve, description
Solenoid valve side shift right (Y6021) (electric servo), page 7:36
controls servo pressure to the side shift
slide in control valve load handling.
position and pressurises the side shift (electric servo), page 7:36
cylinders and sends a load signal to
the shuttle valve for steering and load
handling.

7:36 7 Load handling – Hydraulic oil pump

9 Pressurised oil passes via control valve, - Load handling control valve, description
load handling, to the side shift cylinders. (electric servo), page 7:36
10 The oil pressurises the rod side of one - Side shift cylinder, description, page 7:37
of the side shift cylinders. Oil is forced
out on the piston side.
11 Oil is led to the piston side of the second - Side shift cylinder, description, page 7:37
side shift cylinder. Oil is then forced out
on its rod side and the forks are moved
in parallel laterally. Oil from the side shift
cylinder is returned to control valve, load
handling.
return oil to the hydraulic oil filter. (electric servo), page 7:36
oil tank.

hydraulics.

Hydraulic oil pump, general

servo)
Side shift is controlled by a separate section of the load handling
control valve.
For general information on the control valve, refer to Load handling
control valve, description (hydraulic servo), page 7:12.
For more information on side shift, see Side shift, function description
(hydraulic servo), page 7:33.
Side shift slide
When the side shift control lever is activated, the side shift slide is
pressurised, which controls the direction and flow of oil from the
hydraulic oil pumps to the side shift cylinders. See Side shift cylinder,
description, page 7:37.

servo)
The load handling control valve controls all load handling functions.
See also Load handling control valve, description (electric servo),
page 7:13.
For more information on side shift, see Side shift, function description
(electrical servo), page 7:35.
Side shift slide
The side shift slide controls the direction and flow of oil to the side
shift cylinders.

7 Load handling – Side shift cylinder 7:37
Servo valve, side shift left

On machines with electric servo, Servo valve side shift left is controlled
electrically with Solenoid valve side shift left (Y6020), which is activated
by Control unit, hydraulics (ECU 796). The servo valve directs servo
pressure to the side shift slide which is proportional to the control
current to the solenoid valve.
Servo valve, side shift right
On machines with electric servo, Servo valve side shift right is
controlled electrically with Solenoid valve side shift right (Y6021), which
is activated by Control unit, hydraulics (ECU 796). The servo valve
directs servo pressure to the side shift slide which is proportional to the
control current to the solenoid valve.
7.4.4 Side shift cylinder

Side shift cylinder, description
The side shift cylinder (same cylinders used for spreading function, if
available) is equipped with a spherical plain bearing at the cylinder end.
The piston rod bracket is threaded to the piston rod.

removed using a hook wrench if needed).
Side shift cylinder, replacement
NOTE
Safety.
2 Secure the side shift cylinder to the trolley with straps.

009118
3 Remove the screws holding the side shift cylinder in the fork.
4 Retract the side shift cylinder with the machine running.
7 Position a receptacle under the hydraulic connections for the side
shift cylinder to collect any spilled oil.
009119

8 Mark up and detach the hydraulic hoses from the side shift
cylinder.
NOTE
from impurities.
009120
9 Remove the shaft holding the side shift cylinder to the trolley.
Remove the screw and pull out the shaft.
10 Transfer the connection adapters to the new cylinder.
11 Fit the new cylinder.
12 Fit the shafts and screws holding the side shift cylinder to the
trolley and forks.
13 Connect the hydraulic hoses to the cylinder in accordance with
the marking.
NOTE
008814
position.
run at idle speed.
15 Test the side shift and spreading a couple of times.
16 Check that the connections are sealed tightly.
7.4.6 Trolley
See Trolley, description, page 7:26.


7 Load handling – Spreading (positioning) 7:39
7.5 Spreading (positioning)

Spreading, function description (hydraulic servo)
9
1 8
C 2, 7, 10
6 PS B
T EF P
LS T A
3
C 4
5 11
015291
1 Control lever, spreading, controls 3.5 MPa Section 9 Frame, body, cab and accessories,
servo pressure in proportion to lever group 9.1 Controls and instruments
movement to control valve load handling.
2 The control valve's spreading slide - Load handling control valve, description
changes position and pressurises the (hydraulic servo), page 7:46
spreading cylinders and sends a load
and load handling.
7 Pressurised oil passes via control - Load handling control valve, description
valve, load handling, to the spreading (hydraulic servo), page 7:46
cylinders.

7:40 7 Load handling – Spreading (positioning)

8 Spreading inwards - Section 10 Common hydraulics, group
10.4.2 Axial piston pump with variable
The flow distributor checks that the oil
displacement
volume supplied to the piston sides of
each cylinder is equal.
Spreading outwards
volume that comes from the piston sides
of each cylinder is equal.
9 The spread cylinders move the forks - Spreading cylinder, description, page 7:48
sideways.
oil tank.

hydraulics.

Spreading, function description (electrical servo)

voltage (15E)
2 ECU796 11
D2 10
1
D1
11
3
4, 9, 12
C
8
B
T EF P
LS T
A
5
C 6
7 13
015292
1 The control lever, spreading (R8074) U = 0-10 V DC Section 9 Frame, body, cab and accessories,
sends a voltage signal to the Control group 9.1 Controls and instruments.
unit hydraulics (ECU 796).
ECU 796 input K1:12
valve for spreading inwards (Y6019)
or the solenoid valve for spreading
outwards (Y6018).
ECU 796 input K2:12 (in), output K2:11 (out)
3 The solenoid valve for spreading in - Load handling control valve, description
(Y6019) or the solenoid valve for (electric servo), page 7:47
spreading out (Y6018) controls servo
pressure to the spreading slide in control
valve load handling.
changes position and pressurises the (electric servo), page 7:47
spreading cylinders and sends a load
and load handling.


9 Pressurised oil passes via control - Load handling control valve, description
valve, load handling, to the spreading (electric servo), page 7:47
cylinders.
10 Spreading inwards - Section 10 Common hydraulics, group
displacement
volume supplied to the piston sides of
each cylinder is equal.
Spreading outwards
volume that comes from the piston sides
of each cylinder is equal.
11 The spread cylinders move the forks - Spreading cylinder, description, page 7:48
sideways.
oil tank.

hydraulics.

Individual spreading, function description

(hydraulic servo)
1 8
C 2, 7, 9
6 PS B B
T EF P
LS T A A
3
C 4
5 10
015822
1 Control lever, spreading left or Control 3.5 MPa Section 9 Frame, body, cab and accessories,
lever, spreading right, controls servo group 9.1 Controls and instruments
pressure proportional to lever movement
to the control valve for load handling.
changes position and pressurises (hydraulic servo), page 7:46
spreading cylinder left fork or spreading
cylinder right fork and sends a load
and load handling.
7 Pressurised oil passes via the control - Load handling control valve, description
valve for load handling to spreading (hydraulic servo), page 7:46
cylinder left fork or spreading cylinder
right fork.
8 Spreading cylinder left fork or spreading - Spreading cylinder, description, page 7:48
cylinder right fork moves the left or right
fork laterally.


oil tank.

hydraulics.

Individual spreading, function description

(electric servo)

voltage (15E)
2 ECU796 10
D2
1
D1
10
3
4, 9, 11
C
8 B B
T EF P
LS T A A
C 6
7 12
015823
1 Control lever spreading left (R8075) or U = 0-10 V DC Section 9 Frame, body, cab and accessories,
Control lever spreading right (R8074) group 9.1 Controls and instruments.
sends a voltage signal to Control unit,
hydraulics (ECU 796).
system, group 8.4.4.1 View inputs, menu
3, ECU 796 input K1:12 (R8074) or input
K1:13 (R8075)
2 Spreading, left fork - Load handling control valve, description
(electric servo), page 7:47
Control unit, hydraulics (ECU 796),
sends a current signal to solenoid valve, D2: Diagnostic menu, see section 8 Control
spreading left fork in (Y6023) or solenoid system, group 8.4.4.2 View outputs, menu 2,
valve, spreading left fork out (Y6022). ECU 796 input K2:14 (in), output K2:13 (out)
Spreading, right fork - Load handling control valve, description
(electric servo), page 7:47
Control unit, hydraulics (ECU 796),
sends a current signal to solenoid Spreading, right fork
valve, spreading right fork in (Y6019) or
solenoid valve, spreading right fork out
(Y6018).
ECU 796 input K2:12 (in), output K2:11 (out)
3 Solenoid valve spreading left fork in - Load handling control valve, description
(Y6023), solenoid valve spreading (electric servo), page 7:47
left fork out (Y6022), solenoid valve
spreading right fork in (Y6019) or
solenoid spreading right fork out (Y6018)
control servo pressure to the spreading
slide in the control valve for load
handling.

7:46 7 Load handling – Hydraulic oil pump

changes position and pressurises (electric servo), page 7:47
spreading cylinder left fork or spreading
cylinder right fork and sends a load
and load handling.
9 Pressurised oil passes via the control - Load handling control valve, description
valve for load handling to spreading (electric servo), page 7:47
cylinder left fork or spreading cylinder
right fork.
11 Spreading cylinder left fork or spreading - Spreading cylinder, description, page 7:48
cylinder right fork moves the left or right
fork laterally.
oil tank.

hydraulics.


servo)
Spreading is controlled by a separate section of the load handling
control valve.

For more information on spreading, see Spreading, function description

(hydraulic servo), page 7:39 or Individual spreading, function
description (hydraulic servo), page 7:43.
Spreader slide
When the spreading control lever is activated, the spreading spool
is pressurised. The spool controls the direction and oil flow from the
hydraulic oil pump to the spreading cylinders. See Spreading cylinder,

7 Load handling – Control valve load handling 7:47

servo)

control valve.

control valve, description (electric servo), page 7:13.
For more information on spreading, see Spreading, function description

(electrical servo), page 7:41 or Individual spreading, function
description (electric servo), page 7:45.
Spreading (positioning)
Servo valve, spreading out
Servo valve, spreading out is controlled electrically with Solenoid valve,
spreading out (Y6018) which is activated by Control unit, hydraulics
(ECU 796). The servo valve directs servo pressure to the spreading
slide which is proportional to the control current to the solenoid valve.
Servo valve, spreading in
Servo valve, spreading in is controlled electrically with Solenoid valve,
spreading in (Y6019) which is activated by Control unit, hydraulics
Individual spreading
Servo valve spreading, right fork out
Servo valve spreading, right fork in
Servo valve spreading, left fork out
Servo valve spreading, left fork in

7:48 7 Load handling – Flow divider
7.5.4 Flow divider

Flow divider, description
The flow divider is a pressure-compensated valve that synchronises
the forks' movements during fork spreading. The valve divides the
flow from the main valve in two equal parts, regardless of the load
on the two connected cylinders.
The difference between pressures P1 and P2 behind the respective

adjustment slide balances the slides for the correct size of the control
gaps. When the flow moves in the other direction, the valve combines
the flows by means of each connected cylinder contributing equal
flow to the common return.
Flow divider 009121
Flow divider, replacement
NOTE
Safety.
3 Position a receptacle under the flow divider to collect any spilled

oil.
4 Mark up and detach the hydraulic hoses from the flow divider.
NOTE
from impurities.
5 Remove the two bolts that secure the flow divider to the carriage.
6 Remove the flow divider.
7 Transfer the connection adapters to the new flow divider.
8 Fit the new flow divider.
008431
9 Connect the hydraulic hoses to the flow divider in accordance

with the marking.
NOTE
position.
run at idle speed.
11 Test the spreading a couple of times.
12 Check that the flow divider\qs connections are sealed tightly.
7.5.5 Spreading cylinder

Spreading cylinder, description
See Side shift cylinder, description, page 7:37.

7 Load handling – Trolley 7:49
7.5.6 Trolley
See Trolley, description, page 7:26.


7:50 7 Load handling – Tilt
7.7 Tilt
Tilt, function description (hydraulic servo)
2, 7, 10 9
6 C C
B1
PS
8
T EF P
P
P
A1
9
LS T
4
C C
5 3 11
015293
1 Control lever, tilt, controls servo pressure P = 3.5 MPa Section 9 Frame, body, cab and accessories,
in proportion to lever movement to group 9.1 Controls and instruments
control valve load handling.
2 The servo pressure from control lever, - Load handling control valve, description
tilt, acts on the tilt slide in control valve, (hydraulic servo), page 7:53
load handling, which changes position
and pressurises the tilt cylinders.
7 Pressurised oil passes via control valve, See pressure plate on Load handling control valve, description
load handling, to the load holding valves. left-hand front mudguard. (hydraulic servo), page 7:53

7 Load handling – Tilt 7:51

8 Tilt in - Load control valve, description, page 7:29
The oil is pressed in via the load holding
valve to the tilt cylinders' rod side. Oil is
evacuated from the piston sides of the
cylinders via the load holding valve and
the control valve, back to the tank.
Tilt out
valve to the tilt cylinders' piston side.
Oil is evacuated from the rod sides of
the cylinders to the load holding valve.
This provides counterpressure in the
return line, which prevents unwanted
tilt, which would otherwise occur with
the combination of heavy load and high
lifting height. The oil is returned from the
load holding valve via the control valve
to the tank.
9 The tilt cylinders angle the mast in - Tilt cylinder, description, page 7:55
relation to the frame.
oil tank.

hydraulics.

7:52 7 Load handling – Tilt
Tilt, function description (electrical servo)

Control breaker Disengaged Section 11 Common electrics, group 11.5.1.4
Emergency stop switch voltage (15E)
2 ECU796
1
D2
D1 10
3
4, 9, 12 11
8 C
B1
10
T EF P
P
P
11
LS T A1
C C
7 5 13
015294
1 The tilt control lever (R8072) sends a U = 0-10 V DC Section 9 Frame, body, cab and accessories,
voltage signal proportional to the lever group 9.1 Controls and instruments.
movement to the hydraulics control unit
(ECU 796).
ECU 796 input K1:10
2 The hydraulics control unit (ECU 796), - Load handling control valve, description
valve for tilt out (Y6010) or the solenoid
valve for tilt in (Y6011).
system, group 8.4.4.2 View outputs, menu
1, ECU 796 input K2:5 (tilt out), K2:6 (tilt in)
3 Solenoid valve, tilt out (Y6010) or - Load handling control valve, description
solenoid valve, tilt in (Y6011) allocates (electric servo), page 7:54
servo pressure in proportion to the
control current in the tilt slide in control
valve, load handling.
4 The control valve's tilt slide changes - Load handling control valve, description
position and pressurises the tilt cylinders (electric servo), page 7:54
tilt, pumps oil from the hydraulic oil tank left-hand front mudguard. 10.4.1 Gear pump with fixed displacement
to the control valve for load handling.

7 Load handling – Hydraulic oil pump 7:53

9 Pressurised oil passes via control valve, See pressure plate on Load handling control valve, description
load handling, to the load holding valves. left-hand front mudguard. (electric servo), page 7:54
10 Tilt in - Load control valve, description, page 7:29
valve to the tilt cylinders' rod side. Oil is
evacuated from the piston sides of the
cylinders via the load holding valve and
the control valve, back to the tank.
Tilt out
valve to the tilt cylinders' piston side.
Oil is evacuated from the rod sides of
the cylinders to the load holding valve.
This provides counterpressure in the
return line, which prevents unwanted
tilt, which would otherwise occur with
the combination of heavy load and high
lifting height. The oil is returned from the
load holding valve via the control valve
to the tank.
11 The tilt cylinders angle the mast in - Tilt cylinder, description, page 7:55
relation to the frame.
oil tank.

hydraulics.


servo)
Tilt is controlled by a separate section of the load handling control valve.

For more information about tilting, see Tilt, function description

(hydraulic servo), page 7:50.
Tilt slide
When the tilt control lever is activated, pressure is fed to the tilt slide,
which controls the direction and flow of oil from the hydraulic oil pumps
to the tilt cylinders.

7:54 7 Load handling – Load holding valve (over-centre valve)

servo)

control valve.

control valve, description (electric servo), page 7:13.
For more information on spreading, see Tilt, function description

(electrical servo), page 7:52.
Tilt slide
When the servo valves are activated, pressure is fed to the tilt slide,
which controls the direction and flow of oil from the hydraulic oil pumps
to the tilt cylinders.
Servo valve, tilt out
On machines with electric servo the servo valve, tilt out, is controlled
electrically with solenoid valve, tilt out (Y6010), which is activated by
Control unit, hydraulics (ECU 796). The servo valve directs servo
pressure to the tilt slide which is proportional to the control current to
the solenoid valve.
Servo valve, tilt in
On machines with electric servo the servo valve, tilt in, is controlled
electrically with solenoid valve, tilt in (Y6011), which is activated by
Control unit, hydraulics (ECU 796). The servo valve directs servo
pressure to the tilt slide which is proportional to the control current to
the solenoid valve.
7.7.4 Load holding valve (over-centre valve)

Load holding valve, description
The load holding valve is fitted on the tilt cylinder, on the piston side's
hydraulic connection.
The function of the valve is to provide a counterpressure (50 bar)

in the return line from the tilt cylinders. In this way, unwanted tilt is
forward avoided, which would otherwise result from the combination
of heavy load and high lifting height. Tilting also becomes more
controlled as a result of the load holding valve.
1
2
008923
1. Tilt cylinder
2. Load holding valve
Load holding valve, replacement
NOTE
Safety.

7 Load handling – Tilt cylinder 7:55
3 Position a receptacle under the hose connections of the load

holding valve to collect any spilled oil.
4 Mark up and detach the hydraulic hoses from the load holding
valve.
NOTE
from impurities.
2
1 5 Remove the hydraulic connections that secure the load holding
valve on the tilt cylinder.
6 Remove the load holding valve.
008924 7 Fit the new load holding valve.
3 8 Switch on the system voltage and start the engine. Let the engine
run at idle speed.
9 Test the tilt a couple of times.
10 Check that the load holding valve\qs connections are sealed
tightly.
7.7.5 Tilt cylinder

Tilt cylinder, description
The tilt cylinder is equipped with double fixing lugs at the cylinder end.
The piston rod bracket is threaded to the piston rod and is locked with
lock bolts and lock plate.
The tilt cylinder is attached to the outer mast and to the frame.

removed using a hook wrench if needed).
008811
Tilt cylinder, replacement
NOTE
Safety.
1 Tilt the mast forward.

7:56 7 Load handling – Tilt cylinder

manner.
5 Attach hoisting equipment (overhead crane) to the tilt cylinder.
6 Position a receptacle under the hose connections of the tilt cylinder
7 Mark and undo the hydraulic connections to the tilt cylinder.
NOTE
from impurities.
007786

7 Load handling – Tilt cylinder 7:57
8 Release the tilt cylinder from the mast and frame.

Remove the two screws and locking plate securing the cylinder
shaft.
9 Remove the cylinder shafts. If necessary, use a puller to pull
the shaft out.
10 Remove the tilt cylinder.
11 Transfer the connection adapters to the new tilt cylinder.
12 Connect the new tilt cylinder.
Install the cylinder shafts.
NOTE
008807
Check that the bearings in the cylinder anchorages are correctly
aligned before the cylinder shafts are installed.
Turn the shaft to find the right position for the locking plate. Fit the
locking plate and secure it with the two screws.
13 Grease the cylinder anchorages.
14 Connect the hydraulic hoses to the tilt cylinder in accordance
with the marking.
NOTE
position.

run at idle speed.
17 Test the tilt a couple of times.
18 Check that the tilt cylinders' connections are sealed tightly.
19 Check the tilt function. Adjust the new tilt cylinder as required, see
Tilt cylinder, adjustment, page 7:58.

Tilt cylinder, adjustment

During tilting in or out, the mast should stop firmly and not be twisted.
If the mast is twisted, the tilt cylinders must be adjusted to make their
strokes equal.
1 Tilt the mast so that the cylinders are half extended.
3 Undo the screws.

4 Turn the piston rod with a hook spanner.
5 Check that the cylinder strokes are equal in length.
6 Check the tilt function. Repeat the adjustment until the tilt function
operates correctly.
7 Install the screws.
008812

7.7.6 Mast
Mast, description
See Mast, description, page 7:16.


7 Load handling – Load carrier 7:59
7.9 Load carrier

7.9.1 Lift forks
Lift forks, description
The forks are made of high strength steel. The standard mounting,
with manually adjustable forks, is with hooks on the trolley. The
A B hydraulically manoeuvrable forks are suspended in bearing-mounted
rollers, four rollers at the top and two support rollers at the bottom of
each fork.
C D 008945
A Pin type
B Hook forks (for quick attachment)
C Quick attachment
D Roller forks

7:60 7 Load handling – Lift forks
Lift forks, replacement

2 Remove the screws holding the side shift cylinder in the fork.
3 Place a hand truck under the fork for support.
009119
4 Pull out the fork to the side along the carriage.

Secure the lift fork in a suitable way so that it does not tip.
5 Replace the fork.

7 Load handling – Other functions 7:61
7.10 Other functions

7.10.1 Scale
Scale, description
The scale function is available in two configurations.

1. Electro-hydraulic scale without viewing the display.
2. Electro-hydraulic scale with viewing in the display and functions
for tare and summation of the load. A pressure sensor in the lift
cylinder measures the pressure and by these means indicates
the weight of the load. The scale function can be used by other
functions in the machine independently of viewing in the display.
The accuracy depends on mast movement before measuring. The
scale is very sensitive and is affected by several factors such as
friction in the mast and trolley, oil temperature and bearings. The
mast should be in a vertical position and the trolley centred. The
trolley should be raised and then lowered to about 1 metre above the
ground before calibration and weighing. If the system is calibrated after
gentle lowering, and weighing is performed in the same way, then an
accuracy of approx. 5% of the maximum load capacity is achieved.
The weight is presented continuously on the display, in tonnes to one
decimal place (e.g. 5.2 tonnes).
Scale, calibration
The scale on a machine equipped with complete scale is always
adjusted and calibrated from the factory. For correct use of the scale it
must be calibrated regularly against a known test weight.
NOTE
The mast must be in the vertical position and the trolley centred
during weighing, calibration and taring.
1 Run the lifting carriage up and down a few times to eliminate any
mechanical blocks.
2 Operate the machine for a few minutes before zero adjustment

and weight calibration take place.
3 To select function to calibrate, first navigate to the service menu.

Now press Enter.
000056
4 Enter the code for calibration.

Code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060
The code determines which service menu is activated (Service,

Diagnostic test, Initiation or Calibration).
5 Select SCALE by scrolling with the arrow keys (1 and 2) and

confirming with Enter.
SCALE
000803

7:62 7 Load handling – Scale
6 Unload, operate the trolley up and lower it slowly to approx. 1

CALIBR 1(2) metre above the ground. Reset to zero by pressing in the
600 menu 1 (2).
SCALE 600
WITHOUT LOAD (mV)
000804
7 Load with a known weight (preferably a frequently used loading
CALIBR 2(2) weight or close to the machine's maximum load), adjust with 4
4000 8000 KG and 5 to the correct weight and lower the trolley slightly. Confirm
4000 8000 KG the weight by pressing in the menu 2 (2). For the weight to be
SCALE WITH LOAD adjustable there must be a value in setup for maximum lift capacity.
000805
Function test
If the scale is calibrated, load with a known weight (a different weight
than that used for calibration) and read from the display. Does it
correspond with the weight?
Troubleshooting
Fault symptoms:
• If error code 304 is generated all the time, check the voltage from
the load cells. The total voltage should not be less than 0.2 V.

8:1
8 Control system
Contents 8 Control system

8 Control system ...................................................................................................8:3
8.2 Monitoring ........................................................................................................8:4
8.2.3 Speed limitation...........................................................................................8:4
8.3 Error codes ......................................................................................................8:5
8.4 Diagnostics ......................................................................................................8:6
8.4.1 ECU 790......................................................................................................8:8
8.4.2 ECU 792....................................................................................................8:14
8.4.4 ECU 796....................................................................................................8:17
8.4.5 Last alarms................................................................................................8:23
8.5 Setup..............................................................................................................8:26
8.5.1 ETC-Electronic Throttle Control (electronic throttle)..................................8:26
8.5.2 Automatic gearing .....................................................................................8:28
8.5.4 Joystick control..........................................................................................8:30
8.5.6 Mini-wheel .................................................................................................8:35
8.5.7 Electro-hydraulic servo..............................................................................8:37
8.5.8 Scale .........................................................................................................8:42
8.5.9 Monitoring .................................................................................................8:43
8.5.21 Turnable operator's station........................................................................8:43
8.6 Software.........................................................................................................8:45
8.6.1 Kalmar Smart Link.....................................................................................8:45

8:2

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

• Monitoring
• Error codes
• Diagnostics
• Setup
• Software
Monitoring functions describes the machine's monitoring functions that

warn the operator or limit the machine's functions in the event of any
dangerous situations.
Error codes notify operators and mechanics when malfunctions have

been detected.
Diagnostic test is tool for performing service and troubleshooting with

menus in the machine's display.
Settings is the tool for setting and adapting the machine's functions.
The software creates the functions in the control system.

8:4 8 Control system – Monitoring
8.2 Monitoring
8.2.3 Speed limitation
Speed limitation, description
Speed limitation prevents the machine's road speed from exceeding
the set speed by limiting the engine speed.
Machine speed is limited when:

• constant speed limitation is set.
• conditional speed limitation is activated and there is 0 V on the
digital input in ECU790 K1:16 to conditional speed limitation.

8 Control system – Error codes 8:5
8.3 Error codes

Error codes, description
When a malfunction occurs in the machine error messages (error
codes) are generated by the control unit in question that sends the
error code via the CAN-bus to Control unit EDU 795 that shows the
error codes in the display and stores the error codes.
Explanation of error codes is found in the Operator's manual and

Workshop manual.
Error code indication
Error code indication
41 42
Error code is indicated with illuminated indicator for active error codes
(position 42). The error codes are divided into three error code levels,
depending on how serious they are.
The error code levels are indicated as follows:

• STOP is indicated with a STOP sign in the display, together with
B fixed red light from the indicator for the control system (position
42).
Error code with level stop is shown automatically in the display.
• Warning is indicated with a warning triangle in the display,
together with fixed red light from the indicator for the control
system (position 42).
Error code with level warning is shown automatically in the
display.
• Information is indicated with an adjustable wrench in the display,
together with fixed red light from the indicator for the control
system (position 42).
Error code with level information is shown automatically in the
display.
007192
B. Error code level symbol

41. Control system display (KCS)
42. Control system indicator (KCS)
Error code display
Error code display
307
Error code information is displayed with display images and symbols
that give an indication about the nature of the error that has occurred.
The error code and the display image can be removed temporarily
004257
with the Reset (R) function key and then they disappear from the
display. If the error code is active then these will return in the display
Example figure automatic display figure in 1-3 minutes.
If the error code is the information type and is removed with Reset (R)
then it is not displayed again until the system is restarted.

8:6 8 Control system – Diagnostics
8.4 Diagnostics
Diagnostic test, general
The machine can be delivered in different electrical versions and using
the wiring diagrams, display and a diagnostic display, ECU 790, ECU
792 and ECU 796 inputs and outputs can be diagnosed.
The machine has built-in functions for troubleshooting (diagnostics).
The diagnostic test consists of several menus shown on the display.
DIAGNOSTICS The menus are grouped according to control unit for faster access.
The following pages describe the content of the menu figures and
which functions can be controlled.
000916
The diagnostic test is divided into the following groups:
• General control unit ECU 790, ECU 790, diagnostic description,
page 8:8.
• Steering control unit ECU 792, ECU 792, diagnostic description,
page 8:14.
• Hydraulics control unit ECU 796, ECU 796, diagnostic description,
page 8:17.
• Error codes history, Last alarms, description, page 8:23.
In this section the different diagnosis menus included in the control

system, KCS, are explained.
The values stated in the following menus are relevant examples

(standard values) of what can be shown in these positions. The actual
value may deviate from these examples.
Diagnostics, description
The diagnostic test varies between the different control units as to what
type of diagnostics can be carried out, but the following alternatives
are possible:
• View inputs - means that the inputs can be checked (digital and
analogue).
• View outputs - means that the outputs can be checked (digital
and analogue).
• Control outputs - means that the outputs can be checked and
controlled (digital and analogue).
NOTE
The application program is closed for safety reasons when controlling
the outputs. Output control is only possible with service code.
Diagnostic test, example

If there is a problem with the lifting function then this can be resolved
using the wiring diagram and/or the connections in order to see which
inputs and outputs on the control unit the function is using. See section
E Schematics , group 11 Common electrics , and section 11 Common
electrics , group 11.5.3 Control units.
The input value from a lever is shown in the diagnostic menus (e.g.
mV). The ECU's output current to the valve can be viewed and a
check can be performed to see if the ECU software wants to control
the valve. It can be quickly determined whether the problem is on the
input or output side and if the control unit is working properly without
connecting to other instruments.
This way the diagnosis can quickly be made for all functions in the
control system.

8 Control system – Diagnostics 8:7
With appropriate authorisation, the outputs can also be controlled using

a service code. When this is performed the application program is
closed (not possible to run as normal) as long as the "Control Output"
menu is selected and the red indicators (position 2) are flashing. The
deactivation of the application program enables "forced operation" of
the functions connected to the control unit.
Example 1:
It is discovered that there is no input signal from the lift lever, but to
be able to move the machine to the workshop the attachment must
be lifted from the ground. In this situation the lifting can be "force
operated" from the display using service code and wiring diagram.
Example 2:
It is established that everything seems to be OK for lifting, and input

and output signals are as they should be. Despite this lifting does not
work. If the "forced operation" function does not work despite stronger
current than normal to the solenoid valve, then the fault probably lies in
the valve or cables.
Diagnostic test, work instruction

To select diagnostic test, proceed as follows:
1 Navigate to the service menu.
2 Pressure .
000056
3 State code for diagnostic test (11111).
1 23
4 5
000060
4
Select Diagnostics by pressing .
DIAGNOSTICS
000916

8:8 8 Control system – ECU 790
5 Main selection for diagnostic test now shown on display.

Choose which control unit shall be investigated using the function
DIAGNOSTICS ECU790 keys 1 and 2 and confirm with .
Only accessible control units on the machine are displayed.
Each diagnostic function consists of a sequence of a number
of diagnostic menus. The first diagnostic menu for the selected
diagnostic group opens in the display. Select the next diagnosis
menu using 1 and 2 .
DIAGNOSTICS ECU792
DIAGNOSTICS ECU793
DIAGNOSTICS ECU796
LAST ALARMS
007891
8.4.1 ECU 790

ECU 790, diagnostic description
Select diagnostics as per Diagnostic test, work instruction, page 8:7.
DIAGNOSTICS ECU 790

000918

8 Control system – ECU 790 8:9
Select diagnostics for ECU 790. The screen shows if ECU 790 is
DIAG ECU 790 1(3) selected. Continue by pressing the function key .
The following alternatives can be selected in the diagnostics for ECU

VIEW INPUTS 790:
1. View inputs
2. View outputs
DIAG ECU 790 2(3) 3. Control outputs
VIEW OUTPUTS Scroll forwards to required menu using the function keys 1 and 2
and press to confirm.
DIAG ECU 790 3(3)
CONTROL OUTPUTS 002844
8.4.1.1 View inputs
View inputs, description

Select View inputs for ECU 790 as per ECU 790, diagnostic description,
page 8:8.
1 Check digital input for ECU 790.
DIGITAL IN 1(7) 1:09 involves contact 1, pin 9 on ECU 790. The box is filled if the
1:09 1:13 input voltage is > 12V. The box is empty if the voltage is < 5 V.
1:10 1:14 This applies to all digital inputs.
1:11 1:15
008496
1:12 1:16
2 Check digital input for ECU 790 further.

DIGITAL IN 2(7)
1:17 1:21
1:18 1:22
1:19 1:23
008497
1:20
3 Check temperature input for ECU 790. (Unconnected temperature

input indicates -35.2 °C.)
Check the rheostat input in ohm (2:08).
008498
4 Check analogue input for ECU 790. Measurement range:

ANALOGUE IN (V) 4(7) 0.00–5.50V.
1:01 24.88 1:26 0.54
1:07 24.88 1:27 0.55
1:08 24.88 1:28 2.43
008499
1:24 5.00 1:29 4.41

5 Check analogue input for ECU 790 further.

ANALOGUE IN (V) 5(7)
1:30 1.34 1:34 0.54
1:31 2.30 1:37 0.01
1:32 1.62 1:38 0.55
008500
1:33 0.53 1:39 0.02

ANALOGUE IN (V) 6(7)
1:40 0.01
1:41 0.01
008501
1:42 0.01
7 Check frequency input for ECU 790. Measurement range: 0.5

FREQUENCY IN 7(7) Hz-10 kHz.
2:01 2 Hz
2:03 697 Hz
008502
2:05-06 0 PULSES
8.4.1.2 View outputs
View outputs, description

Select View outputs for ECU 790 as per ECU 790, diagnostic
1 Check digital output for ECU 790.
DIGITAL OUT 1(4)
2:10 means contact 2, pin 10 on ECU 790. The box is filled if the
2:10 2:14 voltage on the output is approx. 24V (active). The box is empty
2:11 2:15 if the output is 0V (not active).
2:12 2:29
008503
2:13 2:38
2 Check digital output for ECU 790 further (for example contact 2,
DIGITAL OUT 2(4) pin 41).
2:39
2:40
2:41
008577
3 Check analogue PWM output for ECU 790. The current on the
ANALOGUE OUT(mA) 3(4) output is indicated in mA.
2:23 0 2:27 0
2:24 0 2:28 0
2:25 0
000930
2:26 0
4 Check analogue 20-80% of analogue outputs dedicated to Sauer

ANALOGUE OUT 4(4) Danfoss PVG valves, contact 2:30 and 2:31.
2:30 8%
008504
2:31 8

8.4.1.4 Control outputs

Control outputs, description
WARNING
When the outputs are controlled directly from the
terminal, this can seriously affect machine performance.
Only accredited personnel, with sufficient knowledge
of the machine and the control system, must therefore
use these menus.
The engine must be shut off if the test does not require
otherwise.
NOTE
Select Control outputs for ECU 790 as per ECU 790, diagnostic
CONTROL OUTPUT 1(19) 2:10 means contact 2, pin 10 on ECU 790. The box is filled if the
voltage on the output is approx. 24V (active). The box is empty if
2:10 the output is 0V (not active). Using the output can be switched
between approx. 24V (active, ON) and 0V (not active, OFF).
008505
ON/OFF = ENTER
2 Check digital output for ECU 790 further.

CONTROL OUTPUT 2(19)
2:11
008506
ON/OFF = ENTER

2:12
008507
ON/OFF = ENTER

2:13
008508
ON/OFF = ENTER

2:14
008509
ON/OFF = ENTER


2:15
008510
ON/OFF = ENTER

2:29
008511
ON/OFF = ENTER

2:38
008512
ON/OFF = ENTER

2:39
008513
ON/OFF = ENTER

2:40
008514
ON/OFF = ENTER

2:41
008515
ON/OFF = ENTER
12 Check PWM output for ECU 790.

CONTROL OUTPUT 12(19) In this and the following menus the actual-value is next to the
output pin designation and the set-value (what is required,
2:23 0 mA adjusted value) is on the row below.
ADJUST (+/-) 0 mA Using and the required current can be adjusted. ON/OFF
008516
4 5
ON/OFF = ENTER
is confirmed with .
13 Check PWM output for ECU 790 further.

2:24 0 mA
ADJUST (+/-) 0 mA
008517
ON/OFF = ENTER


2:25 0 mA
ADJUST (+/-) 0 mA
008518
ON/OFF = ENTER

2:26 0 mA
ADJUST (+/-) 0 mA
008519
ON/OFF = ENTER

2:27 0 mA
ADJUST (+/-) 0 mA
008520
ON/OFF = ENTER

2:28 0 mA
ADJUST (+/-) 0 mA
008521
ON/OFF = ENTER
18 Check analogue output for Sauer Danfoss PVE valves, 20-80%

CONTROL OUTPUT 18(19) of main voltage. Starts at 50%.
Adjust the output using 4 and 5 .

2:30 0%
ADJUST (+/-) 0% ON/OFF is confirmed with .
008522
ON/OFF = ENTER
19 Check analogue output for ECU 790 further, 20-80% of main

CONTROL OUTPUT 19(19) voltage. Starts at 50%.
2:31 0%
ADJUST (+/-) 0%
008523
ON/OFF = ENTER

8.4.2 ECU 792

selected. Continue by pressing the function key .
DIAGNOSTICS ECU 792
008524
792:
DIAG ECU 792 1(3)
1. View inputs
VIEW INPUTS 2. View outputs
3. Control outputs
Scroll forwards to required menu using the function keys 1 and 2
DIAG ECU 792 2(3)

and press to confirm.
VIEW OUTPUTS
DIAG ECU 792 3(3)
CONTROL OUTPUTS
008525
8.4.2.1 View inputs

page 8:8.
DIGITAL IN 1(5) 1:02 involves contact 1, pin 2 on ECU 792. The box is filled if the
1:02 input voltage is > 12V. The box is empty if the voltage is < 5 V.
1:03 This applies to all digital inputs.
1:04
008526
1:05

ANALOGUE IN 2(5) 0.00-5.00V.
1:06 0.55V
1:07 1.54V
1:08_10 310mA
008527
1:09_11 550mA
3 Check analogue input for ECU 792 further. Measurement range:

ANALOGUE IN 3(5) 0.00–5.00 V.
1:14 4.54V
1:23_33 200mA
1:25_34 300mA
008528
1:28_42 400mA

4 Check analogue input for ECU 792 further. Measurement range:

ANALOGUE IN 4(5) 0.00–5.00 V.
1:31 1.08V
1:32 2.89V
1:35 3.75V
008529
1:36 4.99V
5 Check frequency input for ECU 792. Measurement range: 0.5

FREQUENCY IN 5(5) Hz-10 kHz.
1:16 120 Hz
1:17 250 Hz
1:18 1340 Hz
008530
1:19 3490 Hz

DIGITAL OUT 1(2)
1:40 means contact 1, pin 40 on ECU 792. The box is filled if the
1:40 voltage on the output is approx. 24V (active). The box is empty
008531
1:41 if the output is 0V (not active).
2 Check analogue PWM output for ECU 792. The current on the
ANALOGUE OUT 2(2) output is indicated in mA.
1:06 220 1:26 580
1:07 275 1:27 590
1:22 600
008532
1:24 340
Control outputs, description
WARNING
use these menus.
otherwise.
NOTE


CONTROL OUTPUT 1(8) 1:40 means contact 1, pin 40 on ECU 792. The box is filled if the
voltage on the output is approx. 24V (active). The box is empty if
1:40 the output is 0V (not active). Using the output can be switched
between approx. 24V (active, ON) and 0V (not active, OFF).
008533
ON/OFF = ENTER

CONTROL OUTPUT 2(8)
1:41
008534
ON/OFF = ENTER
3 Check PWM output for ECU 792.

1:06 350 adjusted value) is on the row below.
ADJUST (+/-) 350 Using and the required current can be adjusted. ON/OFF
008535
4 5
ON/OFF = ENTER
is confirmed with .

CONTROL OUTPUT 4(8)
1:07 340
ADJUST (+/-) 340
008536
ON/OFF = ENTER

CONTROL OUTPUT 5(8)
1:22 200
ADJUST (+/-) 200
008537
ON/OFF = ENTER

CONTROL OUTPUT 6(8)
1:24 450
ADJUST (+/-) 450
008538
ON/OFF = ENTER

CONTROL OUTPUT 7(8)
1:26 580
ADJUST (+/-) 580
008539
ON/OFF = ENTER

CONTROL OUTPUT 8(8)
1:27 470
ADJUST (+/-) 470
008540
ON/OFF = ENTER

8.4.4 ECU 796

selected. Continue by pressing the function key .
DIAGNOSTICS ECU 796
000955
796:
DIAG ECU 796 1(3)
1. View inputs
VIEW INPUTS 2. View outputs
3. Control outputs
Scroll forwards to required menu using the function keys 1 and 2
DIAG ECU 796 2(3) and press to confirm.
VIEW OUTPUTS
DIAG ECU 796 3(3)
CONTROL OUTPUTS
002843
8.4.4.1 View inputs

page 8:17.
DIGITAL 1(5) 1:30 involves contact 1, pin 30 on ECU 796. The box is filled if the
1:30 1:34 input voltage is > 12V. The box is empty if the voltage is < 5 V.
1:31 1:35 This applies to all digital inputs.
1:32 1:36
008542
1:33 1:37
2 Check digital and temperature input for ECU 796. (Unconnected

temperature input indicates -35.0 °C.)
008543

ANALOGUE (V) 3(5) 0.00-11.10 V.
1:1 24.88 1:10 0.54
1:7 24.88 1:11 0.55
1:8 24.38 1:12 2.43
008544
1:9 5.00 1:13 4.41


ANALOGUE (V) 4(5)
1:16 1.34 1:20 0.54
1:17 2.30 1:21 0.01
1:18 1.62 1:22 0.55
008545
1:19 0.53 1:23 0.02

ANALOGUE (V) 5(5)
1:24 5.00 2:9 0.01
1:25 1.34 3:9 0.01
1:27 0.55
008546
1:29 4.41

1 Check analogue output K2 for ECU 796.
ANALOGUE (mA) 1(4) 2:10 means contact 2 (K2), pin 10 on ECU 796. The box is filled
2:10 2:5 0 if the voltage on the output is approx. 24V (active). The box is
2:6 0 empty if the output is 0V (not active).
2:3 0 2:7 0 On output 2:3 etc. current displayed in mA.
000963
2:4 0 2:8 0
2 Check analogue output K2 for ECU 796 further.

ANALOGUE (mA) 2(4)
2:11 0 2:14 0
2:12 0 2:15 0
000964
2:13 0 2:16 0

ANALOGUE (mA) 3(4) This and the next menu are only displayed if ECU has 24 analogue
3:10 3:5 0 outputs (standard is 12). These outputs are then in connector
3:6 0 3, K3.
3:3 0 3:7 0
000965
3:4 0 3:8 0

ANALOGUE (mA) 4(4)
3:11 0 3:14 0
3:12 0 3:15 0
000966
3:13 0 3:16 0

Control outputs K2, description
WARNING
use these menus.
otherwise.
NOTE
CONTROL OUTPUT 1(13) 2:10 means contact 2 (K2), pin 10 on ECU 796. The box is filled
if the voltage on the output is approx. 24V (active). The box is
2:10 empty if the output is 0V (not active). Using the output can be
switched between approx. 24V (active, ON) and 0V (not active,
000967
ON/OFF = ENTER OFF).
2 Check analogue outputs K2 for ECU 796 further.

2:3 0 mA adjusted value) is on the row below.
ADJUST (+/-) 0 mA Using and the required current can be adjusted. ON/OFF
000968
4 5
ON/OFF = ENTER
is confirmed with .

2:4 0 mA
ADJUST (+/-) 0 mA
000969
ON/OFF = ENTER

2:5 0 mA
ADJUST (+/-) 0 mA
000970
ON/OFF = ENTER

2:6 0 mA
ADJUST (+/-) 0 mA
000971
ON/OFF = ENTER


2:7 0 mA
ADJUST (+/-) 0 mA
000972
ON/OFF = ENTER

2:8 0 mA
ADJUST (+/-) 0 mA
000973
ON/OFF = ENTER

2:11 0 mA
ADJUST (+/-) 0 mA
000974
ON/OFF = ENTER

2:12 0 mA
ADJUST (+/-) 0 mA
000975
ON/OFF = ENTER

2:13 0 mA
ADJUST (+/-) 0 mA
000976
ON/OFF = ENTER

2:14 0 mA
ADJUST (+/-) 0 mA
000977
ON/OFF = ENTER

2:15 0 mA
ADJUST (+/-) 0 mA
000978
ON/OFF = ENTER

2:16 0 mA
ADJUST (+/-) 0 mA
000979
ON/OFF = ENTER

Control outputs K3, description
WARNING
use these menus.
otherwise.
NOTE
CONTROL OUTPUT 1(13) This and the following menu are only displayed if ECU has 24
analogue outputs (standard is 12). These outputs are then in
3:10 connector 3, K3.
000980
ON/OFF = ENTER

3:3 0 mA
ADJUST (+/-) 0 mA
000981
ON/OFF = ENTER

3:4 0 mA
ADJUST (+/-) 0 mA
000982
ON/OFF = ENTER

3:5 0 mA
ADJUST (+/-) 0 mA
000983
ON/OFF = ENTER

3:6 0 mA
ADJUST (+/-) 0 mA
000984
ON/OFF = ENTER


3:7 0 mA
ADJUST (+/-) 0 mA
000985
ON/OFF = ENTER

3:8 0 mA
ADJUST (+/-) 0 mA
000986
ON/OFF = ENTER

3:11 0 mA
ADJUST (+/-) 0 mA
000987
ON/OFF = ENTER

3:12 0 mA
ADJUST (+/-) 0 mA
000988
ON/OFF = ENTER

3:13 0 mA
ADJUST (+/-) 0 mA
000989
ON/OFF = ENTER

3:14 0 mA
ADJUST (+/-) 0 mA
000990
ON/OFF = ENTER

3:15 0 mA
ADJUST (+/-) 0 mA
000991
ON/OFF = ENTER

3:16 0 mA
ADJUST (+/-) 0 mA
000992
ON/OFF = ENTER

8 Control system – Last alarms 8:23
8.4.5 Last alarms

Last alarms, description
A history of the latest error codes generated can be seen under this
menu. If the same error code is generated several times this is
LAST ALARMS counted and the number of faults is shown on the display. The date
and time for when the error code was last generated is also displayed.
Select diagnostics and Last alarms in accordance with Diagnostic
000995
test, work instruction, page 8:7. This display indicates if Last alarms
is selected. Press function key to proceed.
The 10 latest error codes are displayed in chronological order (with

error code number, number of error codes and the respective date and
time for the last error code of this type received).
If only one error code is saved there is only the menu for that fault and
the last menu "Clear all alarms". So the number of menus under Last
alarms is dynamic. Max. number of error codes saved is 10.
1 Latest active error codes (1, latest) in chronological order.
LAST ALARMS 1(13)
ALARM NUMBER 354
COUNTER 11
16.01.2007 10:58
009350
2 Latest active error codes (2) in chronological order.

LAST ALARMS 2(13)
ALARM NUMBER 358
COUNTER 8
16.01.2007 10:58
009351

LAST ALARMS 3(13)
ALARM NUMBER 361
COUNTER 3
16.01.2007 10:58
009352

LAST ALARMS 4(13)
ALARM NUMBER 364
COUNTER 2
16.01.2007 10:58
009353

LAST ALARMS 5(13)
ALARM NUMBER 380
COUNTER 6
16.01.2007 10:58
009354

8:24 8 Control system – Last alarms

LAST ALARMS 6(13)
ALARM NUMBER 384
COUNTER 1
16.01.2007 10:58
009355
LAST ALARMS 7(13)
ALARM NUMBER 601
COUNTER 3
16.01.2007 10:58
009356

LAST ALARMS 8(13)
ALARM NUMBER 610
COUNTER 1
16.01.2007 10:58
009357

LAST ALARMS 9(13)
ALARM NUMBER 900
COUNTER 1
16.01.2007 10:58
009358

LAST ALARMS 10(13)
ALARM NUMBER 1200
COUNTER 2
16.01.2007 10:58
009359
11 Latest active error codes (11) for the engine. In the event of more
LAST ALARMS 11(13) than one error code, scroll through the codes by pressing function
ENGINE ALARM 1(X) key 5 .
SPN: 110
FMI: 10
009360
PRESS (+) FOR NEXT
12 Latest active error codes (12) for the transmission. In the event of
LAST ALARMS 12(13) more than one error code, scroll through the codes by pressing
GEARBOX ALARM 1(X) function key 5 .
SPN: 5490
FMI: 11
009361
PRESS (+) FOR NEXT
13 Clear all error codes (only possible with service code). This menu
13(13) is shown if there is one or more error codes. To clear all error
CLEAR ALL ALARMS? codes, press the function key (Yes = ).
YES = ENTER This menu and function deletes the last active error codes under
"Last Alarms" and also the engine and transmission alternatives
009362
and their control units that support the deletion of inactive error
codes, so-called DM3 in the J1939 CAN standard.

8 Control system – Last alarms 8:25
14 Shown if there are no error codes, and after reset. If there are no
13(13) error codes from the KCS system, only menus 11-13 are shown.
NO ALARMS
009364

8:26 8 Control system – Setup
8.5 Setup
Settings, description
The setting menus are used to initiate and calibrate the different
functions.
Initiation means basic setting of the parameters for the different

functions. Calibration means individual adjustment of the values for
max. and min. of the signals for the different functions. This section
describes how to proceed with initiation and calibration of the different
functions.
The number of menu pages per function can vary depending on

the functions with which the machine's control system is equipped.
Accordingly, the total number of menus is dynamic.
The values stated in the following menus are relevant examples

(standard values) of what can be shown in these positions. The actual
value may deviate from these examples.
8.5.1 ETC-Electronic Throttle Control (electronic

throttle)
ETC, description
Go to the Setting menus by pressing function key in this menu.
000056
To access the setting menus, the service code has to be entered

(authorisation required). Thereafter, access is granted to perform
settings.
1 23
4 5
000060
Select Electronic Throttle Control.

E L E C T R O N IC T H R O T T L E (Scroll to the desired menu with function keys 1 and 2 and press
C O N TR O L
008493
to confirm.)
For ETC, it's possible to choose initiation or calibration, see Initiating

ETC, description, page 8:26 and Calibrate ETC, description, page
8:27.
8.5.1.1 Initiating ETC-Electronic Throttle Control

Initiating ETC, description
Select Electronic throttle control, ETC, according to ETC, description,
page 8:26.
ELEC TR O N IC TH R O TTLE Select initiation of ETC. To proceed, press function key .

C O N TR O L
008494
IN ITIATIO N
IN IT 1 (4 ) Set the output signal 1-100% (use 4 and 5 ) to be sent at 20% of

20 pedal travel (when pedal has been pressed down 20%). Press
P O W E R O U TP U T 20
008489
to continue.
A T 20% G A S
Lower value gives wider range for inching.

8 Control system – ETC-Electronic Throttle Control (electronic throttle) 8:27
Set the output signal level 0-100% to be sent at 50% of pedal travel.
IN IT 2 (4 )
This value cannot be less than the previous setting at 20% in menu
50
P O W E R O U TP U T 50 1(4).
008490
A T 50% G A S A lower value gives a wider range for slow speed control, for example
when driving in hydrostatic mode on certain models.
Set the idling speed to be sent to the engine when the pedal is
IN IT 3 (4 )
released, 600-1000 rpm.
750
008491
M IN E N G IN E R P M 750
Set the maximum speed to be sent to the engine when the pedal is
IN IT 4 (4 )
fully depressed, 600 - 2400 rpm. This value can not be less than
2200
008492
the previous setting in menu 3(4).
M A X E N G IN E R P M 2200
This is an example when:
"Power output at 20% gas" is set to 10%.
The setting is suitable for hydrostatic transmission. It becomes easier

to drive very slowly as to position the machine exactly.
In other cases, the following applies:
8.5.1.2 Calibrate ETC-Electronic Throttle Control
Calibrate ETC, description

Select Electronic throttle control, ETC, according to ETC, description,
page 8:26.
Select calibration of electronic throttle (ETC).
ELEC TR O N IC TH R O TTLE
C O N TR O L
008495
C ALIBR ATIO N
Calibration of the right-hand front accelerator pedal. Fully depress the
C ALIBR 1(8)
R IG H T FR O N T 4417 right-hand pedal and then press the function key .
008472
PE D AL TO 4417
LO W ER PO SITIO N (m V)
Calibration of the right-hand front accelerator pedal. Release the
C ALIBR 2(8)
R IG H T FR O N T 544 right-hand pedal and then press the function key .
008473
PE D AL TO 544
UPPE R PO SITIO N (m V)
Display shown if hydrostatic transmission.
C ALIBR 3(8)
LEFT FR O N T 4403 Calibration of the left-hand front accelerator pedal. Fully depress the
008474
PE D AL TO 4403
LOWE R PO SITIO N (m V) left-hand pedal and confirm with .
Display shown if hydrostatic transmission.

C ALIBR 4(8)
LEFT FR O N T 532 Calibration of the left-hand front accelerator pedal. Release the
008475
PE D AL TO 532
left-hand pedal and confirm with .
UPPE R PO SITIO N (m V)
Calibration of the right-hand rear accelerator pedal. Fully depress the
C ALIBR 5(8)
RIGHT REAR 4406 right-hand pedal and then press the function key .
008476
PE D AL TO 4406
LOWE R PO SITIO N (m V) Display shown if the machine is equipped with a rotating or turnable
driver's seat.

8:28 8 Control system – Automatic gearing
Calibration of the right-hand rear accelerator pedal. Release the

C ALIBR 6(8)
RIGHT REAR 549 right-hand pedal and then press the function key .
008477
PE D AL TO 549
UPPE R PO SITIO N (m V) Display shown if the machine is equipped with a rotating or turnable
driver's seat.
Calibration of the left-hand rear accelerator pedal. Fully depress the
C ALIBR 7(8)
LEFT REAR 4403 left-hand pedal and confirm with .
008478
PE D AL TO 4403
LOWE R PO SITIO N (m V) Display shown if the machine is equipped with hydrostatic
transmission or inching and a rotating driver's seat.
Calibration of the left-hand rear accelerator pedal. Fully depress the
C ALIBR 8(8)
LEFT REAR 532 left-hand pedal and confirm with .
008479
PE D AL TO 532
UPPE R PO SITIO N (m V) Display shown if the machine is equipped with hydrostatic
transmission or inching and a rotating driver's seat.
8.5.2 Automatic gearing

Automatic gearing, description
Relevant transmission functionality can be adjusted. Initiation settings

below is general to all transmission models and can be different
depending on order, so called dynamic menus.

000056

settings.
1 23
4 5
000060
Select Automatic Gear Shift.
AUTOMATIC GEAR SHIFT (Scroll forwards to required menu using the function keys 1 and 2
ECU793 and press to confirm.)
For automatic gearing, it is possible to choose initiation or calibration,

008547
see Automatic gearing, description, page 8:28.
8.5.2.1 Initiating automatic gearing (ECU793)

Initiating automatic gearing, description
Select automatic gearing according to Automatic gearing, description,
page 8:28.
Select initiation of automatic gearing ECU 793. This display and the
AU TO M ATIC following only appear if A_GEAR_SHIFT_793 has been selected.
G EA R SH IFT ECU 793
IN ITIATIO N
008548
IN IT 1(3) Only shown if automatic gearing is present on the machine.

ND
STAR T IN 2 1 Start in second gear means that the transmission always starts in
008549
G EAR 0 second gear and that gear changing takes place between the second
ST ND
0=1 G EAR 1=2 G EA R and the highest available gear, depending on model. Value 0 = start
in first gear, value 1 = start in second gear.

8 Control system – Automatic gearing 8:29
IN IT 2(3) Only shown if automatic gearing is present on the machine.

AU TO M ATIC #### This parameter is used to select manual gear changing. Value 0 =
008550
G EA R SH IFT O FF $$$$ automatic gearing, value 1 = manual gear changing.
0=AU TO 1=M ANU AL
Only shown when automatic gearing and NOT inching is present in
IN IT 3(3)
D EC LU TCH #### the machine.
008551
(CC O )O FF $$$$ This parameter can be used to disable the declutch functionality that
0=O N 1=O FF disengage the gearbox into neutral when brake pedal is pressed.
Value 0 = declutch active, value 1 = declutch disabled.
8.5.2.2 Calibrating automatic gearing, description
Calibrating automatic gearing, description
DANGER
Do not leave the machine during calibration. The
machine may start to move.
1 Stop the machine on level ground, set the gear to neutral and
apply the parking brake. Let the engine run at idle speed.
2 Select automatic gearing according to Automatic gearing,

3 Select CALIBRATION by scrolling with the arrow keys (1 and 2)

and confirm with Enter.
4 Only shown when the engine is running.

CALIBRATION 1(2)
The signals for the parking brake and clutch disengagement have
been temporarily disconnected to make it possible to run "Heat
009098
GEARBOX HEAT MODE Mode". The highest possible gear is always selected.
ACTIVATE P-BRAKE!
CALIBRATION 5 "Heat mode" is a function for heating the transmission with the
transmission stationary, by using the parking brake to brake the
machine and let the torque converter heat the transmission oil.
FWD<->NTRL 15S CYCLE!
SELECTED GEAR F3 NOTE
009541
TEMPERATURE 70”C
Rev up the engine to 1600 rpm for 15 seconds and then select
neutral position to flush the oil around and cool it down for 10
seconds. Repeat this until the desired oil temperature (70 ºC)
has been reached.
When the transmission has reached the desired temperature, the

temperature value in the display will flash.
CALIBRATION 2(2) 6 Only shown when the engine is running. Press "Enter" to access
the next menu.
AUTOMATIC CLUTCH
FILLING PARAMETER
009100
ADJUSTMENTS (AEB)
CALIBRATION 7 The following conditions must be fulfilled before the calibration

can start. Transmission in neutral position and the parking brake
>SELECT NEUTRAL applied. Check that all conditions are fulfilled and that the oil
>P-BRAKE ACTIVE temperature is 70 ºC before proceeding to the next menu by
009101
>TEMP >70grC pressing Enter.

8:30 8 Control system – Joystick control
CALIBRATION 8 When the TCU has started calibration, the display shows
information in plain text about the calibration procedure. Any error
STATUS messages are also displayed.
009103
9 During calibration, engine speed is automatically regulated to the
K1 ADJUST! default value which suits each transmission.
After calibration is completed, the display will show the text:
"ADJUSTMENT FINISHED SWITCH OFF IGNITION FOR 5
SECONDS!", for saving the new parameters.
CALIBRATION 2(2) 10 This is only shown when the engine is switched off and inching is
installed. This is an optional function.
009104
INCH PEDAL The requirement for seeing "CALIBRATION INCH PEDAL" is that
the engine is already switched off. This will not be displayed at
all otherwise.
--> Engine switched off = INCH PEDAL CALIBRATION Engine
running = AEB CLUTCH CALIBRATION.
CALIBRATION 11 When the TCU has started calibration, the display shows
information in plain text about the calibration procedure. Any error
STATUS messages are also displayed.
009105
12 Depress the pedal slowly and keep it depressed until the text
PRESS PEDAL SLOW! shown on the display changes to "Release pedal slow!". Release
the pedal slowly.
After successful calibration, switch off ignition for 5 s for saving
the new parameters.
8.5.4 Joystick control

Joystick control, description

000056

settings.
1 23
4 5
000060
Select Joystick control (Lever steering).
(Scroll to the desired menu with function keys 1 and 2 and press
LEVER STEERING
to confirm.)
For joystick control, it is possible to choose initiation or calibration,

000741
see Initiating joystick control, description, page 8:30 and Calibrating

joystick control, description, page 8:34.
8.5.4.1 Initiating joystick control
Initiating joystick control, description

Select Joystick control according to Joystick control, description, page
8:30.

8 Control system – Joystick control 8:31
Select initiation for Joystick control (Lever steering).

LEVER STEERING
INITIATION
000742
Indicates joystick's linearity.
INIT 1(12)
CHARACTERISTIC 3 0 = the wheel angle is equal in relation to the lever angle during the
STEERING LEVER 3 entire lever movement.
0-10, 0=LIN 10 = the wheel angle is small at the beginning of the lever movement
004754
and large at the end.
Recommended value: 3
Setting of speed at reference point 1. Affects steering characteristics.
INIT 2(12)
Recommended value: 5 km/h or acc. to operator's wishes.
SPEED AT 5.0
BREAK POINT 1 5.0
008565
For adjusting, see Adjusting joystick control, description, page 8:33.

INIT 3(12)
SPEED AT 10.0
BREAK POINT 2 10.0 For adjusting, see Adjusting joystick control, description, page 8:33.
008566

INIT 4(12)
SPEED AT 15.0
BREAK POINT 3 15.0 For adjusting, see Adjusting joystick control, description, page 8:33.
008567
Percent of max. steering capacity (% steering value) at reference

INIT 5(12) point 2. Reduces the joystick's influence when speed increases.
70
Recommended value: 70% or acc. to operator's wishes.
% STEERVALUE 70
AT BREAKPOINT 2 For adjusting, see Adjusting joystick control, description, page 8:33.
012854

INIT 6(12) point 3. Reduces the joystick's influence when speed increases.
40
Recommended value: 40% or acc. to operator's wishes.
% STEERVALUE 40
012855
Sensitivity of joystick's change.

INIT 7(12)
Low value gives slow change.
5
SENSITIVITY 5 High value gives fast change.
DEFAULT VALUE 1-9
004753
Recommended value: 5, if 0 = the latest adjusted value is memorised

and used when starting the machine.

Setting the percentage of battery voltage, which provides full flow

to steering left.
INIT 9(12)
25.0 For adjusting, see Adjusting joystick control, description, page 8:33
END PERCENT 25.0
STEERING LEFT (%)
012856
Setting the percentage of battery voltage when steering to the left
starts (exactly when the valve starts to open and provides a small flow
INIT 10(12)
to the steering cylinder).
44.0
START PERCENT 44.0 For adjusting, see Adjusting joystick control, description, page 8:33.
STEERING LEFT (%)
012857
Setting the percentage of battery voltage when steering to the right
INIT 11(12)
56.0
STEERING RIGHT (%)
012858
Setting the percentage of battery voltage, which provides full flow to

steering right.
INIT 12(12)
75.0 For adjusting, see Adjusting joystick control, description, page 8:33.
END PERCENT 75.0
STEERING RIGHT (%)
012859

8 Control system – Joystick control 8:33
8.5.4.2 Adjusting joystick control
Adjusting joystick control, description

Adjusting currents for joystick control/mini-wheel
Whether the percentage shall be raised or lowered depends on
whether it is for steering right or left:
25% = full steering left
approx. 44% = start steering left
50% = neutral position
approx. 56% = start steering right
75% = full steering right
To find the best value for start currents:

• Set START PERCENT STEERING LEFT and END PERCENT
STEERING LEFT to the same value. Start with 44.0 mA. Start
voltage and final voltage are set to the same value in order to know
exactly what voltage the steering valve receives.
• Steer to the left (with lever/mini-wheel). The wheels should move
slowly. If the wheels do not move, decrease the current values a
couple of steps and try again. When this is done, you have to
stand on the footstep to assess how the wheels are moving. When
the correct value has been found, the wheels move slowly.
• Set START PERCENT STEERING RIGHT and END PERCENT
STEERING RIGHT to the same value. Start with 56.0 mA. Start
voltage and final voltage are set to the same value in order to know
exactly what voltage the steering valve receives.
• Steer to the right (with lever/mini-wheel). The wheels should move
slowly. If the wheels do not move, increase the current values a
couple of steps and try again. When this is done, you have to
stand on the footstep to assess how the wheels are moving. When
the correct value has been found, the wheels move slowly.
• Note that steering speed should be the same in both directions.
• The final value is used for START PERCENT STEERING LEFT
and RIGHT.
To find the best value for final currents:

• Set END PERCENT STEERING LEFT to 25% and END PERCENT
STEERING RIGHT to 75%.
• Check that the machine has the same steering speed in both
directions when the joystick is deflected completely (or mini-wheel
is turned quickly, approx. one steering wheel turn per second).
When this is done, you have to stand on the footstep to assess
how the wheels are moving. Steering speed may vary slightly
depending on whether the engine is running at idling speed or at
a higher rpm.
• Test-run the machine and try to assess if the steering capacity
is sufficient at low speeds, can the machine be turned quickly
enough? If not, change the final voltage slightly and try again.
Setting of sensitivity
If rapid steering is required with high sensitivity, set "SENSITIVITY" to
high. Slow steering is achieved with a low value.
A new inexperienced operator often wants slow, forgiving steering.
An experienced operator expects fast reactions from lever/steering

wheel to the steering axle.

Setting of characteristics (Characteristic steer lever)
Output signal Setting of characteristics (Characteristic steer lever)
Indicates joystick's characteristics.
0= steering angle is equal in relation to the lever angle during the

entire steering movement (linear).
10= steering angle is small at beginning of the lever movement and

greater at the end.
004196
Lever deflection
Setting of speed dependence
Setting of speed dependence
Break point 1 Break point 2 Break point 3
The diagram explains how speed dependence can be adjusted using

the break points.
Speed dependence
120
% of max steering capacity
Break point 1 indicates at what speed it applies (for example, 5 km/h),

100 but steering capacity is always 100% For break point 2, speed (for
80 example, 10 km/h) and steering capacity (for example, 70%) are
60 specified. For break point 3, speed (for example, 15 km/h) and
40 steering capacity (for example, 40%) are specified.
20
If one wants steering to be even more "careful" at high speed, the
0
value shall be changed as follows:
0 5 10 15 20 25 30 35
012860
Speed For break point 1, enter speed 5 km/h For break point 2, enter speed
10 km/h and steering capacity 60%. For break point 3, enter speed
15 km/h and steering capacity 30%.
If one wants steering to be completely without speed dependence,

the value shall be changed as follows:
For break point 1, enter speed 5 km/h For break point 2, enter speed
10 km/h and steering capacity (100%). For break point 3, enter speed
15 km/h and steering capacity (100%).
The speed limits and break points can be adjusted in accordance with
customer requirements. However, it is important to not "stretch the
limits" too far. Change and test.
Test-run
Do not forget to test-run the machine in different situations. The setting
of the start voltages is very sensitive. The machine must steer even
when the steering wheel is turned slowly, otherwise it is impossible to
travel straight ahead at full speed. he result may be that regardless of
how much you steer, at first nothing happens, then the machine turns
sharply. Then the cause is that the start voltages have been set too
close to 50%, see above.
If the start voltages are set too far from 50% then the machine's
steering feels very unstable and erratic at high speeds. It is impossible
to steer accurately as the smallest turn of the steering wheel results in
a large wheel angle.
8.5.4.3 Calibrating joystick control
Calibrating joystick control, description

Select Joystick control according to Joystick control, description, page
8:30.

8 Control system – Mini-wheel 8:35
Select calibration for Joystick control (Lever steering).

LEVER STEERING
CALIBRATION
000755
Do not touch the joystick when calibrating the middle position. The
CALIBR 1(6) display shows the joystick's middle position. Press to save this
STEERING LEVER 2442 position as "middle position".
TO CENTRE 2442
POSITION (mV)
000756
Move the lever to far left. The display shows the joystick's position.
CALIBR 2(6) Press to save this position.
STEERING LEVER 4526
TO LEFT 4526
POSITION (mV)
000757
Move the lever to far right. The display shows the joystick's position.
CALIBR 3(6) Press to save this position.
STEERING LEVER 435
TO RIGHT 435
POSITION (mV)
000758
8.5.6 Mini-wheel
Mini-wheel, description

000056

settings.
1 23
4 5
000060
Select Mini steering.
MINI STEERING
to confirm.)
For Mini-wheel (Mini steering), it's only possible to select initiation,

000769
see Initiating Mini-wheel, description, page 8:35.
8.5.6.1 Initiating Mini-wheel
Initiating Mini-wheel, description

Select Mini steering according to Mini-wheel, description, page 8:35.

8:36 8 Control system – Mini-wheel
Setting of speed at reference point 1 (BP1). Affects steering

INIT 1(10) characteristics.
SPEED AT 5
Recommended value: 5km/h.
BREAK POINT 1 5
000770
SPEED AT 10
BREAK POINT 2 10
000771
SPEED AT 15
BREAK POINT 3 15
000772

INIT 4(10) point 2. Reduces the mini-wheel's influence when speed increases.
70
Recommended value: 70%.
% STEERVALUE 70
012861

INIT 5(10) point 3. Reduces the mini-wheel's influence when speed increases.
40
Recommended value: 40%.
% STEERVALUE 40
012862
Sensitivity of mini-wheel's change.

INIT 6(10)
Low value gives many steering wheel turns from lock-to-lock.
5
SENSITIVITY 5 High value gives few steering wheel turns from lock-to-lock.
DEFAULT VALUE 1-9
004545
Recommended value: 5, if 0 = the latest adjusted value is memorised

and used when starting the machine.
Setting the percentage of battery voltage, which provides full flow
to steering left.
INIT 7(10)
END PERCENT 25.0
STEERING LEFT (%)
012863
Setting the percentage of battery voltage when steering to the left

INIT 8(10)
44.0
STEERING LEFT (%)
012864

8 Control system – Electro-hydraulic servo 8:37
Setting the percentage of battery voltage when steering to the right

INIT 9(10)
56.0
STEERING RIGHT (%)
012865
Setting the percentage of battery voltage, which provides full flow to
steering right.
INIT 10(10)
END PERCENT 75.0
STEERING RIGHT (%)
012866
Adjusting mini-wheel
See Adjusting joystick control, description, page 8:33.
8.5.7 Electro-hydraulic servo

Electro-hydraulic servo, description
Each function can be set individually and must be calibrated. For

this reason, 10 solenoid valves must be calibrated and initiated for 5
hydraulic functions.
The first step for activating the electric servo is a basic setting called
Initiation. This is where the dead zone for the levers is set, as well as
min. and max. currents for the solenoid valves.
The method for setting the min. current for the solenoid valves is
to set both min. and max. currents to the same value, for example
260mA, and then increase successively until a movement is obtained
for each hydraulic function. The value stopped at shall be the value
for the min. current.
Max. current should be specified as a maximum by the valve

manufacturer. For Parker L90 the range is 260-510 mA. In some cases
a lower max. current can be set for better adaptation of hydraulic
movement speed and synchronisation with engine performance and
the capacity of the hydraulic pumps.

000056

settings.
1 23
4 5
000060

8:38 8 Control system – Electro-hydraulic servo
Select Electro-hydraulic servo.
ELHYDRAULIC SERVO
to confirm.)
For Electro-hydraulic servo, it's possible to choose initiation or
000780
calibration, see Initiating Electro-hydraulic servo, description, page
8:38 and Calibrating Electro-hydraulic servo, description, page 8:41.
8.5.7.1 Initiating Electro-hydraulic servo
Initiating Electro-hydraulic servo, description

Select electric servo according to Electro-hydraulic servo, description,
page 8:37.
Select initiation of electric servo.
ELHYDRAULIC SERVO
INITIATION
000781
Enter the amount of control lever movement around the middle

INIT 1(25) position to be interpreted as middle position (dead zone). The range
30 is 30-1000 of the total lever movements +/-1000. As small value as
DEAD ZONE 30 possible should be set. Recommended value is 30. The dead zone is
LEVERS 30-1000 required so that hydraulic movements are not triggered by vibration
008569
when the machine is in use, in particular on uneven ground.
Start value, min. current, for lowering movement's solenoid valve.

INIT 2(25) This display is shown if one or more hydraulic functions are selected.
FUNCTION 1A 260
(LOWER) 260
MIN CURRENT (mA)
004547
Stop value, max. current, for lowering movement's solenoid valve.

INIT 3(25) This display is shown if one or more hydraulic functions are selected.
FUNCTION 1A 510
(LOWER) 510
MAX CURRENT (mA)
004548
Start value, min. current, for lifting movement's solenoid valve. This
INIT 4(25) display is shown if one or more hydraulic functions are selected.
FUNCTION 1B 260
(LIFT) 260
MIN CURRENT (mA)
004549
Stop value, max. current, for lifting movement's solenoid valve. This
INIT 5(25) display is shown if one or more hydraulic functions are selected.
FUNCTION 1B 510
(LIFT) 510
MAX CURRENT (mA)
004550

Start value, min. current, for tilt out movement's solenoid valve. This
INIT 6(25) display is shown if two or more hydraulic functions are selected.
FUNCTION 2A 260
(TILT OUT) 260
MIN CURRENT (mA)
004551
Stop value, max. current, for tilt out movement's solenoid valve. This
FUNCTION 2A 510
(TILT OUT) 510
MAX CURRENT (mA)
004552
Start value, min. current, for tilt in movement's solenoid valve. This
display is shown if two or more hydraulic functions are selected.
INIT 8(25)
FUNCTION 2B 260
(TILT IN) 260
MIN CURRENT (mA)
004553
Stop value, max. current, for tilt in movement's solenoid valve. This
FUNCTION 2B 510
(TILT IN) 510
MAX CURRENT (mA)
004554
Start value, minimum current, for left-hand side shift's solenoid valve.
This display is shown if three or more hydraulic functions are selected.
INIT 10(25)
FUNCTION 3A 260
(SHIFT LEFT) 260
MIN CURRENT (mA)
008573
Stop value, max. current, for left-hand side shift's solenoid valve. This
display is shown if three or more hydraulic functions are selected.
INIT 11(25)
FUNCTION 3A 510
(SHIFT LEFT) 510
MAX CURRENT (mA)
004556
Start value, minimum current, for right-hand side shift's solenoid valve.
INIT 12(25)
FUNCTION 3B 260
(SHIFT RIGHT) 260
MIN CURRENT (mA)
004557
Stop value, max. current, for right-hand side shift's solenoid valve.
INIT 13(25)
FUNCTION 3B 510
(SHIFT RIGHT) 510
MAX CURRENT (mA)
004558

8:40 8 Control system – Electro-hydraulic servo
Start value, min. current, for solenoid valve for spreading out. This
display is shown if four or more hydraulic functions are selected.
INIT 14(25)
FUNCTION 4A 260
(SPREAD OUT) 260
MIN CURRENT (mA)
004559
Stop value, max. current, for solenoid valve for spreading out. This
display is shown if four or more hydraulic functions are selected.
INIT 15(25)
FUNCTION 4A 510
(SPREAD OUT) 510
MAX CURRENT (mA)
004560
Start value, min. current, for solenoid valve spreading in. This display
is shown if four or more hydraulic functions are selected.
INIT 16(25)
FUNCTION 4B 260
(SPREAD IN) 260
MIN CURRENT (mA)
004561
Stop value, max. current, for solenoid valve spreading in. This display
is shown if four or more hydraulic functions are selected.
INIT 17(25)
FUNCTION 4B 510
(SPREAD IN) 510
MAX CURRENT (mA)
008570
Start value, min. current, for solenoid valve levelling up. This display
is shown if five or more hydraulic functions are selected.
INIT 18(25)
FUNCTION 5A 260
(EXTRA) 260
MIN CURRENT (mA)
004563
Stop value, max. current, for solenoid valve levelling up. This display
is shown if five or more hydraulic functions are selected.
INIT 19(25)
FUNCTION 5A 510
(EXTRA) 510
MAX CURRENT (mA)
004564
Start value, min. current, for solenoid valve levelling down. This
display is shown if five or more hydraulic functions are selected.
INIT 20(25)
FUNCTION 5B 260
(EXTRA) 260
MIN CURRENT (mA)
004565
Stop value, max. current, for solenoid valve levelling down. This
display is shown if five or more hydraulic functions are selected.
INIT 21(25)
FUNCTION 5B 510
(EXTRA) 510
MAX CURRENT (mA)
004566

8.5.7.2 Calibrating Electro-hydraulic servo
Calibrating Electro-hydraulic servo, description

This is the second step after basic setting in the initiation menus.
Calibration has to be performed to adapt the levers' output signal and
so that maximum value from the lever can be used by KCS. This must
also be performed after replacing a lever.
Select electric servo according to Electro-hydraulic servo, description,

page 8:37.
Select calibration for electro-hydraulic servo.
ELHYDRAULIC SERVO
CALIBRATION
000679
Calibration of voltage for lowering function. When the lever is in max.
CALIBR 1(10) position for lower, press the function key .
F1A (LOWER) 867
LEVER TO MAX 867
POSITION (mV)
004757
Calibration of voltage for lifting function. When the lever is in max.

CALIBR 2(10) position for lift, press the function key .
F1B (LIFT) 8775
LEVER TO MAX 8775
POSITION (mV)
004758
Calibration of voltage for tilt out function. When the lever is in max.
CALIBR 3(10) position for tilt out, press function key .
F2A (TILT OUT) 867
LEVER TO MAX 867
POSITION (mV)
004759
Calibration of voltage for tilt in function. When the lever is in max.

CALIBR 4(10) position for tilt in, press function key .
F2B (TILT IN) 8775
LEVER TO MAX 8775
POSITION (mV)
004760
Calibration of voltage for side shift left function. When the lever is in
CALIBR 5(10) max. position for side shift left, press the function key .
F3A (SHIFT 867
LEFT) LEVER TO 867
MAX POSITION (mV)
004761
Calibration of voltage for side shift right function. When the lever is in
CALIBR 6(10) max. position for side shift right, press the function key .
F3B (SHIFT 8775
RIGHT)LEVER TO 8775
MAX POSITION (mV)
004762

8:42 8 Control system – Scale
Calibration of voltage for spreading out function. When the lever is in

CALIBR 7(10) max. position for spreading out, press the function key .
F4A (SPREAD 867
OUT) LEVER TO 867
MAX POSITION (mV)
004763
Calibration of voltage for spreading in function. When the lever is in
CALIBR 8(10) max. position for spreading in, press the function key .
F4B (SPREAD 8775
IN) LEVER TO 8775
MAX POSITION (mV)
004764
Calibration of voltage for levelling up function. If four hydraulic
functions have been selected in setup, this display is not shown.
CALIBR 9(10)
When the lever is in max. position for levelling up, press the function
F5A (EXTRA) 867
LEVER TO 867 key .
MAX POSITION (mV)
004765
Calibration of voltage for levelling down function. If four hydraulic

functions have been selected in setup, this display is not shown.
CALIBR 10(10)
When the lever is in max. position for levelling down, press the
F5B (EXTRA) 8775
LEVER TO 8775 function key .
MAX POSITION (mV)
004766
8.5.8 Scale
Scale, description

000056

settings.
1 23
4 5
000060
Select Scale.
SCALE (Scroll to the desired menu with function keys 1 and 2 and press
to confirm.)
For the scale, it is only possible to select calibration, see section 7

000803
Load handling, group 7.10.1 Scale.
8.5.8.1 Calibrating Scale
Calibrating scale, description

See section 7 Load handling, group 7.10.1 Scale.

8 Control system – Monitoring 8:43
8.5.9 Monitoring
Monitoring, description
000056
settings.
1 23
4 5
000060
Select Monitoring.
MONITORING
to confirm.)
For Monitoring, it's only possible to select initiation, see Initiating

000806
Monitoring, description, page 8:43.
8.5.9.1 Initiating Monitoring
Initiating Monitoring, description

Select Monitoring according to Monitoring, description, page 8:43.
Menu for setting service interval. Access directly via the service code.
INIT 1(1)
50h Enter new interval with 4 and 5 and press the function key to
SERVICE 50h confirm. On delivery from the factory, this should be set to 50 h.
INTERVAL 0-1000
008568
Resetting the service interval
NOTE
500h TO NEXT SERVICE This menu can only be accessed by entering the special code
(authorisation required) instead of the service code.
PRESS ENTER TO
CONFIRM!
000808
Menu for resetting service time (time to next service).
Press function key to confirm.
8.5.21 Turnable operator's station

Turnable operator's station, description

000056

8:44 8 Control system – Turnable operator's station

settings.
1 23
4 5
000060
Select Seat position.
SEAT POSITION
to confirm.)
For turnable operator's station, it is possible to select calibration, see
004225
Calibrating Turnable operator's station, description, page 8:44.
8.5.21.2 Calibrating Turnable operator's station
Calibrating Turnable operator's station, description

Select turnable operator's station according to Turnable operator's
station, description, page 8:43.
Select calibration of Reversible driver's station (turnable operator's
SEAT POSITION station).
004232
CALIBRATION
When calibrating the turnable operator's station, the parking brake
CALIBR 1(4) must be applied. Press to proceed.
P-BRAKE MUST BE ON!
PRESS ENTER FOR
CALIBRATION!
008561
Turn the driver's seat to the end position, facing straight ahead. Press
CALIBR 2(4) to confirm/save the position.
1104
FWD END 1104
POSITION (mV)
008562
Turn the driver's seat so that it is in the position where it shifts from
CALIBR 3(4) front-facing to rear-facing. This should be within the range of 80-120.
2464 Press to confirm/save the position.
SHIFT F/R 2464
POSITION (mV)
008563
Turn the driver's seat to the end position, facing straight back. Press
CALIBR 4(4) to confirm/save the position.
3895
REV END 3895
POSITION (mV)
008564

8 Control system – Software 8:45
8.6 Software
Software, general
The firmware in Kalmar machines is handled by a PC tool called
Kalmar Smart Link. This is developed by Kalmar to be able to create
the functionality in the machine depending on the customer selected
options and to be able to download parameters and firmware into the
system in the machine.
8.6.1 Kalmar Smart Link

Kalmar Smart Link, general
Kalmar Smart Link (hereinafter called KSL) is Kalmar's internally
developed software for managing KCS, Kalmar Control System. The
program's uses include:
• Downloading basic program to the ECUs' FLASH memory.
• Setting current functions.
• Calibrating current functions. Both basic and fine-tuning calibration.
• Giving clear diagnosis for each function.
• After test or service, load the system's settings for saving centrally
at Kalmar.
The program has different authority levels to ensure that no

unauthorised person accesses the system and changes the firmware
in a manner undesirable to Kalmar.
Requirements
To use KSL, you need to fulfil following requirements:
Operating system: Microsoft Windows version NT 4.0, 2000, XP

or W7.
Hardware: Intel PIII - 700 MHz or better, 64 MB RAM,
Screen resolution - 1024x768 or higher
At least 80 MB free on the hard disk
Serial COM port, RS232 (COM1-COM4)
Other: Internet connection
Data transferring
It is very important to understand the principles of data exchange in
KSL. Parameters and data can be stored in two ways, see figure.
1. In a database.
2. In the KCS-system in the truck
This means that you can read and write information from both places.
004574
Example illustration
The database contains a lot of data structured in different tables. Most

of the data is encrypted.

8:46 8 Control system – Kalmar Smart Link
Kalmar Smart Link data infrastructure

With KSL it is possible to share data with other users. An application
server is used for this purpose. The application server is connected
to the Internet via a web server and handles all data used in the KSL
system. To share data with other users the replication function inside
KSL must be used. This function downloads all relevant updates to the
local computer and uploads all new data stored in the local computer.
LAN / Internet
008596
Network Web server Localdatabase
Application server
KCS-memory and parameters

In the KCS-system we have three different kinds of parameters:
1. Setup parameters. These parameters define the configuration of
the complete system. These data are identical in all ECUs and can
normally not be changed in the field by a service technician. An
example can be which ECUs are present in the system.
2. Settings parameters. These parameters are connected to a special
function and are unique for each respective ECU. An example is
the start and stop current for valves etc. These parameters can
normally be changed by a service technician.
3. Calibrated parameters. These parameters are connected to
a special function and are unique for each respective ECU.
An example is the lever positions for joystick control. These
parameters can normally be changed by a service technician.
See the memory map in figure.
Memory map KCS-system
ECU790 EDU795 ECU796
= Setup = = Setup = = Setup =
Settings- and Settings- and Settings- and

calibrated values calibrated values calibrated values
004577
How to connect Kalmar Smart Link to the truck.

Connect the computer to the truck using a null-modem cable, Kalmar
P/N 923994.0001. Connect one end of the cable to the serial COM-port
on the computer and the other end to the 9-pin D-sub connector in
the electronic box, located to the left behind the driver's seat in the
cab. Make sure that it is working by defining the right COM-port in the
KSL-menu, Config -> Setup COM-port.

8 Control system – Kalmar Smart Link 8:47
How to start the Kalmar Smart Link

To start KSL, double-click on the icon on the desktop named Kalmar
Smart Link - 2006, or use the Windows start button: Start -> Programs
-> Kalmar Smart Link - 2006.
How to find help for Kalmar Smart Link

Help for Kalmar Smart Link can be obtained via the Windows start
button: Start -> Programs -> Kalmar Smart Link - 2006 -> Help Kalmar
Smart Link, or visit our website www.kalmarind.com/ksl or simply
press the F1 key on the computer keyboard.
How to apply for user account to Kalmar Smart Link

Visit www.kalmarind.com/ksl and click on Join the KSL user team,
after you have received your user account you can login on Kalmar
Smart Link Online and for example find more user instructions,
download recent updates etc.

8:48

9:1
Contents 9 Frame, body, cab and accessories

9 Frame, body, cab and accessories ..................................................................9:5
9.1.1 Multi-function lever ....................................................................................9:10
9.2 Safety and emergency equipment .................................................................9:14
9.2.1 Control breaker .........................................................................................9:14
9.2.2 Seat belt ....................................................................................................9:14
9.2.3 Fire extinguisher........................................................................................9:14
9.2.4 Seat buzzer ...............................................................................................9:15
9.2.5 Roof grating...............................................................................................9:15
9.3 Seat................................................................................................................9:16
9.3.1 Seat cushion .............................................................................................9:20
9.3.2 Back rest cushion ......................................................................................9:21
9.3.3 Heating coil ...............................................................................................9:21
9.3.4 Bumper......................................................................................................9:22
9.3.5 Air suspension...........................................................................................9:22
9.3.6 Compressor air-suspension seat...............................................................9:22
9.3.7 Mechanical seat adjustment......................................................................9:23
9.3.8 Passenger seat .........................................................................................9:23
9.3.9 Reversible operator\qs seat ......................................................................9:24
9.3.10 Rotating driver's seat.................................................................................9:25
9.3.11 Arm rest.....................................................................................................9:26
9.3.12 Directional control valve, turnable driver's seat.........................................9:26
9.3.13 Sensor turnable driver's seat.....................................................................9:26
9.3.17 Head rest...................................................................................................9:26
9.4 Heating, ventilation and air conditioning ........................................................9:27
9.4.1 Fresh air / recirculation valve ....................................................................9:29
9.4.2 Defroster nozzles ......................................................................................9:29
9.4.3 Cab fan......................................................................................................9:30
9.4.4 Fresh air filter ............................................................................................9:32
9.4.5 Heat exchanger heat .................................................................................9:33
9.4.6 Water valve ...............................................................................................9:35
9.4.7 AC compressor .........................................................................................9:35
9.4.8 Thermostat ................................................................................................9:36
9.4.9 Condenser unit ..........................................................................................9:37
9.4.10 Expansion valve ........................................................................................9:39
9.4.11 Evaporator.................................................................................................9:40
9.4.12 Sensor for ECC .........................................................................................9:41
9.4.13 Control unit ECC .......................................................................................9:42
9.4.14 Air distributor .............................................................................................9:42
9.4.15 Fine filter ...................................................................................................9:42
9.4.16 Pause heater .............................................................................................9:43
9.4.18 Cab heater ................................................................................................9:43
9.4.20 Cooling unit ...............................................................................................9:43
9.4.21 Particle and moisture filter.........................................................................9:44
9.4.22 Actuator motor...........................................................................................9:46
9.5 Wiper/washer system.....................................................................................9:49
9.5.1 Wiper front.................................................................................................9:49
9.5.2 Wiper roof..................................................................................................9:49
9.5.3 Wiper rear .................................................................................................9:49
9.5.4 Washer motor and reservoir......................................................................9:49
9.5.5 Wiper motor front ......................................................................................9:50
9.5.6 Wiper motor roof .......................................................................................9:51
9.5.7 Wiper motor rear .......................................................................................9:54
9.6 Lighting system ..............................................................................................9:56
9.6.1 Headlights .................................................................................................9:56

9:2 8 Control system – Kalmar Smart Link
9.6.2 Running lights ...........................................................................................9:57

9.6.3 Tail lights ...................................................................................................9:57
9.6.4 Brake lights ...............................................................................................9:57
9.6.5 Back-up lights............................................................................................9:57
9.6.6 Direction indicators....................................................................................9:57
9.6.7 Warning lamp, Hazard...............................................................................9:58
9.6.8 Revolving beacon......................................................................................9:58
9.6.9 Working lights, mast ..................................................................................9:60
9.6.10 Working lights, cab ....................................................................................9:60
9.6.11 Interior lighting...........................................................................................9:60
9.6.12 Working lights, fenders..............................................................................9:60
9.6.13 Engine room lighting .................................................................................9:61
9.7 Signalling system ...........................................................................................9:62
9.7.1 Horn ..........................................................................................................9:63
9.7.2 Warning lamp, Hazard...............................................................................9:63
9.7.3 Revolving beacon......................................................................................9:63
9.7.4 Warning parking brake ..............................................................................9:63
9.7.5 Back-up alarm ...........................................................................................9:63
9.7.6 Flashing brake light for reversing ..............................................................9:64
9.8 Entertainment and communication ................................................................9:65
9.8.1 Radio with CD ...........................................................................................9:65
9.8.2 Communication radio ................................................................................9:66
9.8.3 Telephone..................................................................................................9:66
9.8.4 Terminal.....................................................................................................9:67
9.8.5 Screen .......................................................................................................9:67
9.8.6 Computer ..................................................................................................9:67
9.8.7 Voltage converter ......................................................................................9:67
9.9 Glass/windows/mirrors...................................................................................9:69
9.9.1 Windscreen ...............................................................................................9:70
9.9.2 Side window ..............................................................................................9:73
9.9.3 Roof window..............................................................................................9:75
9.9.4 Rear window .............................................................................................9:76
9.9.5 Rear view mirror ........................................................................................9:76
9.9.6 Protective panel in front of windscreen .....................................................9:76
9.9.8 Reversing camera .....................................................................................9:76
9.9.9 Monitor, reversing camera.........................................................................9:77
9.10 Cab structure and suspension .......................................................................9:78
9.10.1 Cab frame .................................................................................................9:78
9.10.2 Doors.........................................................................................................9:78
9.10.3 Cab substructure .......................................................................................9:79
9.10.4 Cab tilting ..................................................................................................9:80
9.10.5 Door stop...................................................................................................9:81
9.10.6 Roof and door mouldings ..........................................................................9:82
9.10.7 Cab tilting cylinder .....................................................................................9:82
9.11 Cab interior ....................................................................................................9:87
9.11.1 Instrument and control panels ...................................................................9:87
9.11.2 Interior fittings, plastic ...............................................................................9:88
9.11.3 Interior fittings, textile ................................................................................9:91
9.11.4 Floor covering ...........................................................................................9:92
9.11.5 Insulation ...................................................................................................9:92
9.11.6 Sun visors .................................................................................................9:93
9.11.7 Terminal console .......................................................................................9:93
9.11.8 Writing desk...............................................................................................9:93
9.11.9 Compartment for A4 papers ......................................................................9:93
9.11.10 Holder for pump lever................................................................................9:93
9.12 Frame.............................................................................................................9:94
9.13 Body structure................................................................................................9:95
9.13.1 Wings ........................................................................................................9:95

8 Control system – Kalmar Smart Link 9:3
9.13.2 Hood engine compartment ........................................................................9:95

9.13.3 Footstep ....................................................................................................9:96
9.13.4 Counterweight ...........................................................................................9:97
9.13.5 Battery compartment .................................................................................9:98
9.13.7 Mud guards ...............................................................................................9:98
9.13.8 Tool kit .......................................................................................................9:98
9.13.9 Lifting lugs .................................................................................................9:99
9.14 Central lubrication ........................................................................................9:100
9.14.1 Pump unit ................................................................................................9:100
9.14.2 Distribution block .....................................................................................9:101
9.14.3 Lines........................................................................................................9:101
9.14.4 Grease nipples ........................................................................................9:101
9.15 Paint/coatings ..............................................................................................9:102

9:4

9 Frame, body, cab and accessories – Frame, body, cab and accessories 9:5
9 Frame, body, cab and

accessories
Frame, body, cab and accessories, general
The workshop manual only describes components and job descriptions
related to installation in the machine. See the supplier documentation
for descriptions and instructions for components and systems of the
frame, body, cab and accessories.


9:6 9 Frame, body, cab and accessories – Controls and instruments

Cab overview Spirit Delta
1 2 3 4A 5
R
1 4 5
14 2 3
7A
4B 7B
014486
13 12 11 10 9 8
1 Left instrument panel

2 Gear and direction of travel selector
3 Steering wheel panel
4A Steering wheel
4B Joystick or mini-wheel
5 Multi-function lever
6 Parking brake
7A Control for load handling
7B Alternative control for load handling

8 Arm rest
9 Driver's seat
10 Accelerator
11 Brake pedal
12 Brake pedal
13 Electronic box with fuses and relays
14 Hour meter

9 Frame, body, cab and accessories – Controls and instruments 9:7
Left-hand instrument panel
30 31 32 33 Left-hand instrument panel
15 Control for heating

16 Controls for fan
17 Controls for defroster/cab
18 Controls for cooling AC

27 28 29
19 .. 26
19 Switch for recirculation/fresh air
(Only for heater unit with cooling AC)
18
17 20 Switch for cooling AC
16
15 Switch for extra working lamps
21 Switch for working lamps on mast

30 31 32 33
24 Switch for revolving beacon

25 Switch for warning lamp
26 Switch for headlights
27 28 29
19 .. 26 27 Switch for seat heating
(The switch may be in the driver's seat.)
006908
TO E
AU O D
M
34
28 Switch for central lubrication
Left-hand instrument panel, upper with heater unit and
lower with climate control system 29 Switch for pause heater
30 Spare
31 Spare
32 Spare
33 Socket for 12/24V
34 Climate control system ECC

See section Air conditioning ECC.

9:8 9 Frame, body, cab and accessories – Controls and instruments
Steering wheel panel

Steering wheel panel
35 36 37 38 39 40 41 42 43
A buzzer is built in under the steering wheel panel (not visible). It
is activated if:
• starting attempts are made with a gear engaged and parking
brake not activated
• the parking brake is not activated when the driver leaves the
driver's seat
• the machine has low coolant level, low brake pressure or a
F
parking brake fault
N
R • an error code is generated, when a short sound signal sounds
1 2
R
3
35 Spare
4 5
36 Warning lamp for air filter replacement
37 Indicator lamp for vertical hold

006903
44 45 46 47 48 49 38 Warning lamp, low battery charging

Steering wheel panel 39 Indicator light, high beams
40 Indicator light for direction indicators
41 Display for the Control system, KCS
42 Alarm indicator for control system, KCS
43 Ignition
44 Switch for turnable driver's seat

45 Switch for engagement and disengagement of alternative
travel direction selector
46 Inching switch
47 Function keys for Control system, KCS
48 Switch for windscreen wiper, rear
49 Switch for windscreen wiper, roof

9 Frame, body, cab and accessories – Controls and instruments 9:9
Right instrument panel

Right instrument panel
51 52 53 54 55 56 57 58 59
51 Switch for reverse alarm cutout
52 Switch for raising/lowering driver's seat
54 Switch for electrically heated rear-view mirrors
007728
55 Spare
Right instrument panel 56 Spare
57 Spare
58 Spare
59 Spare
Control for load handling
For more controls for load handling and associated functions, see
section Load handling.

9:10 9 Frame, body, cab and accessories – Multi-function lever
Switch, replacement
2 Remove the screws securing the instrument panel and lift up the
panel.
3 Disconnect the pin terminal from the switch and any bulb socket.
4 Remove the bulb socket using a pair of pliers.
5 Replace the switch.
Spirit Delta 008341
Indicator lamp, replacement

2 Remove the screws securing the instrument panel and lift up the
panel.
3 Disconnect the bulb socket pin terminal.
4 Open the bulb holder using a pair of pliers.

5 Replace the bulb.
9.1.1 Multi-function lever

Windscreen wiper and washer
The windscreen wipers and washers are controlled by the
multi-function lever (position 5). Turn the control to the following
positions:
• 0 - No wiper action
• Intermittent wiper
• I - Continuous wiper action
006998
• II - Continuous wiper action

• Push the control towards the steering wheel to wash windscreen,
roof window and rear window.

9 Frame, body, cab and accessories – Multi-function lever 9:11
Light control, horn and direction indicators

Headlamps and horn are controlled with the multi-function lever
(position 5).
• With headlamps on: Multi-function lever is used to switch
between high and low beams. Move the control towards you to
switch between high and low beams.
• With headlamps off: The multi-function lever is used to flash with
the headlamps (high beam). Move the control away from you for
main beam flash. The control returns automatically.
006998
A • Press the button (position A) for horn.
• Move the lever rearward or forward for the left and right-hand
direction indicator.
Multi-function lever, replacement

2 Remove the centre cover from the steering wheel and unscrew
the nut securing the steering wheel. Remove the steering wheel.
(If the steering wheel is firmly fixed to the steering wheel shaft,
tap carefully with a drift the same diameter as the steering wheel
shaft, and lift the steering wheel at the same time.)
3 Remove the lower steering panel cover (six screws).

008343

9:12 9 Frame, body, cab and accessories – Multi-function lever
4 Remove the upper steering panel cover (two screws).
008344
008345 5 Remove the Allen screws securing the both levers.
6 Remove the covers from the steering wheel shaft (seven screws).
7 Thread the lever through the lower cover.

9 Frame, body, cab and accessories – Multi-function lever 9:13
8 Remove the nine clips holding the dashboard. Press in the centre
pin on the clip (approx. 3 mm) to unlock the clip.
NOTE
Reuse the clips by re-inserting the centre pin and pressing this
flush with the head on fitting.
9 Raise the instrument panel slightly.
NOTE
This only applies to cab Spirit Delta.
10 Cut the cable ties securing the cable harness.

11 Unplug the connector for the multi-function lever in question.
12 Withdraw the cables and multi-function lever.
13 Replace the multi-function lever.
008346
NOTE
Torque tighten the socket cap screws that hold the multi-function
lever to the steering wheel shaft to 2.5-3.0 Nm.
Torque tighten the nut in the centre of the steering wheel to 40 Nm
(5 Nm).

9:14 9 Frame, body, cab and accessories – Safety and emergency equipment
9.2 Safety and emergency equipment

Safety and emergency equipment, description
Safety components for protecting the driver.
The operator's cab contains equipment designed to fulfil the safety

requirements imposed by authorities, customers, operators and
Cargotec.
9.2.1 Control breaker

Emergency stop switch, description
Only with electrically controlled control lever, electrical servo.
See section 7 Load handling , group 7.1.1 Control levers load handling.
9.2.2 Seat belt

Seat belt, description
Two-point type belt. Mounted in the seat.
9.2.3 Fire extinguisher

Fire extinguisher, description
Usage instructions are on the fire extinguisher.

008339

9 Frame, body, cab and accessories – Seat buzzer 9:15
9.2.4 Seat buzzer

Seat buzzer, description
The seat buzzer is located on the underside of the driver's seat and its
sensors in the seat cushion. The buzzer sounds if the parking brake
is not applied when:
• the engine is switched off and the operator\qs seat is not occupied.
• the ignition key lock is in operating position and the operator\qs
seat is not occupied.
(A buzzer sound also indicates that the parking brake pressure is too
low.)
9.2.5 Roof grating

Roof grating, description
The roof grating protects the operator from falling objects. This
constitutes protection that goes beyond the legal requirements.
001151

9:16 9 Frame, body, cab and accessories – Seat
9.3 Seat
Seat, general
This section describes the driver's seat. The following alternative seats
are available:
• Driver's seat Bege is equipped with:
• mechanical adjustment of height and suspension
• air suspension
• integrated horizontal suspension (can be switched off)
• rotatable 40
• mechanically adjustable lumbar support
• mechanically adjustable seat angle
• seat belt, 2-point
• head rest
• adjustable armrest, right
• adjustable armrest, left
• seat heating
• ventilated seat and back rest cushion (air-vent). The seat
requires compressed air. The option includes an externally
mounted compressor underneath the cab floor.
• Driver's seat Isringhausen 6500. The seat is equipped with:
• air suspension
• air-adjusted lumbar support
• mechanically adjustable damping
• horizontal suspension (disengageable)
• head rest
• seat heating
• integrated compressor

9 Frame, body, cab and accessories – Seat 9:17
• Driver's seat Grammer Actimo XXL. The seat is equipped with:

• air suspension (height)
• air-adjusted lumbar support
• mechanically adjustable seat length
• mechanically adjustable damping
• integrated horizontal suspension
• head rest
• seat heating
• integrated compressor
• Driver's seat Isringhausen 6000. The seat is equipped with:
NOTE
Other alternatives of driver's seat may be available.
Grammer, Actimo XXL and Be-Ge seats,

replacement
2 Slide the seat fully backwards, remove the two front screws that
hold the seat in place.
3 Slide the seat fully forwards, remove the two rear screws that hold
the seat in place.
4 Undo the necessary connectors for the cables.
5 Remove the seat.
6 Fit in reverse order. See also Wiring to seat, installing, page 9:18.

9:18 9 Frame, body, cab and accessories – Seat
Wiring to seat, installing
NOTE
The description below shows attachment of wiring at the BE-GE
driver's seat. Wiring for other seat options is attached according to
the same principle, but some details may be different.
Seat without seat column

2 Check that the wiring has sufficient slack when the seat is in the
forward position. If the wiring is too slack, it can end up between
the rails when the seat is slid back.
3 Position the seat in the max. upward position.
010762
4 Strap the wiring in place in the seat cross-bar, with the wiring
forming a sufficient slack arch across the cross-bar.
NOTE
Check that the wiring is not pinched between the rails when
seat height or length is adjusted.
5 Strap the wiring in the rear edge of the seat undercarriage.

010763
Seat with seat column

2 Secure the wiring for the seat orientation sensor (1) with
self-adhesive cable tie mounting. The seat switch wiring is routed
inside the seat column (2).
1 3 Position the seat in the max. upward position.
2
010765

9 Frame, body, cab and accessories – Seat 9:19
4 Strap the wiring in place in the seat cross-bar, with the wiring
forming a sufficient slack arch across the cross-bar.
NOTE
Check that the wiring is not pinched between the rails when
seat height or length is adjusted.
010764

9:20 9 Frame, body, cab and accessories – Seat cushion
9.3.1 Seat cushion

Seat cushion, description
The seat cushion's filling and upholstery are replaceable. These should
be replaced with new ones when they show signs of wear.
Seat cushion, replacement (product alternative

BE-GE)
2 Loosen the rubber bellows by removing the plastic clips.
3 Unhook the upholstery's rails from the seat frame and remove
the upholstery.
2 5 4 Remove the padding.
If the seat is equipped with seat heater.
4 Unplug the connector for the heating coil before the padding is
removed.
NOTE
The seat's heating coil is glued to the padding. Exercise caution
if the padding is to be replaced but the heating coil is to be
re-used, or if only the coil is to be replaced.
3
5 Assemble in reverse order.
1
006276
1. Plastic clip, rubber bellows

2. Upholstery
3. Seat frame
4. Padding
5. Heating coil

9 Frame, body, cab and accessories – Back rest cushion 9:21
9.3.2 Back rest cushion

Back rest cushion, description
The back rest cushion's filling and upholstery are replaceable. These
should be replaced with new ones when they show signs of wear.
Back rest cushion, replacement (product alternative

BE-GE)
2 Detach the rubber bellows on the rear of the seat by removing
the plastic clips and folding down the rubber bellows. See Seat
cushion, replacement (product alternative BE-GE), page 9:20.
3 3 Remove the back rest by first removing the attaching bolts on the
right and left-hand side of the seat and then remove the attaching
bolts for the seat belt on the right and left-hand side of the seat.
4 4 If the seat is equipped with 3-point seat belt.
Remove the belt guide by removing the cover and the attaching
bolt.
5 If the seat is equipped with arm rests.
Remove the arm rest by removing the attaching bolts.
6 Position the back rest on the seat and fit the attaching bolts, do
5 not tighten them. Then fit the attaching bolts for the seat belt.
Tighten the attaching bolts for the seatbelt with a torque of 42 Nm,
then tighten the attaching bolts with a torque of 33 Nm.
7 If the seat is equipped with 3-point seat belt or arm rest.
6 Cut holes in the upholstery for seat belt and arm rest on the new
back rest before arm rest or seat belt is installed.
006278
1 2
1. Attaching bolt back rest
2. Attaching bolt, seat belt
3. Cover, belt guide
4. Attaching bolt, belt guide
5. Arm rest
6. Attaching bolt, arm rest
9.3.3 Heating coil

Heating coil, description
Used for seat and backrest heating.

9:22 9 Frame, body, cab and accessories – Bumper
9.3.4 Bumper
Bumper, description
The shock absorbers are integrated in the suspension unit and are
self-adjusting, that is, adjust automatically to the operator\qs weight.
Bumper, replacement (product alternative BE-GE)

2 Remove the driver's seat from the frame and lift it out of the
2 machine. See and Grammer, Actimo XXL and Be-Ge seats,
replacement, page 9:17.
3 Remove the seat cushion, see Seat cushion, replacement (product
alternative BE-GE), page 9:20.
4 Remove the back rest cushion, see Back rest cushion,
1 replacement (product alternative BE-GE), page 9:21.
5 Remove the shock absorber's attaching bolts.
6 Replace the shock absorber.
7 Assemble in reverse order.
006277
1. Bumper
2. Attaching bolt
3. Attaching bolt
9.3.5 Air suspension

Air suspension, description
A seat with air suspension has rubber bellows and a compressor. The
air suspension is self-adjusting, that is, it adjusts automatically to the
operator's weight. The compressor supplies the suspension unit with
compressed air.
9.3.6 Compressor air-suspension seat

Compressor air-suspension seat, description
The compressor can be part of the air-suspended seat. In this case it

is located inside the seat's suspension unit.
The compressor and compressed air tank can also be located in the
truck. The location may vary. In this case, compressed air is led to
the control valve in the seat via a compressed air hose. The design of
the compressor may vary.
008347
Compressor located on the truck.

9 Frame, body, cab and accessories – Mechanical seat adjustment 9:23
Compressor located under the cab floor, replacement

2 Undo the air hoses and the electric connectors for the compressor.
1 2 3
4 3 Remove the screws that hold the compressor in place on the
compressor bracket.
5
4 Remove the compressor.
008637
7 6
1. Air filter
2. Screw
3. Compressor bracket
4. Compressor
5. Compressed air tank
6. Air hose
7. Electric connectors
8. Pressure switch
9.3.7 Mechanical seat adjustment

Mechanical seat adjustment, description
See Seat, general, page 9:16.
9.3.8 Passenger seat

Passenger seat, description
Passenger seat are available in several different designs.
The seat folds (vertically) in order not to obstruct the entrance when
not in use. Located to the left of the driver's seat.
001627
Console with folding passenger seat.

9:24 9 Frame, body, cab and accessories – Reversible operator\qs seat
9.3.9 Reversible operator\qs seat

Reversible operator\qs seat, description
This seat is electrically rotatable and is only found on Spirit Delta

cabs. On Spirit Delta, the driver's seat position is adjusted with an
electric motor and a gear.
The seat console has an integrated steering column and steering

wheel with panel. This follows round in the console during rotation.
The driver's seat is no different from other seat options.
Spirit Delta cabs with turnable driver's seat have duplicated controls
and pedals. Since the steering wheel and hand controls follow when
turning, the direction of the control valve and headlights, for example,
are turned with special reversing valves (directional control valves). I
this way the front of the machine is always in the direction in which
the driver's seat is turned.
Steering wheel angle is transmitted to the steering valve via a chain.

The chain has a tensioner which can be adjusted from the outside. It
is accessible via a cover lid on the console.
006144
Reversible operator\qs seat, electric motor,

replacement
2 Tilt the cab.
3 Undo the connector for the electric motor.

4 Remove the four screws that hold the electric motor in place.
5 Remove the electric motor.
1
006148
1. Electric motor

9 Frame, body, cab and accessories – Rotating driver's seat 9:25
9.3.10 Rotating driver's seat

Rotating driver's seat, description
Often foot operated to manually rotate 10 degrees to the left or 40

degrees to the right, but also available with electrically controlled
locking for configurable rotation: left 0, 20 or 35 degrees or right 35 or
55 degrees. This is primarily intended to facilitate entry and exit and
eliminate the need to turn your head when reversing. The pedal (in
the bracket) is released with the foot.
This seat console is available in different reversible alternatives, with

or without doubled pedals.
001625
NOTE
Console for manual rotating operator\qs seat. Avoid reversing the seat while operating.
1. Servo-motor
1 2. Top plate
3. Wire
4. Ball
5. Micro switch (left)
2 6. Base plate
7
11 7. Ball distance ring
10 3 8. Central plate
9
8 9. Wire screw
4 10. Lock lever
11. Spring
7 5
6
4
008586
Console for electrically rotating driver's seat.

9:26 9 Frame, body, cab and accessories – Arm rest
9.3.11 Arm rest

Armrests, description
The arm rests are attached in the seat's back rest. Their height can be
adjusted individually (around the attachment point).
Depending on options there is also an arm rest for the left-hand side:
A B A. Mini-wheel
B. Joystick control
006285
9.3.12 Directional control valve, turnable driver's

seat
Directional control valve, turnable driver's seat,
description
See section 5 Steering , group 5.2.15 Directional control valve, turnable
driver's seat.
9.3.13 Sensor turnable driver's seat

Sensor, turnable driver's seat, description
See section 5 Steering , group 5.2.16 Sensor, turnable driver's

seat.
9.3.17 Head rest

Head restraint, description
Some models of seat can be adjusted with a head restraint for

increased comfort.

9 Frame, body, cab and accessories – Heating, ventilation and air conditioning 9:27
9.4 Heating, ventilation and air

conditioning
Heating, ventilation and air conditioning,
description
A standard truck with the Spirit Delta cab only has heater/defroster.
The heating unit (cab/defroster) is connected to the engine's cooling
system and provides heat when the engine is warm. The heating
unit consists of a fan and elements for heating the air. The air is
then distributed through built-in ducts in the cab interior and can, for
example, be directed to the defroster or towards the floor.
Climate control available in different types:

• Climate control, AC (manual control of cooling, dehumidifying and
heating)
• Climate control, ECC (Electronic Climate Control, electronic control
of cooling, dehumidifying and heating).

9:28 9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
Air conditioning includes the parts presented in the illustration and

ensures the operator's cab climate is as comfortable as possible. The
F function of the air conditioning is to:
• heat the air when it is cold
• dehumidify the air when it is damp
2
• clean the air of impurities
4
• cool the air when it is hot
D
C • defrost (defroster function)
The unit is controlled with switches and controls on the instrument

E E panel.
3
The unit's fan is controlled in stages 0-I-II-III (with the fan control).
With climate control ECC, the fan is infinitely variable 0-100%.
IMPORTANT
6 A B
On machines with ECC or AC, it is vital that the engine
cooling system is refilled with coolant with the correct
concentration of antifreeze. Otherwise there is a risk
that the air conditioning system will freeze during
usage.
5 1
G
000762
1. Fluid reservoir/receiver dryer

2. Evaporator
3. Fan
4. Expansion valve
5. Condenser
6. Compressor
A. High-pressure gas
B. High-pressure fluid
C. Low-pressure fluid
D. Low-pressure gas
E. Heat, cab air
F. Cooled air to cab
G. Outdoor air for removal of heat

9 Frame, body, cab and accessories – Fresh air / recirculation valve 9:29
9.4.1 Fresh air / recirculation valve

Fresh air/recirculation valve, description
The valve is located in the external unit for fresh air intake into the
cab. An electrically controlled recirculation damper is only available in
combination with air conditioning and climate control. Fully open for
fresh air, or the recirculation air from the cab.
015659
Fresh air intake to cab, Spirit Delta
9.4.2 Defroster nozzles

Defroster nozzles, Spirit Delta, description
The cab interior has a number of fixed defroster nozzles, such as at
the front edge of the doors and the defroster vents for the windscreen.
There are also two adjustable nozzles in the outer corners of the
dashboard panel. Adjustable flow and direction (flow is proportional
to fan speed).
A large air vent is located low in the cab (floor). This allows the gradual
adjustment of the air flow from the lower part of the cab to defroster.
An optional, adjustable defroster nozzle located central in the

instrument panel is available.
001839
Defroster nozzles to cab

9:30 9 Frame, body, cab and accessories – Cab fan
Air vents, Spirit Delta, replacement

2 Remove the instrument panel for warning lights and switches.
3 Squeeze the four catches towards the centre and remove the vent.
4 Remove the two screws and the rest of the vent.
9.4.3 Cab fan

Cab fan, description
The cab fan is located in the external unit for fresh air intake to the
cab (between the tilt cylinders). The fan consists of two single fans.
015659

9 Frame, body, cab and accessories – Cab fan 9:31
Cab fan, replacement

2 Remove the cover plate holding the wiper motor.
3 Remove the washer fluid hose and unplug the connector from
the wiper motor.
4 Remove the bolts securing the cab fan to be replaced.

5 Unplug the connector from the cab fan.
6 Replace the cab fan.

9:32 9 Frame, body, cab and accessories – Fresh air filter
9.4.4 Fresh air filter

Fresh air filter, description
The fresh air filter is standard equipment on machines with only
heating, but can also be selected for machines with AC or ECC. It is
located in the external unit for fresh air inlet to the cab, on Spirit Delta
in front of the cab fan (between the tilt cylinders) and on Spirit Delta
Space on the right-hand side of the cab.
A fine filter is standard equipment on machines with AC and ECC, but

can also be selected for machines with only heating.
NOTE
Ensure that the filter cassettes are installed with the arrow markings
pointing in the direction of air travel.
015660
Fresh air intake to cab with fine filter and filter holder.

9 Frame, body, cab and accessories – Heat exchanger heat 9:33
9.4.5 Heat exchanger heat

Heat exchanger heat, description
Pipes and fins in the heat exchanger transfer heat from the hot
coolant in the engine to the ventilation air in the cab.
The heat exchanger for heating is located in the external unit for fresh
air intake to the cab (between the tilt cylinders).
NOTE
Clamps should be installed on the hoses to prevent unnecessary
loss of coolant when any work is done on the coolant circuit.
Wear protective gloves and use a collection vessel to collect the
coolant that runs out.
NOTE
After work is performed, check the coolant circuit for leaks and
check the coolant level. Top up coolant if necessary.
015661
The heat exchanger for heating at bottom (located in

fresh air intake to cab)
Heat exchanger, heating, replacement

2 Remove the cover plate holding the wiper motor.

9:34 9 Frame, body, cab and accessories – Heat exchanger heat
the wiper motor.
4 Remove the fresh air filter and the two screws securing the grille
for the fresh air intake.
5 Drain the cooling system of coolant, see Maintenance manual.
6 Clamp the hoses to and from the heat exchanger with pinch-off
pliers to prevent coolant escaping.
Picture shows heating with AC.
7 Disconnect the coolant hoses from the heat exchanger under the
cab.
8 Withdraw the heat exchanger from its rest position.

9 Replace the heat exchanger.

9 Frame, body, cab and accessories – Water valve 9:35
9.4.6 Water valve

Water valve, description
The water valve is located under the cab on one of the hoses that leads
coolant to the cab fan. The valve has a shutdown function that opens
or closes the coolant flow to the cab fan. On machines with ECC, the
water valve is electrically operated.
Water valve machines with ECC, replacement

2 3 1 Machine in service position, see section B Safety.
2 Install clamps on the hoses to prevent coolant from running out.
1
3 Undo the hose clamps and remove the hoses. Use a receptacle to
4 collect any coolant that runs out.
4 Unscrew the water valve.
5 Undo the water valve connector.
6 Fit in the reverse order
5
NOTE
015301
After fitting the water valve, check the valve for leaks and check
the coolant level. Top up coolant if necessary.
1. Water valve
2. Hose clamp
3. Hose NOTE
4. Connectors The water valve centre shaft has a groove that can be used for
fault tracing the heating system.
5. Screw
9.4.7 AC compressor
AC compressor, description
The compressor drives the system by working as a pump. It draws
1 2 3 in cold low pressure gas from the evaporator and compresses the
gas to the condenser.
The compressor is fitted on the machine's engine and is driven by a

V-belt directly from the engine. The magnetic clutch that is controlled
by the thermostat inside the AC unit (in front of the steering wheel
shaft), and the control unit for ECC, activates the compressor.
4
014877
1. Screw and nut

2. AC compressor
3. Connections
4. Compressor belt

9:36 9 Frame, body, cab and accessories – Thermostat
Compressor, replacement
IMPORTANT
Working on the air conditioning requires special
authorisation.
NOTE
It is extremely important to prevent contamination and foreign
particles from getting into the refrigerant circuit. For this reason, the
particle and moisture filters must always be replaced when any work
is carried out on the refrigerant circuit.
NOTE
For tightening torque of refrigerant hoses and pressure switch, see
section F Technical data.
2 Open the hood on the right side.
3 Drain the AC system of R134a refrigerant.
4 Release the belt tension and remove the AC compressor belt.
5 Undo the hose fittings and disconnect the inlet and outlet hoses
from the AC compressor, plug the fittings to prevent contamination.
6 Remove the nuts holding the AC compressor.
7 Empty the oil from the old AC compressor (through inlet/outlet)

and measure the quantity.
8 Empty the oil from the new AC compressor.
9 Refill the new AC compressor with the same amount of oil as was
emptied from the old AC compressor.
11 Turn the AC compressor over several turns by hand.
12 Using vacuum equipment, refill the system with R134a refrigerant

and test for leaks.
13 Check the function of the system.
9.4.8 Thermostat
Thermostat, description
The thermostat controls the cooling capacity from 0 to 100 percent.

The thermostat is located under the dashboard panel's controls
for cooling in Spirit Delta and in the cooling unit's control panel for
FlexCab. The thermostat's sensor is located between the evaporator's
flanges. In addition to controlling the cooling capacity the thermostat
1
disengages the compressor when ice has formed on the evaporator
006516
(defrosting).
ECC has an electronically monitored defrosting system. The sensor

1. Thermostat Spirit Delta is located under the evaporator's outlet pipe and is connected directly
to the ECC control unit.

9 Frame, body, cab and accessories – Condenser unit 9:37
9.4.9 Condenser unit

Condenser unit, description
The condenser unit is located on the cab roof. The condenser is a

1 heat exchanger and its function is to convert the hot high-pressure
2 gas from the compressor into liquid form. Pipes and flanges in the
condenser battery absorb the heat, which is then dissipated with a fan.
Refrigerant temperature in the condenser varies depending on the

9 ambient temperature and the air flow through the condenser. When
10 the refrigerant is condensed into liquid it is forced onward to the
8
particle and moisture filter.
7
6
008640
5
4
Condenser unit, Spirit Delta

1. Outer Casing
2. Screw
3. Fan
4. Condenser
5. Screw
6. Fan casing
7. Particle and moisture filter
8. Clamp
9. Relay
10. Pressure switch
Condenser unit, replacement
IMPORTANT
authorisation.
NOTE

9:38 9 Frame, body, cab and accessories – Condenser unit
3 Remove the outer protective cover from the condenser, four M6

screws.
4 Cut off the cable ties and unplug any lighting cables.
NOTE
Make certain the AC system is drained of R134a refrigerant.
The figure depicts Spirit Delta
5 Remove the refrigerant hoses from the condenser unit.

1 6 Plug the hoses to avoid contamination of the refrigerant circuits.
7 Remove the four screws for the rubber buffers on the condenser.
8 Separate the condenser from the cover by drilling out the pop
rivets.
9 Pop rivet the cover to the new condenser.
2
and test for leaks.
005923
1. Condenser unit
2. Connections

9 Frame, body, cab and accessories – Expansion valve 9:39
9.4.10 Expansion valve

Expansion valve, description
The expansion valve (evaporator) is the part in the circuit that
separates the high-pressure side from the low-pressure side. The
refrigerant arrives in liquid form at the expansion valve under high
pressure and leaves it under low pressure. After the expansion valve,
the refrigerant converts to a gaseous state and is transported to the
compressor once again.
The amount of refrigerant that passes through the expansion valve

varies depending on the heat load. The valve works from fully open to
fully closed and searches between these for an optimal evaporation
point.
001622
Cab Spirit Delta:

Expansion valve

9:40 9 Frame, body, cab and accessories – Evaporator
9.4.11 Evaporator
Heat exchanger, cooling, description
The evaporator consists of pipes carrying refrigerant through the
cooling fins. The heat from the cab's air is channelled via the flanges
to the refrigerant in the pipes.
The refrigerant circulates and returns to a gaseous state, becoming

cold, and is drawn from the evaporator back to the compressor. The
cycle has come full circle.
The evaporator is located under the heat exchanger for heating in the
external unit for fresh air intake to the cab (between the tilt cylinders).
015662
Cab Spirit Delta:

Evaporator at bottom (located in fresh air intake to cab)
Cooling evaporator, replacement
IMPORTANT
authorisation.
NOTE
1 Machine in service position.
2 Remove the heat exchanger for heating as described under Heat

exchanger, heating, replacement, page 9:33.

9 Frame, body, cab and accessories – Sensor for ECC 9:41
4 Remove the hoses from the expansion valve.

5 Detach the screw, that secure the expansion valve to the hosing.
6 Carefully pull out the thermostat\qs capillary tube and bend aside.
7 Remove the evaporator together with the expansion valve.
8 Remove the two fitting nuts of the evaporator from the expansion
valve.
9 De-icing sensor for ECC, see Sensor for ECC, description, page
9:41, is located on the pipe under the insulation.
a. Undo the insulation.
b. Cut off the cable tie that holds the de-icing sensor to the pipe.
c. Remove the de-icing sensor from the pipe.
10 Replace the evaporator.
12 Use new O-rings when installing and replace the old dryer and
moisture filter before refilling the cooling system.
and test for leaks.
9.4.12 Sensor for ECC

Sensor for ECC, description
There are four sensors when the ECC climate unit is installed. The
following sensors are fitted:
1. Sensor for temperature in the cab. In the Spirit Delta the sensor is
fitted on the dashboard panel's left-hand edge. In the Spirit Delta
Space it is fitted in the air flow by the climate unit's recirculation
inlet.
2. The ambient temperature sensor is located on the left or right
hand side of the rear edge of the roof so that it always senses the
current outdoor temperature, without being affected by heat from
the vehicle.
3. The after coil sensor is built into the climate unit's wiring and is
fitted in the air distribution's outlet. The after coil sensor can be
accessed from within the cab in the Spirit Delta, see Actuator
motor, air distribution, replacement, page 9:47, in the Spirit Delta
it can be accessed from outside the cab.
1
006304
Spirit Delta
1. After coil sensor

9:42 9 Frame, body, cab and accessories – Control unit ECC
4. The de-icing sensor is integrated into the climate unit's wiring and
is located on the evaporator's manifold, fixed with cable ties to the
pipe and insulated. This can be accessed from outside the cab.
006303
Spirit Delta
1. De-icing sensor
NOTE
1 When the de-icing sensor is replaced on a horizontal pipe, it is
important that the de-icing sensor should be positioned between
03.00 and 05.00 o'clock (see figure 1).
It is also very important for climate unit function that the de-icing
03.00 sensor has full contact with the pipe, it is fixed to the pipe with a
cable tie and that insulation material is applied over the de-icing
sensor and pipe.
2
05
006316
.00
Figure 1
1. Pipe
2. De-icing sensor
9.4.13 Control unit ECC

Control unit ECC, description
The ECC control unit (Electronic Climate Control) is located to the left
in the dashboard panel. It controls the heating and cooling in the air
conditioning. Cab temperature is kept within a set interval, independent
of the outside temperature.
NOTE
Due to different applications, the control units are designed in
different versions, dedicated for Spirit Delta respective for Spirit
Delta SpaceCab
9.4.14 Air distributor

Air distributor, description
The air distributor distributes the air between the defroster and the floor
nozzles. It is fitted on top of the climate unit under the dashboard panel.
9.4.15 Fine filter

Fine filter, description
The climate unit can be equipped with a fine filter, which delimits
smaller particles, pollen etc. to contaminate the cab air.
Machines with AC or ECC have a fine filter as standard equipment.

9 Frame, body, cab and accessories – Pause heater 9:43
9.4.16 Pause heater

Pause heater, description
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 heating system when the engine is switched off. The cab fan
forces the air into the cab. The pause heater is automatically switched
2 off by means of a thermostat in the coolant circuit when the coolant
temperature is below a set value. The pause heater is activated with
the pause heater switch.
008635
1. Switch, pause heater (S1019)
2. Circulation pump, pause heater (M663)
9.4.18 Cab heater

Cab heater, description
The machine can be equipped with an electric cab heater. The heater
is connected to an electric socket fitted in the cab.
When using an electric cab heater, the machine must be parked and
attached to a external electric socket.
9.4.20 Cooling unit

Cooling unit, description
The air conditioning is fitted in front of the cab and consists of an

expansion valve, evaporator, fan, adjustable nozzles and controls.
The refrigerant is evaporated in the cooling unit inside the cab. When
the refrigerant is evaporated the air which the cab fan forces through
the climate unit is cooled.
015659
Air conditioning

9:44 9 Frame, body, cab and accessories – Particle and moisture filter
9.4.21 Particle and moisture filter

Particle and moisture filter, description
When the refrigerant passes through the absorption and filter material,
it collects in the bottom of the fluid reservoir, from which it is pumped
through a pipe. You can look through a sight glass to check that there
1 are no bubbles in the flow, and that the system is sufficiently filled
with refrigerant.
The particle and moisture filter is a component not normally subject to

wear and not normally requiring replacement. Only replaced when
working in the coolant circuit, e.g. when replacing other components
requiring that the coolant circuit be open for a while, or when there
is a risk that the opened coolant circuit has been contaminated with
foreign particles.
006158
Spirit Delta

9 Frame, body, cab and accessories – Particle and moisture filter 9:45
Particle and moisture filter, replacement
IMPORTANT
authorisation.
NOTE
particles from getting into the refrigerant circuit.
The filter is filled with nitrogen under pressure on delivery and is
plugged to ensure that no moisture is absorbed. For this reason,
never remove the plugs until you are just about to connect it to the
coolant circuit (open connections can allow the absorbent material to
become saturated with moisture after only a few hours).
2 Drain the R134a refrigerant out of the AC system.
3 Remove the four screws holding the housing over the condenser.
2 2
1
006159
1. Screws
2. Condenser housing

9:46 9 Frame, body, cab and accessories – Actuator motor
4 Undo the connections for the coolant hoses.

3 5 Plug the hoses to avoid contamination of the refrigerant circuits.
2
6 Undo the connections for the pressure switch
4
7 Undo the clamps which hold the particle and moisture filter.
8 Remove the filter.
006160
1
1 9 Unscrew and remove the pressure switch.
1. Connections
NOTE
2. Pressure switch
The pressure switch is installed on the drying filter pipe, via a
3. Clamp valve built into the pipe, which allows it to be replaced without
4. Sight glass having to drain the refrigerant. For this reason, proceed as
follows to replace the pressure switch:
A. Undo the cable connectors.
B. Unscrew the pressure switch.
C. Screw in a new pressure switch and refit the cable
terminals.
10 Install the sensor in the new particle and moisture filter.

and test for leaks.
9.4.22 Actuator motor

Actuator motor, description
The climate unit with ECC or AC is equipped with actuators which

controls distribution of fresh air/recirculation respectively air distribution
inside the cab.
Actuator motor, fresh air, replacement

1 2 Remove the cover plate holding the wiper motor, washer fluid
hose and the grille for the fresh air intake., See Heat exchanger,
heating, replacement, page 9:33.
2
008373
1. Actuator motor, air distribution

2. Actuator motor, fresh air

9 Frame, body, cab and accessories – Actuator motor 9:47
3 Undo the connector and remove the two screws which hold the
actuator motor for fresh air (position 2). Remove and replace the
actuator motor.
NOTE
Be careful when installing the front of the climate unit, to ensure
that no electric cables are pinched or damaged.
006311
Actuator motor, air distribution, replacement
1 1 Allows access to the climate unit from inside the cab as per Interior
plastic components, replacement, page 9:88 by:
a. Undoing the steering wheel shaft and folding it backwards.
b. Undoing and lifting up the top front dashboard panel.
c. Undoing and removing the plastic cover in front of the pedal
assembly, see Interior plastic components, replacement, page
9:88.
2
008373
1. Actuator motor, air distribution

2. Actuator motor, fresh air
2 Cut off the four pop rivets which fix the top section on each side
of the climate unit, using a cold chisel etc.
006313
006314

9:48 9 Frame, body, cab and accessories – Actuator motor
3 Lift out and fold forwards the top part of the climate unit, on which
the air distribution actuator (position 1) is located.
4 Undo the screw which holds the air distribution actuator motor (1)
on the top part of the climate unit and replace the air distribution
actuator motor.
006315

9 Frame, body, cab and accessories – Wiper/washer system 9:49
9.5 Wiper/washer system

Wiper/washer system, description
Spirit Delta and Spirit Delta Space cab have wipers for front, rear
3 and roof windows.
On open cab with weather protecting windows as well as on cab there

are wipers for front, rear and roof windows.
The wiper arm is attached to the wiper motor's shaft over a grooved
taper. The shaft is made of hardened steel and the wiper arm's
bracket is made of a mild die cast material.
When installing it is important to make sure that the grooves are free
2 from burrs and similar. Also, the nuts must be tightened so tight that
the grooves are pressed into the bracket and work as drive flanges.
Counterhold the wiper arm when installing so that the force is not
transmitted to the wiper motor, which may then be damaged.
1
001878
1. Wiper, front
2. Wiper, roof
3. Wiper, rear
9.5.1 Wiper front

Wiper front, description
These wipers are of the parallel wiper type.
9.5.2 Wiper roof

Wiper roof, description
Sector wiper with approximately 180 degree wiping angle. A

parallel wiper unit is available as an option (see Wiper front, description,
page 9:49).
Side-mounted roof wiper.
9.5.3 Wiper rear

Wiper rear, description
The wipers for Spirit Delta are of the same model as the wiper for the
roof (sector wipers).
9.5.4 Washer motor and reservoir

Washer motor and reservoir, description
The washer motor is located in the washer fluid reservoir. The reservoir
is located at the boarding step on the left-hand side of the machine.
There are non-return valves on the lines from the reservoir to the wiper
arms. The nozzles are mounted on the wiper arms.

9:50 9 Frame, body, cab and accessories – Wiper motor front
Washer motor and reservoir, replacement

2 Unscrew the reservoir and empty out the washer fluid.
3 Remove the hoses from the pumps.
2 4 Undo the connector on the electric cable for the pumps.

5 Remove the pumps from the reservoir. A rubber bushing seals
between the pumps and the reservoir.
1
6 Replace the pump.
8 Fill the reservoir up with screenwasher fluid.
3 015763
1. Reservoir
2. Pumps
3. Hoses
9.5.5 Wiper motor front

Wiper motor front, description
The wiper motor drives the wiper for the front window. The wiper arm
is mounted directly on the motor. The motor produces the movement
of the wiper.
Wiper motor front, replacement

2 Raise the nut protector and remove the nut securing the wiper
arm (two nuts).
3 Remove the four screws securing the cover plate.

4 Disconnect the washer hose.

9 Frame, body, cab and accessories – Wiper motor roof 9:51
the wiper motor.
6 Remove the two nuts securing the motor to the cover plate.
7 Replace the wiper motor.
8 Fit in the reverse order. Tighten the wiper arms to 16-20 Nm.
NOTE
When installing it is important to make sure that the grooves are
free from burrs and similar. Also, the nuts must be tightened to
16-20 Nm, so that the grooves are pressed into the bracket and
work as drive flanges.
9.5.6 Wiper motor roof

Wiper motor roof, description
The wiper motor drives the roof wiper. The wiper arm is mounted
directly on the motor. The motor produces the movement of the wiper.
Wiper motor roof, replacement

2 Remove the two screws securing the plastic cover to the wiper
motor.

9:52 9 Frame, body, cab and accessories – Wiper motor roof
3 Disconnect the washer hose and the wiper motor connector.
4 Undo the lock nut securing the wiper arm and disconnect the
washer fluid hose.
5 Remove the two screws securing the wiper motor.
7 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.
NOTE
Wiper motor roof, side-mounted roof wiper,

replacement
2 Remove the plastic cover from the wiper motor.

006177

9 Frame, body, cab and accessories – Wiper motor roof 9:53
3 Unplug the wiper motor connector and earth cable.
1 2
006176
1. earth cable
2. Wiper motor connector
4 Undo the lock nut securing the wiper arm and disconnect the
washer fluid hose.
1 2
006179
1. Lock nut
2. Screenwasher fluid hose
5 Remove the two nuts securing the wiper motor.

NOTE
1 work as drive flanges.
006178
1. Nuts

9:54 9 Frame, body, cab and accessories – Wiper motor rear
9.5.7 Wiper motor rear

Wiper motor rear, description
The wiper motor drives the wiper for the rear window. The wiper arm
is mounted directly on the motor. The motor produces the movement
of the wiper.
Wiper motor rear, replacement

2 Remove the upper panels behind the operator\qs seat.
3 Remove the two screws securing the plastic cover over the wiper
motor.

9 Frame, body, cab and accessories – Wiper motor rear 9:55
4 Unplug the connector from the motor.
5 Raise the plastic cover and remove the nut securing the wiper
arm. Disconnect the washer hose.
6 Remove the two screws securing the motor and the lock nut on
the motor.
NOTE

9:56 9 Frame, body, cab and accessories – Lighting system
9.6 Lighting system

Lighting system, description
The purpose of the lighting is to increase safety during operation and
load handling.
The following lighting is fitted on the machine:
6,10,12,14,15 8 7 9 13
11,12
1,2,3,4
16
3,4,5
014447
1. Tail light, red 10. Extra work lights, cab roof, rear edge, 2 lamps
2. Brake light 11. Work lights, mast, 2 lamps
3. Direction indicators 12. Extra work lights, cab roof, rear edge, 2, 4 or 6 lamps
4. Running lights
5. Headlights 13. Extra work lights, cab roof, front edge, 2 lamps
6. Reversing light, white 14. Extra work lights for container handling, 4 lamps
7. Adjustable searchlight 15. Extra work lights for container handling, cab roof rear
edge, 4 lamps
8. Revolving beacon
16. Extra work light between the tilt cylinders, 1 lamp
9. Interior lighting
NOTE
It is important that the right type of bulb is used for each area. See
9.6.1 Headlights
Headlights, description
Headlights are located in the front part of the machine in order to give
the operator enhanced vision when manoeuvring in darkness, and to
provide surrounding traffic and the environment an indication of the
machine's position. Headlights have high beam and a low beam (to
avoid dazzling other road users).
The headlights are turned on with a switch on the instrument panel.

The headlights switch between high and dipped beam using the
multi-function lever.
NOTE
The turnable operator's station option includes headlights at both
ends of the machine. The headlights are activated in the relevant
direction so that the headlights are always illuminated in front of
the operator.

9 Frame, body, cab and accessories – Running lights 9:57
9.6.2 Running lights

Running lights, description
There are position lights on the right and left side of the machine to give
others in traffic and the surroundings an indication of the machine\qs
position.
The position lights are activated with the same switch as the headlights.
9.6.3 Tail lights

Tail lights, description
There are tail lights at the back of the machine to give others in traffic
and the surroundings an indication of the machine\qs position in the
dark.
NOTE
The turnable operator's station option includes tail lights at both ends
of the machine. The tail lights are activated in the relevant direction
so that the tail lights are always illuminated in front of the operator.
9.6.4 Brake lights

Brake lights, description
There are brake lights at the back of the machine to give others in
traffic and the surroundings an indication that the machine is braking
and is thus reducing speed.
NOTE
The turnable operator's station option includes brake lights at both
ends of the machine. The brake lights are activated in the relevant
direction so that the brake lights are always illuminated behind the
operator.
9.6.5 Back-up lights

Back-up lights, description
There are reversing lights at the rear of the machine to indicate to other
traffic users and the surroundings that the machine is reversing. In
addition, this provides the operator enhanced view when operating
in darkness.
Reversing lights are activated when reverse is engaged.
NOTE
The turnable operator's station option includes reversing lights at
both ends of the machine. The reversing lights are activated in the
relevant direction so that the reversing lights are always illuminated
behind the operator.
9.6.6 Direction indicators

Direction indicators, description
There are indicators on both the front and the rear of the machine,
to give other road users and the environment an indication that the
machine is about to change direction of travel, i.e. turn.
The indicators are controlled by using the indicator switch (lever), and
is indicated with a green indicator lamp on the steering panel.

9:58 9 Frame, body, cab and accessories – Warning lamp, Hazard
9.6.7 Warning lamp, Hazard

Warning lamp, Hazard, description
The machine is equipped with hazard warning flashers. By pressing a
switch, all the direction indicators can be made to flash simultaneously,
to show others that there is danger, such as a mechanical failure.
9.6.8 Revolving beacon

Revolving beacon, description
The revolving beacon is fitted high up on the cab. There are two
versions, roof-mounted and mast-mounted. It is used to give other road
users and the environment an indication that the machine is moving
and working. It is an indication to bystanders to exercise caution.
Available as an option is a rotating beacon in combination with flashing

direction indicators front and rear.
The function is activated with a switch on the dashboard panel, where

the symbol flashes at the same rate as the direction indicators. A relay
generates the direction indicator and hazard light function.
Rotating beacon, pole mounted, replacement

2 Undo the wing nut which fixes the revolving beacon to the pole.
3 Lift the rotating warning beacon off.
4 Install the new revolving beacon.
5 Tighten the wing nut.
1
3
005909
1. Revolving beacon
2. Wing nut
3. Pole

9 Frame, body, cab and accessories – Revolving beacon 9:59
Rotating beacon, roof mounted, replacement

2 Turn the lamp dome counter-clockwise.
008351
3 Remove the screws securing the lamp base.

008352
4 Unplug the connector.

5 Replace the beacon.

9:60 9 Frame, body, cab and accessories – Working lights, mast
9.6.9 Working lights, mast

Mast working lights, description
Work lights are fitted on the mast. Used to provide the operator with
better vision for load handling in the dark.
The working lights are turned on with a switch on the instrument panel.
On machines with reversible operator\qs seat or reversible driver\qs

station the working lights will become reversing lights, when the driver
shifts working direction and has the back against the mast.
Additional work lights can be installed for increased illumination.
9.6.10 Working lights, cab

Working lights, cab, description
These working lights are located on the cab and provide better vision
for load handling in the dark.
On machines with reversible operator\qs seat or reversible driver\qs

station the working lights will become reversing lights, when the driver
shifts working direction and has the back against the mast.
Additional work lights can be fitted if improved illumination is required.

Different numbers and designs are available as options. The lights
can be fitted at the front or rear of the cab roof and/or the cab's front
panel.
9.6.11 Interior lighting

Interior lighting, description
Interior lighting lights the cab up, and is selected by the interior lighting
switch.
There is background illumination in all switches, function keys and

rotary controls. This is so that the driver will be able to read their
functions and settings in darkness.
A reading lamp is usually fitted together with a writing board. The

reading lamp is fitted on a front door pillar, on a bracket with a flexible
arm on which the lamp housing is fitted. The lamp is activated by a
switch on the lamp housing when the ignition is switched on.
9.6.12 Working lights, fenders

Working lights, fenders, description
The machine can be equipped with additional working lights located on

the fenders to provide better vision for work in the dark.

9 Frame, body, cab and accessories – Engine room lighting 9:61
9.6.13 Engine room lighting

Engine room lighting, description
The machine can be equipped with lighting in the engine room, to

facilitate service and maintenance.

9:62 9 Frame, body, cab and accessories – Signalling system
9.7 Signalling system

Signalling system, description
Signal system for alerting the driver or surroundings.
The signal system is regarded as being the following:

• Horn
• Flashing hazard lights
• Revolving beacon
• Warning lamp, parking brake
• Buzzer, not activated parking brake. The buzzer starts when the
seat is unoccupied and the parking brake is not applied (circuit
closed by seat occupant switch and sensor on the hydraulic line
to the parking brake calliper).
• Buzzer, low pressure hydraulic accumulator (brake system). The
buzzer sounds when the pressure is below a set value (circuit
closed by a sensor on the hydraulic line to the accumulator
system).
• Back-up alarm
Signalling system, component location

The purpose of the signals is to increase safety during operation and
load handling. This can take place by means of light and sound. The
following signalling systems are available in the machine:
NOTE
It is important that the right type of bulb is used for each area. See
7 4
8
5, 6
3, 5
2
014448
1
1. Horn 5. Direction indicators
2. Electrically-driven loud horn 6. Back-up alarm
3. Flashing hazard lights 7. Back-up lights
4. Revolving beacon 8. Buzzer in cab

9 Frame, body, cab and accessories – Horn 9:63
9.7.1 Horn
Horn, description
Electromagnetic horn, operated from the multi-function lever.
The horn is located under the front of the cab.
A compressed air activated strong tone horn is available as an option.
001247
The strong tone has an electric compressor and is operated with a
switch on the instrument panel.
9.7.2 Warning lamp, Hazard

Warning lamp, Hazard, description
See Warning lamp, Hazard, description, page 9:58.
9.7.3 Revolving beacon

Revolving beacon, description
See Revolving beacon, description, page 9:58.
9.7.4 Warning parking brake

Warning parking brake, description
A buzzing sound is activated when the operator leave the seat without
activating the parking brake.
A sensor in the seat indicates whether the seat is occupied.
The buzzer is located in the seat.
9.7.5 Back-up alarm

Reverse alarm, description
When reverse direction is selected, a warning sound and the

reversing lights are activated. This is to indicate to other road users
and the environment that the machine is reversing. An indication to
bystanders to exercise caution.
The reverse alarm receives an input signal from the transmission and
the output signal goes to the reverse alarm and reversing lights.
The reverse alarm is fitted on the rear counterweight. Alarm volume

is determined by the ambient sound level.
Reverse alarm, replacement

2 Unplug the connector from the reverse alarm.
3 Remove the two Allen screws securing the reverse alarm.
4 Replace the reverse alarm.

9:64 9 Frame, body, cab and accessories – Flashing brake light for reversing
9.7.6 Flashing brake light for reversing

Flashing brake light for reversing, description
When reverse is selected, the brake lamps flash as a warning to others

nearby.

9 Frame, body, cab and accessories – Entertainment and communication 9:65
9.8 Entertainment and

communication
Entertainment and communication, description
This section describes items for supporting the driver or facilitating
communication for the driver.
Entertainment and communication consist of the following:

• Radio with CD
• Communication radio, Cargotec can prepare the installation but
does not provide the equipment.
• Phone, Cargotec can prepare the installation but does not
provide the equipment.
• Terminal, Cargotec can prepare the installation but does not
• Display screen, Cargotec can prepare the installation but does
not provide the equipment.
• Computer, Cargotec can prepare the installation but does not
• Voltage converter
• Reversing camera with monitor in the cab, Cargotec can
prepare the installation and provide the equipment if required.
• Load camera with monitor in the cab, Cargotec can prepare the
installation and provide the equipment if required.
• Barcode reader camera on mast or beam clamp. Cargotec can
prepare the installation but does not provide the equipment.
9.8.1 Radio with CD

Radio with CD, description
The cab can be equipped with a radio. This is powered by the battery
via a converter (24 V to 12 V).
The converter is located beside the electronic box, see Voltage

converter, description, page 9:67.

9:66 9 Frame, body, cab and accessories – Communication radio
Radio antenna, description

The cab roof provides provisions for the installation of a radio and/or
communication radio.
The radio antenna is permanently mounted on the cab roof. The

antenna is made of a flexible material.
Radio antenna, replacement

2 Undo the screws which fix the roof panel and remove the roof
panel.
3 Undo the antenna cable connector.
008350
4 Undo the lock nut which fixes the antenna to the roof panel and
remove the antenna.
5 Replace the antenna.
006127
9.8.2 Communication radio

Communication radio, description
If desired, the machine can be prepared for a communication radio.
9.8.3 Telephone
Phone, description
If desired, the machine can be prepared for a telephone.

9 Frame, body, cab and accessories – Terminal 9:67
9.8.4 Terminal
Terminal, description
If desired, the machine can be prepared for a terminal.
9.8.5 Screen
Screen, description
If desired, the machine can be prepared for a screen.
9.8.6 Computer
Computer, description
If desired, the machine can be prepared for a computer.
9.8.7 Voltage converter

Voltage converter, description
The voltage converter is located under a protective cover to the right

behind the operator\qs seat.
Its function is to convert the voltage (from 24 V to 12 V) so that it can

be used for radio, communication radio, computer, etc.
2
006642
Overview, location of voltage converter

1. Positioning of voltage converter on machines
with AC.
2. Positioning of voltage converter on machines
without AC.

9:68 9 Frame, body, cab and accessories – Voltage converter
Voltage converter 12/24V, replacement

2 Remove the cover from behind the operator\qs seat (five clips).
3 Detach the electrical cables to the converter.
4 Remove the converter from its bracket.
NOTE
The voltage converter is available in two versions, one of which
is a variant with plastic brackets. The plastic brackets are
fragile, so exercise caution during replacement.
5 Replace the converter.

006129

9 Frame, body, cab and accessories – Glass/windows/mirrors 9:69
9.9 Glass/windows/mirrors
Glass/windows/mirrors, description
Spirit Delta windows are made of hardened safety glass (tempered,
reinforced), except for the roof window, which is made of a
scratch-resistant polycarbonate material. As an option they can be
equipped with laminated glass (except sliding windows) and/or tinted
3 windows.
The mirrors are all convex type. The interior rear view mirror is fitted
in all trucks.
Mirrors with extra convexity are available as an option, both as

2 exterior and interior rear view mirrors. Exterior rear view mirrors
are also available in other sizes, such as electrically heated and/or
electrically adjustable from the operator's station.
1
001879
Overview, cab windows.

1. Windscreen
2. Roof window
3. Rear window
Silicone adhesive, handling advice

The window panes are secured with decor strips adhesive and silicone
adhesive.

9:70 9 Frame, body, cab and accessories – Windscreen
NOTE
The purpose of this instruction is to describe how silicone adhesive
923854.0001 should be handled in connection with replacement of
the windscreen and roof window on the Spirit Delta cab.
• Silicone adhesive 923854.0001 is a quick-hardening,
two-component silicone adhesive that can withstand
temperatures between -50 ºC and +200 ºC. The hardening
properties of the adhesive are extremely dependent on the
ambient temperature. An increase of 10 ºC cuts hardening time
in half.
Silicone adhesive 923854.0001 is mixed at a ratio of 1:10
in a static mixer. Change mixer after every interruption that
lasts more than 5 minutes. The short setting time means that
work has to be planned carefully in order to avoid undesired
hardening.
Fixing time:
10-20 minutes at 20 ºC
approx. 5 minutes at 60 ºC
Hardening time:
approx. 24 hours at 20 ºC
approx. 1 hour at 60 ºC
Full strength is obtained after 7 days.
• In warm climates, it is advantageous to cool the container to
increase hardening time. The silicone adhesive should not be
used at temperatures above +75 °C.
• In cold climates, the hardening time can be shortened by
covering the joints so that cooling is prevented. The window
pane can be warmed with defroster or cab heater.
• The recommended storage temperature is between -30 ºC
and +20 ºC. Storage in a refrigerator or a colder environment
is recommended.
9.9.1 Windscreen
Windscreen, description
The windscreen consists of the front window and side windows. The
windscreen is attached to the cab with a decor strip and is glued to
the roof window with silicone adhesive. Front and side windows are
joined with silicone adhesive to give good all-round visibility from the
operator's station.
For location see, Glass/windows/mirrors, description, page 9:69.

9 Frame, body, cab and accessories – Windscreen 9:71
Windscreen, replacement
Front, side and roof window, replacement
NOTE
Read the handling advice for silicone adhesive before starting work.
See Silicone adhesive, handling advice, page 9:69.
2 Remove the decor strip.

3 Remove the broken window pane and check that no remains of
glass or other particles remain in the window pane's groove on the
strip. Cut apart silicone joints with a sharp tool.
NOTE
Make sure that no silicone adhesive remains between the
window pane and the strip by the window pane's lower front
edge.
If the roof window is to be replaced, then all bolts must be
removed before the silicone adhesive is cut away.
CAUTION
Removing the decor strip Strong dissolvents, e.g. acetone, must not come
into contact with a window made of polycarbonate
plastic. Dissolvents have a chemical effect on the
polycarbonate plastic which reduces the strength of
the roof.
4 Clean all surfaces thoroughly. Remove old remains of silicone with

a razor blade or similar.
5 Fit masking tape on the inside and outside of the window panes by
the surfaces that are to be glued.

9:72 9 Frame, body, cab and accessories – Windscreen
1 2 3 6 When the windscreen or a side window is to be replaced, then the

window panes must be adjusted so that the upper edge on the side
window has the same height as the upper edge of the cab roof and
so that the distance between windscreen and side window.
Use spacers against the roof member to ensure that the distances
are maintained.
1,0
006268
1
Adjusting side window - cab roof
1. Side window
2. Rubber strip
3. Cab frame/door opening
006269
1,0
Adjusting side window - windscreen
1. Masking tape
7 Fit the decor strip around the whole window pane.
8 Apply silicone adhesive 923854.0100 around the window panes.
Make the new joint wider than the old one in order to create a
good seam.
The silicone should be applied from the outside of the joints, to
give a full and smooth joint.
NOTE
There must be silicone between the window panes, to avoid
contact between the window panes.

9 Frame, body, cab and accessories – Side window 9:73
9 Remove excess silicone from the outer vertical corners, using a

tool made of cardboard. Smooth out the joints on the inside with a
finger soaked in water or soapy water.
10 Apply silicone adhesive 923854.0100 between the strip and
window pane at the bottom edge of the front corners, so-called
top sealing.
11 If the roof window is to be replaced, apply silicone adhesive
923854.0100 by the cab frame (where it was glued earlier).
12 Align the roof window into place and check that there is a uniform
distance of one or several millimetres along the window pane's
edges and by the protection over the frame's sides. Then tighten
the corner bolts for the window pane.
13 Apply silicone adhesive 923854.0100 by the edges and smooth
out the joints with a finger, wet with water or soapy water.
006272 IMPORTANT
Cardboard tool template for silicone joint scale 1:1 Mark the window panes with "New adhesive. Do not
touch".
14 Remove the masking tape immediately after applying adhesive to

avoid edge formation. Hardening time is dependent on ambient
temperature, plan the change so that downtime is minimised.
9.9.2 Side window

Side window, description
See Windscreen, description, page 9:70.
Side window, replacement
NOTE
The method describes a general procedure.
2 Use special tools to detach the decor strip.

9:74 9 Frame, body, cab and accessories – Side window
3 Remove the decor strip which runs around the whole window.
4 Carefully remove any remains of glass from the rubber strip.
5 Fit the new window, securing it at the bottom edge in the rubber
strip.
6 Spray soap solution on the window and rubber strip to facilitate

fitting.

9 Frame, body, cab and accessories – Roof window 9:75
7 Thread the rubber strip around the whole window; use special
tools.
8 Secure the decor strip with a special tool. Use a soap solution on
the decor strip and rubber strip.
9 Pull the decor strip around the whole window. Avoid stretching
the decor strip.
10 Cut off the decor strip approx. 2 cm too long.

11 Fit the other end of the decor strip edge to edge.
12 Adjust the decor strip so that the correct fit is obtained. Push in
the remaining part of the decor strip in the rubber strip. Press the
decor strip toward its opposite end.
9.9.3 Roof window

Roof window, description
The polycarbonate roof window is a safety detail, intended to protect
the operator from falling objects. The polycarbonate window is elastic
and virtually unbreakable. Safety is maintained within a temperature
range from +120 °C to -45 °C (becomes brittle first at -110 °C, glass
transition temperature +145 °C). The roof window has a patented
surface layer that increases its durability and resistance to UV light
and chemicals.

9:76 9 Frame, body, cab and accessories – Rear window
9.9.4 Rear window

Rear window, description
See Windscreen, replacement, page 9:71.
The roof window is joined with the windscreen. The joint is sealed with
silicone. Align a new seal of silicone when replacing.
9.9.5 Rear view mirror

Rear view mirror, description
The cab is equipped with a rear view mirror. The function of the rear
view mirror is to give the operator rearward vision.
Exterior rear-view mirrors are available as an option. Exterior

rear view mirrors are also available in other sizes, such as electrically
heated and/or electrically adjustable from the operator's station.
9.9.6 Protective panel in front of windscreen

Protective panel in front of windscreen, description
Machines with a Spirit Delta cab can be equipped with a protective

panel, made of polycarbonate plastic, tempered safety glass, tempered
and heat reflecting glass or laminated safety glass, in front of the
windscreen. The protective panel can easily be replaced if it is
damaged or scratched.
Machines with a Spirit Delta can also be equipped with a protective

grating.
9.9.8 Reversing camera

Reversing camera, description
The reversing camera sits at the rear of the horizontal counterweight

at the rear of the machine for increased visibility when reversing.
The reversing camera is waterproof and has microphone and
infrared lighting for visibility in the dark. In addition, the camera is
equipped with automatic heating, which is activated when the outside
temperature falls below +10 °C.
1
The reversing camera sends colour images and audio to the monitor
2 in the cab; see Monitor, reversing camera, description, page 9:77.
1
007425
3
1. IR diodes
2. Camera
3. Microphone

9 Frame, body, cab and accessories – Monitor, reversing camera 9:77
9.9.9 Monitor, reversing camera

Monitor, reversing camera, description
The monitor conveys images and sound from the rear camera. The
C A .S E
L
1 picture is in colour and the brightness is adjusted automatically
according to the light conditions in the cab. The monitor supports
M ENU
signals from four different cameras.
2
VO L
The monitor is mounted on a hinged bracket to the left in front of
3 the door in the cab.
BRI
007416
5
1. Selection of camera
2. Menu
3. Brightness
4. Volume setting
5. Switching ON/OFF

9:78 9 Frame, body, cab and accessories – Cab structure and suspension
9.10 Cab structure and suspension

Cab structure and suspension, description
The cab is mounted in a cab substructure via strong rubber insulators
fitted 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
1 corner. Each insulator mounting has one rubber bushing and one bolt.
003206
4
Cab Spirit Delta
1. Cab frame
2. Door
3. Cab suspension
4. Cab substructure
9.10.1 Cab frame

Cab frame, description
The cab's frame is made of high-strength steel sheet profiles. The cab
is dimensioned to handle impacts and, to some degree, dropped loads.
9.10.2 Doors
Doors, description
The cab has two doors. The left-hand door is the driver's door and the
right-hand door is the emergency exit. The door has:
• support rail (inside)
• opening handle (inside and outside)
• key lock
• opening window, (sliding window on left-hand side is standard
equipment).

9 Frame, body, cab and accessories – Cab substructure 9:79
Doors, replacement
2 Remove the screws securing the roof.

3 Lift the roof slightly (40-50 mm) using an overhead crane.
4 Lift off the door in question by hand.
5 Replace the door.
008356
9.10.3 Cab substructure

Cab substructure, description
The cab is mounted at four points, one in each corner. Each mounting
has one rubber bushing and one attaching bolt.
The cab can be equipped with an optional mounting frame. The

mounting frame is mounted on undampened brackets on the truck. The
cab is mounted on the mounting frame in accordance with the above.
Cab mounting, rubber bushings, replacement

2 Tilt the cab.
3 Remove the four bolts that secure the rubber bushings to the cab
floor.
4 Remove the nut to split the locating pin and the rubber bushing.
5 Replace the rubber bushing.
Cab mounting raising frame, rubber bushings,

replacement
2 Do not tilt the cab. Only lift the cab just enough to remove the
load from the rubber dampers and allow the rubber dampers to
be replaced.

9:80 9 Frame, body, cab and accessories – Cab tilting
9.10.4 Cab tilting

Cab tilting, description
The cab can be tilted at an angle, over its centre of gravity, pivoted
around the left-hand side suspension or hinge at the cab's mounting
frame, assisted by a hydraulic cylinder. The hydraulic oil pressure is
generated by a hand-controlled pump with integrated reset valve for
tilting up or down.
On the right-hand side mounting are locking devices which secure the
cab to the frame and can be easily released for tilting the cab.
Electric tilting of the cab is available as an option.
Manual cab tilting pump, replacement

2 Place a receptacle under the pump.
3 Detach the hydraulic hoses from the pump.

4 Remove the two bolts that secure the pump to the frame.
5 Replace the pump.
7 Fill up the system with hydraulic fluid.
1
NOTE
Vent the system by lifting and lowering the cab a few times.
Check the fluid level and refill if necessary.
2
008823
1. Screws
2. Hydraulic hoses

9 Frame, body, cab and accessories – Door stop 9:81
Electric cab tilting pump, replacement

1 2 For replacing the manual cab tilting pump, see Manual cab tilting
pump, replacement, page 9:80.
3 Place a receptacle under the pump.
2 4 Detach the hydraulic hoses from the electric pump.
5 Release the electric connections from the electric pump.
6 Remove the bolts that secure the electric pump to the bracket.
7 Replace the electric pump.
3
4 NOTE
008824
1. Manual cab tilting pump

2. Bracket
3. Hydraulic hoses
4. Electric pump
9.10.5 Door stop

Door stop, description
The door stop prevents the door from being damaged when it is
opened.
Door stop, replacement

2 Remove the inside of the door.

3 Remove the nuts holding the components for the door stop inside
of the door.
1 2 4 Remove the door stop components.
5 To gain access to the nuts for the door stop section on the cab
side, remove the three screws that fix the interior trim to the inside
of the cab wall.
6 Remove the screws and nuts that fix the door stop section to the
cab side behind the door on the left side.
7 Remove the door stop components.
008354

1. Components of door stop on the door.
2. Components of door stop on the cab side.

9:82 9 Frame, body, cab and accessories – Roof and door mouldings
9.10.6 Roof and door mouldings

Roof and door mouldings, description
The cab is equipped with roof and door mouldings.
The roof seal moulding has a rectangular cross-section and is made

of soft foam material with a self-adhesive long side. The roof seal
moulding is not normally subject to any wear. The roof seal moulding
can only be replaced if the roof panel is removed.
The door seals are "clip-on types", with a permanently vulcanised

tubular moulding. The door seals are fitted on the cab, at the door
pillars and the roof, and at the bottom of the plastic cover on the door.
The door seals can only be replaced when the plastic components
have been loosened or removed.
9.10.7 Cab tilting cylinder

Cab tilting cylinder, description
The cab is tilted by means of a hydraulic cylinder which is located
underneath the cab, on its left-hand side. The cylinder is fixed into the
frame and the cab's base, or mounting frame if so equipped, and is
powered by a hand or electrically operated hydraulic pump.
Cab tilting cylinder, replacement

2 Tilt the cab.
3 Secure the cab in the tilted position by opening both the cab doors
and pulling a lifting strop through, which is fixed to a lifting device
(travelling crane).
NOTE
Protect the cab in a suitable manner, to ensure that it is not
damaged when fixed or lifted by the lifting device.
4 Place a receptacle under the hydraulic cylinder.

1
5 Detach the hydraulic hoses from the hydraulic cylinder.
6 Remove the two bolts that secure the hydraulic cylinder to the
frame and cab.
7 Replace the hydraulic cylinder.
2
NOTE
008822
3
1. Hydraulic cylinder
2. Screws
3. Hydraulic hoses
Cab tilting cylinder, repair


9 Frame, body, cab and accessories – Cab tilting cylinder 9:83
2 Remove the cab tilting cylinder, see Cab tilting cylinder,

NOTE
Prior to any repair or reconditioning procedures check the
cylinder assembly for excessive wear, damage and in particular
scratches and dents on the chrome piston rod. In the event of
such damage, replace the whole cylinder, as repair efforts will
not be justified.
3 Install the protection plug on the connection coupler and clean

the cylinder assembly in a suitable cleaning solvent. Dry with
compressed air.
4 Connect the cab tilting cylinder to a suitable hand pump. Make

sure that connections A and B correspond with same connections
on the cylinder. Turn selector valve on the hand pump to the
UP position and operate the pump until the piston rod is fully
extended. Thereafter shift the selector valve to DOWN position
and retract the piston rod approx. 10 mm.
008641
5 Remove the dust wiper from the cylinder top end carefully with
two small screw drivers.
008642
6 Use a special tool to tap the gasket 5 to 10 mm back on the piston

rod.
008643

9:84 9 Frame, body, cab and accessories – Cab tilting cylinder
7 Remove the upper retaining ring from the cylinder and operate
pump to remove the piston rod.
DANGER
Never use compressed air to drive out the piston rod
assembly.
008644
8 Remove the retaining ring from the piston rod, remove the piston
and the O-ring below it.
008645
9 Remove the retainer stop-ring and the gasket.

008646
10 Check the piston rod and the top part of the cylinder once more
for scratches and damage. The same procedure applies for the
inner cylinder barrel. Replace the whole cylinder in the event of
scoring or scratches.
008647

9 Frame, body, cab and accessories – Cab tilting cylinder 9:85
11 Slide carefully a new wiper on the piston rod, to be followed by

the gasket.
12 Use a special cone to fit the retainer ring on the piston rod.
008648 13 Fit a new O-ring in the groove at the piston rod end. Slide on the
piston and make sure the piston is fitted in the correct direction.
o-ring
008649
14 After dismantling of plunger assembly from cylinder, unscrew

valve (hexagon 17 mm) with an extended socket wrench.
15 Remove piston by blowing with air nozzle in port B.
16 Check piston and O-ring on scratches and damage.
17 Mount piston together with a new valve assembly and new seal
rings as illustrated while the cylinder barrel is clamped horizontally
in the vice.
18 Torque tighten the valve seat to a torque of 50 Nm.
A
008650

9:86 9 Frame, body, cab and accessories – Cab tilting cylinder
19 Use special tool to tap the upper bearing approx. 10 mm into the
cylinder and fir the lock ring. Make sure the ring has snapped
into its groove.
008643
20 Pull back cylinder rod with an instant jerk in order to place upper
bearing in the correct position.
008651
21 Reconnect the cylinder to the hand pump, make sure it is correctly

connected, turn the selector valve to the DOWN position, start
pumping and retract the piston rod completely. Refill the pump's
reservoir with the appropriate fluid as required.
22 Replace pump selector valve to UP position, pump piston rod to
fully extended position and pressurise system.
Check for leaks.
23 Reset the pump selector valve to the DOWN position again. The
pressure decreases immediately. At this stage the piston rod must
remain as the safety valve will block off the internal pressure.
Immediately after a following pump stroke the valve should open
and release the internal pressure. If this procedure fails, repeat
008641
this check, or else the non-return valve has a suspected leak.

24 After completing the tests, fit the dust wiper.

9 Frame, body, cab and accessories – Cab interior 9:87
9.11 Cab interior

Cab interior equipment, description
The cab is designed for optimum operator comfort. Switches, controls,
warning and indicator lamps are grouped on the dashboard panels to
provide the operator with a good driving environment.
Recyclable materials have been used for all parts.

• Instrument panels
• Interior parts, plastic
• Interior parts, textile
• Insulation
9.11.1 Instrument and control panels

Instrument and control panels, description
The Spirit Delta cab contains the following instrument and control
panels.
A B C
R
1 4 5
2 3
015470
A. Left instrument panel
B. Steering wheel panel
C. Right instrument panel
D. Hydraulic controls with levers (4-lever, 5-lever, electrical servo
or joystick)
E. Joystick control/mini-wheel

9:88 9 Frame, body, cab and accessories – Interior fittings, plastic
9.11.2 Interior fittings, plastic

Interior fittings, plastic, description
The interior plastic components of the cab are made of recyclable
material.
Interior plastic components, replacement

Steering wheel panel and steering wheel shaft cover
2 For removing the steering wheel panel and steering wheel shaft
cover, see Multi-function lever, replacement, page 9:11.
Plastic cover over wiper motor

2 For removing the plastic cover over the rear wiper motor, see
Wiper motor rear, replacement, page 9:54.
3 For removing the plastic cover over the roof wiper motor, see
Wiper motor roof, replacement, page 9:51 and Wiper motor roof,
side-mounted roof wiper, replacement, page 9:52.

9 Frame, body, cab and accessories – Interior fittings, plastic 9:89
Instrument panel
2 To remove the dashboard panel, remove the nine clips holding

it in place. Press in the centre pin on the clip (about 3 mm) to
unlock the clip.
NOTE
Reuse the clips by re-inserting the centre pin and pressing this
flush with the head on fitting.
3 Raise the dashboard panel slightly and unplug all electric

connectors. Then remove the dashboard panel.
4 When the instrument panel is replaced all equipment, for example
switches and gauges, which are mounted on the instrument panel
must be removed and transferred to the new instrument panel.
Instrument panel

9:90 9 Frame, body, cab and accessories – Interior fittings, plastic
Rear covers
2 When removing the rear covers in the cab, loosen the screws
holding the covers. Remove the covers.
Rear side panels, two + three screws.

006655
Rear panel (middle section) two screws.

9 Frame, body, cab and accessories – Interior fittings, textile 9:91
Front middle lower cover

2 For removing the front middle lower cover in the cab, loosen the
steering wheel shaft and fold it backwards.
006656
Loosen the steering wheel shaft.
3 Loosen the screws holding the cover. Remove the cover.
Loosen the two screws.
Door opening covers

2 For removing the plastic cover in the door front and top opening,
loosen the screws holding the panels and remove the panels.
006659
9.11.3 Interior fittings, textile

Interior fittings, textile, description
The interior textile components of the cab are made of recyclable
material.

9:92 9 Frame, body, cab and accessories – Floor covering
Interior textile components, replacement

2 The interior textile components are replaced as depicted in figure

1-2.
3 When the roof panel is replaced, all equipment such as
loudspeakers and lamps mounted on the roof must be removed
and transferred to the new roof panel.
006653
Figure 1
006654
Figure 2
9.11.4 Floor covering

Floor covering, description
The floor covering is recyclable and is made of wear- and water
resistant material.
Floor covering, replacement

2 Open the doors on both sides.
3 Undo the screws which hold the sill moulding in the cab entry,
and remove the sill moulding.
4 Undo and remove all equipment in the cab which is screwed
through the floor matting, such as the seat and pedal base.
5 Replace the floor matting.
006652
9.11.5 Insulation
Insulation, description
The cab insulation consists of recyclable material.
The insulation material consists of both self-adhesive foam plastic

material for noise and heat insulation and of self-adhesive matting
(heavy material for good sound insulation at low noise frequencies).

9 Frame, body, cab and accessories – Sun visors 9:93
9.11.6 Sun visors

Sun visors, description
Sun visors can be specified for the front window (windscreen) and
the roof window.
1. Sun visors, front and rear window: Adjustable up and down with
the cord on the right-hand side. Stops in the chosen position.
2. Sun visor, roof window: Extends forward to fasten in two hooks in
the front edge of the window or is continuously adjustable.
9.11.7 Terminal console

Terminal console, description
The function of terminal console is to provide a work area for

computer/terminal aided operations. It is normally located to the right
of the steering wheel, easily accessible for the operator.
9.11.8 Writing desk

Writing desk, description
The function of the writing desk is to provide a work surface for a

writing and notes. It is located to the right of the steering wheel, easily
accessible for the operator.
9.11.9 Compartment for A4 papers

Compartment for A4 papers, description
The function of the writing desk is to provide a work surface for a

writing and notes. It is located to the right of the steering wheel, easily
accessible for the operator.
9.11.10 Holder for pump lever

Holder for pump lever, description
The cab is equipped with a holder for the pump lever at hinge-side of
the emergency exit door, (right hand side).

9:94 9 Frame, body, cab and accessories – Frame
9.12 Frame
Frame, description
The frame consists of two longitudinal frame sides cut from a piece of
solid steel plate. The mudguards, footsteps, tanks and counterweights
are bolted into the frame.
The frame contains attachment points for the steering axle and cab.
The brackets for engine, transmission, fuel tank and hydraulic tank are
bolted into the frame, see the appropriate sections. The mudguards
are bolted into the frame.
The space in the rear section is welded to the longitudinal frame sides
and is used to contain the counterweights. The number and size of
counterweights is adapted to the machine in question.
5 3
1 7
014449
1. Frame front section 5. Drive axle mount
2. Frame rear section 6. Steering axle mounting
3. Beam pair 7. Mast mount
4. Mounting, rear fenders

9 Frame, body, cab and accessories – Body structure 9:95
9.13 Body structure

Body, safety
WARNING
The hood may be slippery.
Slipping hazard.
It is forbidden to walk on the hood when it has no
anti-slip protection or is not flat.
Body structure, description

The body is regarded as being the following:
• Wings
• Engine compartment cover
• Footstep
• Counterweights
• Battery compartment
9.13.1 Wings
Wings, description
There are wings over the wheels to protect from dirt thrown up by the
wheels during operation.
1 2 The fenders can be equipped with extra mudguards when the

machine's work environment requires such .
015766
1. Rear fenders
2. Front fenders
9.13.2 Hood engine compartment

Hood engine compartment, description
2 A hood protects the machine's engine compartment. The hood is
easy to lift and gas dampers hold it up when it is lifted.
1
015772
3
1. Hood engine compartment
2. Gas damper
3. Air intake

9:96 9 Frame, body, cab and accessories – Footstep
Hood engine compartment, replacement

2 Open the hood and hold it up with an overhead crane.
3 Remove the lock ring from the gas struts and detach the strut.
Remove the gas struts on both sides of the hood.
4 Remove the screws holding the hood in the frame.

5 Replace the hood.
9.13.3 Footstep
Footstep, description
The cab entrances have non-slip steps on the sides of the machine.
If the optional mounting frame is installed, there are also non-slip
steps on the sides of the subframe.
A
Fenders with slip-protected surfaces can optionally be used as
008825
steps.
A Footstep

9 Frame, body, cab and accessories – Counterweight 9:97
9.13.4 Counterweight
Counterweights, description
The machine has counterweights to balance the machine\qs lifting
capacity and may therefore vary in quantity and weight.
The counterweights are located at the very back on the frame for
1 maximal leverage.
2
There are two counterweights with fixed weight:
• Vertical counterweight (rear weight)
015666
There is a towing eye in the vertical counterweight at the back
of the frame.
1. Horizontal counterweight (upper weight) • Horizontal counterweight (upper weight)
2. Vertical counterweight (rear weight) The horizontal counterweight is located above the vertical
counterweight. There are tapped holes on the counterweight for
accessories. The machine can also be fitted with lifting lugs
(to lift the rear of the machine) in the counterweight.
There are a number of weight elements (in the counterweight box)

under the horizontal counterweight that are adapted to balance the
machine\qs lifting capacity.
In addition to the weights named above, weights may in some cases

also be located on the steering cradle.
DANGER
The counterweights are factory fitted and are adapted
according to the machine's properties.
The machine's operating characteristics are changed!
Never change the quantity of counterweights.

9:98 9 Frame, body, cab and accessories – Battery compartment
9.13.5 Battery compartment

Battery compartment, description
The machine has a battery compartment where the two batteries
are connected in series, and where the main fuses and battery
disconnector are located.
NOTE
The battery compartment must not be used as storage space.
015667
9.13.7 Mud guards

Mud guards, description
Fenders can also be equipped with elastic mud guards for

reducing splash from the wheels when driving at wet surfaces.
015668
9.13.8 Tool kit

Tool kit, description
The machine can be equipped with a tool kit.

9 Frame, body, cab and accessories – Lifting lugs 9:99
9.13.9 Lifting lugs

Lifting lugs, description
The machine can be equipped with lifting lugs.
The front lifting lugs are welded to the mast and the rear lifting lugs
are screwed through the counterweight.
013952

9:100 9 Frame, body, cab and accessories – Central lubrication
9.14 Central lubrication

Central lubrication, description
1
Central lubrication (replaces manual lubrication) is available in
different variants. The alternatives are:
3 • Manual, hand pumping lubricant at a lubrication point which via

lines are distributed to all selected lubrication points.
• Automatic, pre-programmed lubrication unit lubricates all selected
lubrication points at pre-set time interval.
It is also possible to select the number of lubrication points as follows:

• Total 14 lubrication points: 8 on the steering and 6 on the mast
(the only alternative with manual central lubrication).
and 8 on the assembly.
009090
2 and 11 on the assembly (with central levelling assembly).
Central lubrication comprises the following components:

1. Pump unit
• Pump unit, with lubricant reservoir.
2. Safety valve
• Distribution block.
3. Distribution block
• Lines, to all selected lubrication points.
• Grease nipples, at all selected lubrication points.
NOTE
Brake pedal, mast wheels on inner mast, upper and lower rollers
on forks is always greased manually.
9.14.1 Pump unit

Pump unit, description
The pump unit consists of a reservoir with agitator, pump housing with
integrated motor, timer, pump element and filler nipple.
The unit works by means of lubrication cycles (pause and run-time and
read time). A pressure limiting valve is fitted to the pump element,
ensuring that the pressure in the system does not become too high.
The central lubrication is controlled as follows:
There is a circuit board with a timer in the pump. This can be used to
set the run and pause time of the pump motor.
This is normally set so that the running time is four minutes and pause
time six hours.
In addition, from the cab via a button on the instrument panel, the
operator can manually start a lubrication cycle of four minutes, is so
desired.

9 Frame, body, cab and accessories – Distribution block 9:101

The number of distribution blocks can vary depending on how
many (and which) lubrication points are selected. However, the first
distribution block (i.e. the block closest to the pump unit) is always
included.
The distribution blocks consist of progressively controlled pistons.

These are powered by the lubricant and have no springs and seals. The
lubricant is pressurised and then drives the pistons in the distributor.
The pistons move in a predetermined way, and this pattern of

movement is repeated time after time. Each piston must have complete
its movement before the next piston can move. The pistons are
interdependent. It is technically impossible for a connected lubrication
point to be missed.
There is an indicator pin on the system's first distribution block (i.e.

the block closest to the pump unit). If the pin moves forward and
backward (in time with the piston movement) this means that all the
system's distribution blocks are working. If one distributor block cannot
supply grease to its lubrication points then the pin stops and so does
the whole system.
9.14.3 Lines
Lines, description
The lubricant is carried to the lubrication points through hoses.
9.14.4 Grease nipples

Lubrication points, description
The lubrication points have grease nipples with couplings to which the
lines are connected. The couplings can be straight or angled.
1 2 3
008978
1. Lubrication point with coupling

2. Lines
3. Distribution block on steering axle

9:102 9 Frame, body, cab and accessories – Paint/coatings
9.15 Paint/coatings
Paint/coatings, description
The machine is painted with paint which is applied by brush or spray.
For colour code (RAL), see machine card.
Check the machine frequently for stone chips, dents and paint
scratches, repair them at once to prevent corrosion on the metal
underneath. Only use touch-up paint for small stone chips and
scratches. More extensive paint damage should be repaired by a paint
workshop.
NOTE
Before touching up, the surfaces to be touched up must be
thoroughly cleaned.
Contact Cargotec for information about other surface treatment and

material colours.

10:1
Contents 10 Common hydraulics

10 Common hydraulics .........................................................................................10:3
10.2 Safety valves..................................................................................................10:9
10.2.1 Accumulator drain valve ............................................................................10:9
10.2.2 Pipes and hoses........................................................................................10:9
10.3 Tanks and accumulators ..............................................................................10:10
10.3.1 Tank.........................................................................................................10:10
10.3.2 Accumulator ............................................................................................10:10
10.3.3 Sensor, low brake pressure.....................................................................10:13
10.3.4 Pipes and hoses......................................................................................10:13
10.4 Pumps..........................................................................................................10:14
10.4.1 Gear pump with fixed displacement ........................................................10:14
10.4.2 Axial piston pump with variable displacement.........................................10:17
10.4.3 Pipes and hoses......................................................................................10:21
10.5 Hoses, pipes and valves ..............................................................................10:22
10.5.1 Pipes and hoses......................................................................................10:22
10.5.3 Priority valve............................................................................................10:23
10.5.4 Shuttle valve............................................................................................10:26
10.5.5 Proportional valve ...................................................................................10:26
10.6 Temperature control, cleaning and hydraulic oil...........................................10:27
10.6.1 Tank heater .............................................................................................10:28
10.6.2 Hydraulic oil cooler ..................................................................................10:30
10.6.3 Sensor hydraulic oil temperature.............................................................10:30
10.6.4 Make-contact (closing switch), cooling fan..............................................10:31
10.6.5 Cooling fan ..............................................................................................10:31
10.6.6 Thermal bypass valve .............................................................................10:32
10.6.7 Breather filter hydraulic oil tank ...............................................................10:32
10.6.8 High-pressure filter ..................................................................................10:33
10.6.9 Hydraulic oil.............................................................................................10:33
10.6.10 Hydraulic oil pump...................................................................................10:33
10.6.11 Pipes and hoses......................................................................................10:33
10.7 Other ............................................................................................................10:34
10.7.1 Hydraulic cylinders ..................................................................................10:34

10:2

10 Common hydraulics – Common hydraulics 10:3
Hydraulic pressure, inspection and
adjustment
NOTE
Safety.
Servo pressure for control levers (PS)

reaches operating temperature, approx. 50 ºC.
2 Turn off engine.
3 Connect a pressure gauge (0-25 MPa) to the measuring outlet PS

on the control valve for load handling.
4 Start the engine and check the servo pressure. Compare with
the pressure plate.
014473

10:4 10 Common hydraulics – Common hydraulics
5 Adjust the servo pressure if necessary.

6 Switch off the engine and remove the pressure gauge, and refit
the protective cap on the measuring outlet.
015349
Pump pressure, steering and load handling.

2 Turn off engine.
3 Connect a pressure gauge (0–25 MPa) to the measuring outlet on

the priority valve.
5 Check the stand-by pressure for one pump at a time in the
following order:
Hydraulic oil pump for steering and load handling: 3.0 MPa
Hydraulic oil pump for lifting/lowering and tilt: 2.8 MPa
The settings apply to standard machine, certain machines may
have higher standby pressure. For correct standby pressure, see
pressure plate. However, the difference in pressure between the
different pumps must always be maintained.
6 Increase engine speed to approx. 1800 rpm and run tilt function
014474
against end-position (overflow).

Tilt in the mast to max. and continue to request max. tilt in with the
control lever. This will cause the tilt function to overflow.
Check the max. pressure on the hydraulic oil pump for lift/lowering
and tilt, the pressure should match the value on the pressure plate.
7 Increase engine speed to approx. 1800 rpm and turn to max.
steering right or left and continue to activate the function.
Check the max. pressure on the hydraulic oil pump for steering
and load handling, the pressure should match the value on the
pressure plate.

8 If necessary, adjust the hydraulic pressure so that it is consistent

with the specified value on the pressure plate.
9 Switch off the engine and remove the pressure gauge, and refit
the protective cap on the measuring outlet.
015363
Steering pressure
2 Turn off engine.
3 Connect a pressure gauge (0–25 MPa) to the measuring outlet at

the priority valve.
4 Start the engine and increase the engine speed to approx. 1200
rpm.
5 Turn the steering wheel fully and read pump pressure during the
steering wheel movement. Compare this to the steering pressure
on the hydraulics plate.
6 If necessary, adjust the steering pressure on the priority valve
for steering.
measuring outlet.
014475
9 If necessary, adjust the steering pressure on the priority valve for

steering.
a) Stop the engine.
b) Depressurise the hydraulic systems, See section B Safety.

c) Detach the hydraulic hose and adapter.
015362
d) Adjust the pressure by turning the adjusting screw, which is

located under the hydraulic hose and adapter.
Anticlockwise: reduce pressure.
Clockwise: increase pressure.
e) Screw back the adapter and hydraulic hose and repeat steps
4-6 until the steering pressure is consistent with the data on the
pressure plate.
Pump pressure, brake system

1 Operate and warm up the machine so that the oil in the brake
system reaches operating temperature, at least 50 ºC.
4 Connect a pressure gauge (0-25 MPa) to the pump pressure

measuring outlet on the accumulator charging valve.
014477
Measuring outlet, pump pressure

6 Close the drain valve on the accumulator charging valve and

check the pump pressure during charging.
NOTE
During charging the pressure should increase to 20.5±1.0 MPa

before the accumulator charging valve switches to cooling. When
the accumulator charging valve switches to cooling, the pressure
drops.
7 Check the pressure during cooling.
During cooling the pressure should be max. 0.10–0.15 MPa at
014476
max. engine speed.
Close the accumulator charging valve
8 Adjust the pressure if necessary.

9 Turn off engine.
measuring outlet.
NOTE
015353
Checking the accumulator charging


014478
Measuring outlet, accumulator pressure

NOTE
5 Check that the pressure increases slowly to 16.5±0.5 MPa.

6 Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve must change to charging at 12 MPa.
014476
Close the accumulator charging valve
7 Adjust the accumulator charging pressure if necessary.

measuring outlet.
NOTE
015350

10 Common hydraulics – Safety valves 10:9
10.2 Safety valves

10.2.1 Accumulator drain valve
Accumulator drain valve, description
NOTE
The valve should be closed during operation and is opened to
depressurise the machine.
The accumulator drain valve is fitted on the return line from the
accumulator. The accumulator must be drained before work on the
hydraulic system using its controls. To drain the hydraulic system,
1 see section B Safety.
014452
1. Accumulator drain valve with opening knob and

lock ring
To verify that the accumulator pressure has been released, measure
with a pressure gauge at the pressure test outlet for the accumulator
charging valve.
014478
Measuring outlet, accumulator pressure

See Pipes and hoses, general, page 10:22.

10:10 10 Common hydraulics – Tanks and accumulators
10.3 Tanks and accumulators

10.3.1 Tank
Tank, description
The main task of the hydraulic oil tank is to function as storage for the
oil acting in the hydraulic system.
The hydraulic oil tank forms part of the side panel on the right-hand
side of the machine. Hydraulic oil is filled directly through a hole on
top of the tank (for oil grade and volume, see section F Technical
data, group 10 Common hydraulics). There is a drain plug located
at the bottom of the tank.
The tank is equipped with a filtered breather that allows volume

changes in the tank, due to temperature variations and use. See
Breather filter hydraulic oil tank, description, page 10:32.
B
The oil level is checked on the sight glass on the tank's side (when all
hydraulic cylinders are in the bottom position).
NOTE
When filling hydraulic oil, make sure that the pumps are filled with
C oil before the system is activated since they\qre located higher
than the tank.
10.3.2 Accumulator
Accumulator, description
The accumulator stores pressure so that there is a pressure reserve
1
in the event of the engine stopping or faults in the brake system.
The accumulator is divided into two compartments by a diaphragm.

One side of the diaphragm is pressurised by nitrogen gas. The
other side is pressurised by the hydraulic oil, which compresses the
nitrogen gas.
The accumulator has a test outlet on the top for checking the pressure
of the nitrogen gas (and topping up the nitrogen with special filling
equipment).
015305
The accumulator pressure is measured on the valve block.

1. Accumulator When the accumulator is charged with hydraulic oil the diaphragm
is pressed upward and the nitrogen gas pressure rises. When the
hydraulic system needs feeding from the accumulator, the diaphragm
presses back the oil to the system.
Pressurised oil from the accumulator is used for the servo brake and
parking brake systems, and to feed the reducing valve for the servo
hydraulics, see section 4 Brakes and 7 Load handling.
NOTE
If the accumulator delivers low oil pressure, the pumps may be
damaged and the hydraulic functions may stop working.

10 Common hydraulics – Accumulator 10:11
Accumulator, checking
NOTE
Safety.
NOTE
Special tools for checking the accumulators can be ordered from
Cargotec. The following describes the procedure without special
tools.
3 The accumulators can be tested with separate test equipment or

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

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

6 Detach one accumulator from the distribution block. Plug the
distribution block's connections with plugs that can withstand high
pressure. Plug the accumulator to protect it from impurities.

9 Close the drain valve on the accumulator charging valve and
charge the accumulator until the accumulator charging valve
changes to cooling.
10 Check that the plugs seal properly.
11 Turn off 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
014478
decrease immediately to 0 MPa.

If the pressure drops immediately when the engine is switched off
then the accumulator does not have any precharge pressure. This
indicates internal leakage and the accumulator must be replaced.
If the pressure can be reduced slowly to a pressure below 10
MPa then the precharge pressure is too low and the accumulator
must be replaced or handed over to authorised personnel for
maintenance or charging.
Safety.

10:12 10 Common hydraulics – Accumulator
14 Mark up and disconnect the tested accumulator. Plug the

connections. Connect the other accumulator to the distribution
block.
15 Repeat steps 6 - 14 for the second accumulator.
Safety.
Installation and final checking
17 Connect all accumulators to the distribution blocks. If necessary,
replace or fill deficient accumulators.
NOTE
Check that the seals are intact, clean and in the correct position.

19 Close the drain valve on the accumulator charging valve so that
the accumulators are charged.
NOTE
20 Check that the accumulators' connections are sealed tightly.

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

Safety.
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.

10 Common hydraulics – Sensor, low brake pressure 10:13
6 Bend the clamp away and remove the accumulator.
7 Fit the new accumulator.
NOTE
Check that the seal is intact, clean and fitted in the correct
position.
8 Secure the accumulator's clamp and tighten the bolt.
NOTE

11 Check that the accumulator's connection is sealed tightly.
12 Check precharging and function, see Accumulator, checking, page
10:11 steps 18-22.
014476
10.3.3 Sensor, low brake pressure

Sensor, low brake pressure, description
This sensor is located by the brake valve.
See section 4 Brakes, group 4.3.8 Switch normally open (NO), low
brake pressure.


10:14 10 Common hydraulics – Pumps
10.4 Pumps
10.4.1 Gear pump with fixed displacement
Gear pump with fixed displacement, description
All hydraulic pumps with fixed displacement are the gear pump type.
6 1 They are driven by splines from the engine. The pump shafts are
bearing-mounted with slide bearings lubricated by the oil flowing
through.
The gear pumps pump oil with two gears that run against each other
in an oval housing. One of gears is driven, while the second rotates
freely and follows the first.
5 2
The movement of the gears creates suction between gear and
housing. Each turn that the gears spin pumps a certain quantity of
oil (fixed displacement). The pump's flow varies with the rotational
speed of the input shaft.
On each side of the pump wheels there are pressure plates that seal
3 between the suction and pressure side.
000660
The displacement, i.e. how many cubic centimetres of oil that the
4 pump can deliver per pump revolution, may differ between the
1. Pump housing different gear pumps.
2. Outlet
NOTE
3. Drive wheel
It is very important that the clearance between the gears and
4. Tooth slot between the gear and the housing is correct. Clearance that is too
5. Intake small creates wear damage. Clearance that is too large reduces
the pump's power output.
6. Following wheel
The machine's hydraulics are supplied from three pumps. Two
axial piston pumps with variable displacement for load handling and
steering, and one fixed gear pump for the brake system.
1. Pump 1, see Axial piston pump with variable displacement,
2. Pump 2, see Axial piston pump with variable displacement,
3. Pump 3. The fixed hydraulic oil pump (position 3) supplies the
1 2 3 brake system's brake and cooling circuit over an accumulator
charging valve, see section 4 brakes.
014442
Hydraulic oil pumps in standard version.

1. Hydraulic oil pump for steering and load handling
2. Hydraulic oil pump for lifting and tilting
3. Hydraulic oil pump for the brake system

10 Common hydraulics – Gear pump with fixed displacement 10:15
Gear pump with fixed displacement, replacement
NOTE
Safety.
3 Clean the hydraulic oil pump and its surrounding area.
4 Mark up and detach the hydraulic hoses from the pump.
NOTE
from impurities.
015325
5 Remove the pump.

Remove the attaching bolts, pull the pump forward and lift it away.
6 Transfer the connection adapters to the new pump.
NOTE
position.
7 Inspect the seals between the pumps, replace as necessary.

015318
8 Fit the gear pump in place.

Install the pump and check that the splines engage on the shaft.
Fit the pump's attaching bolts, use locking fluid to lock the bolt
and seal the screw holes.
015318

10:16 10 Common hydraulics – Gear pump with fixed displacement
9 Connect the hydraulic hoses in accordance with the markings.
NOTE
position.

11 Check that the hose connections and seal between gear pump
and axial piston pump are sealed tightly.
NOTE
015325
Prefill the pump with oil through the pressure connection before
it is taken into operation.
Bleed the pump if necessary before starting the engine by
detaching the hoses from the pressure side.
NOTE
If the pump is replaced due to malfunction, change the oil and
filter in the hydraulic system as well.
CAUTION
Do not overfill!
fully retracted.

10 Common hydraulics – Axial piston pump with variable displacement 10:17

displacement
Axial piston pump with variable displacement,
description
The machine's hydraulics are supplied from three pumps. Two
axial piston pumps with variable displacement for load handling and
steering, and one fixed gear pump for the brake system.
1. Pump 1 supplies the steering system and load handling. The
priority valve ensures that there is always pressure for the
steering, the residual flow goes to the control valve for load
handling.
2. Pump 2 supplies lift and tilt via the control valve for load handling.
1 2 3 3. Pump 3, see Gear pump with fixed displacement, description,
page 10:14.
The pumps are assembled into one pump bank which is mounted to
014442 the transmission's power take-off.
Hydraulic oil pumps in standard version.

1. Hydraulic oil pump for steering and load handling
2. Hydraulic oil pump for lifting and tilting
3. Hydraulic oil pump for the brake system
Axial piston pump with variable displacement, change
NOTE
Safety.
3 Clean the hydraulic oil pumps and the areas around them.
4 Remove the gear pump, see Gear pump with fixed displacement,

10:18 10 Common hydraulics – Axial piston pump with variable displacement
5 Mark up and release the hydraulic hoses.
NOTE
from impurities.
015317
6 Remove the pump.

NOTE
position.
015326
8 Mark up and release the hydraulic hoses.
NOTE
from impurities.
015327

10 Common hydraulics – Axial piston pump with variable displacement 10:19
9 Remove the pump.

NOTE
position.
11 Inspect the seals between the pumps, replace as necessary.
015328
Fit the pump's attaching bolts, use locking fluid to lock the bolt and
seal the screw holes in the transmission.
015328
NOTE
position.
14 Check that the hose connections and the seal between the axial
piston pump and the transmission are sealed tightly.
NOTE
015327


10:20 10 Common hydraulics – Axial piston pump with variable displacement

Fit the pump's attaching bolts, use locking fluid to lock the bolt.
015326
NOTE
position.
17 Check that the hose connections and the seal between the axial
piston pumps are sealed tightly.
NOTE
18 Fit the gear pump, see Gear pump with fixed displacement,
015317

20 Check that the hose connections and the seal between the pumps
and the transmission are sealed tightly.
NOTE
If the pump is replaced due to malfunction, change the oil and
filter in the hydraulic system as well.
CAUTION
Do not overfill!
fully retracted.

10 Common hydraulics – Pipes and hoses 10:21


10:22 10 Common hydraulics – Hoses, pipes and valves
10.5 Hoses, pipes and valves

Pipes and hoses, general
Hoses with ORFS couplings are used almost exclusively. For maximum
service life and function, the following should be observed when
replacing hoses.
1. To avoid stresses in the connection, there should be a length of
straight hose after the connection.
2. The hose must not be twisted. (A twist of 7% reduces service life
by 90%.)
3. Minimise the number of bends by using correct couplings.
4. Avoid sharp bends.
5. Keep the hoses clean internally. Leave the plugs in place as long
as possible when installing.
6. Check the position of the O-rings and tighten to the correct torque,
see section F Technical data.
NOTE
Straight coupling requires a counterhold wrench to prevent
damage to the O-ring.
7. The O-rings must not be oiled when fitted.

Hose length
Hose length
C/L
Hose length is measured on a hose laid out between the sealing
surfaces. On angled connections, measure from the sealing surface's
centre line [C/L] as illustrated.
Cleanliness
The function and service life of hydraulic components depend to
a great extent on how clean the hydraulic oil is. It is therefore very
important to prevent dirt from entering the brake and hydraulic system.
Some simple advice to keep the hydraulic system clean.

• Always clean the area around a component before starting to
work.
001015
• Plug hose connections immediately after disconnecting. If

possible, use correct plugs for the connection type. If plugs are
C/L line for measuring hose length missing, use clean plastic bags and cable ties or tape to seal
the connection.
• Never re-use oil that has been drained from the machine.
• Oil drums often contain contaminants.
When filling hydraulic oil, fill through the cover on the hydraulic oil
filters in the tank so that the oil is filtered.

10 Common hydraulics – Priority valve 10:23
10.5.3 Priority valve

Priority valve, description
The priority valve is acted on by the steering valve's LS-signal and
ensures that the steering circuit receives sufficient supply. The valve
prioritises the pressure in order to supply the steering with oil prior to
load handling.
015364
2
Applies to machines equipped with joystick control/mini-wheel.
The priority valve divides the oil flow from hydraulic oil pump, steering
and load handling, so that there is always oil to the steering valve.
Residual flow goes to the working hydraulics.
3
The priority valve is load sensing and pilot pressure compensating.
Load sensing means that the valve adapts the control signal to the
1
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.
4
6 5
015669
1. Load signal to shuttle valve for steering/load

handling (LS)
2. Priority valve
3. Pressure feed from the hydraulic oil pump for
steering and load handling (P)
4. Pressure feed to control valve for load handling
(EF)
5. Measuring outlet control pressure

10:24 10 Common hydraulics – Priority valve
Priority valve, replacement
NOTE
Safety.
3 Mark up and detach the hydraulic hoses from the priority valve.
NOTE
from impurities.
015677
4 Undo the screws that affix the valve to the attaching plate.
015678

10 Common hydraulics – Priority valve 10:25
5 Remove the priority valve from the control valve. Place the valve
on a clean and protected surface.
6 Transfer parts to the new priority valve.
NOTE
position.
NOTE
Transfer one connection at a time so that the marking is not
mixed up.
7 Fit the new valve and attach it to the control valve and attaching
plate.
8 Connect the hydraulic hoses to the control valve in according to
015678
the marking.
NOTE
position.
NOTE

CAUTION
014476
product damage.
CAUTION
Do not overfill!
The hydraulic oil level is checked with the boom
completely lowered and retracted.

10:26 10 Common hydraulics – Shuttle valve
10.5.4 Shuttle valve

Shuttle valve, description
A shuttle valve selects between two pressure signals and sends the
strongest. The shuttle valves are used to send load signals to the
hydraulic oil pumps. This means that the pumps are controlled by the
function that requires the highest pressure if several functions are
activated simultaneously.
On machines with turnable operator's station there is an extra

brake pedal for reversing. The brake pedal is connected in parallel
with the brake pedal for driving forward. The shuttle valve selects the
015365
strongest pressure signal and forward this to the wheel brakes.
10.5.5 Proportional valve

Proportional valve, description
The proportional valve is an electrically controlled pressure reducing
valve for electric remote control of hydraulic functions. The output
signal is a proportional, hydraulic servo pressures used for controlling
the slides in the directional control valves.
The proportional valve consists of a magnet as well as a pilot control

valve and is connected to the directional control valve's slide.
The electromagnet controls the pilot control valve with proportional

force. There is a bleed screw on magnet's end face.
The pilot control valve gives an outgoing control pressure to the slide
which is practically linearly proportional to the input current. The pilot
control valve is closed in neutral position.

10 Common hydraulics – Temperature control, cleaning and hydraulic oil 10:27
10.6 Temperature control, cleaning

and hydraulic oil
Temperature control, general
The cooling system lowers the temperature of the hydraulic oil in

vehicle. The cooling system consists of a separate electrically operated
fan mounted in the return pipe from the control valve.
Thanks to the oil cooler, the reduction of hydraulic oil temperature
benefits the entire hydraulic system.
Cooling system via electrically operated cooler,

description
C C
4
P T
5
3
°C 7
2
9
6 10
M 8
1
014454
1 The hydraulic oil pump pumps oil from - Tank, description, page 10:10
the hydraulic oil tank.
Gear pump with fixed displacement,
description, page 10:14
2 The high pressure filter cleans the oil. - High-pressure filter, description, page 10:33
3 The accumulator charging valve directs Max. 0.1 MPa Section 4 Brakes, group 4.3.13 Accumulator
oil to charging of accumulators or charging valve
through the brake system's cooling
circuit.
4 Return oil from the accumulator charging - -
valve is led via the wheel brakes and
the distribution block to the hydraulic oil
cooler.
5 The distribution block leads the oil to the - -
thermal bypass valve or the oil cooler.
6 A thermal bypass valve leads the 55-65 °C Thermal by-pass valve, description, page
hydraulic oil past the cooler directly to 10:32
the tank if the temperature is below 55
°C. When the oil temperature is above
65 °C all the oil is led through the cooler.
7 Make-contact (closing switch) cooling The fan starts at 60 Make-contact (closing switch), cooling fan,
fan (S240–1) opens and actuates relay °C and stops when the description, page 10:31
(K359) for the electric cooling fan if the temperature is below 50
hydraulic oil temperature is too high. °C.
8 The relay (K359) supplies voltage to the U = 24 V Cooling fan, description, page 10:31
electric cooling fan (M668).

10:28 10 Common hydraulics – Tank heater

9 The cooling fan (M668) increases the - Cooling fan, description, page 10:31
air flow through the hydraulic oil cooler,
hence the cooling effect.
10 The hydraulic oil cooler cools the - Cooling fan, description, page 10:31
hydraulic oil.
Hydraulic diagram, see section E Schematics group 10 Common

hydraulics.
10.6.1 Tank heater

Tank heater, description
The tank can be equipped with a tank heater. The tank heater is
primarily intended for use in cold climates. The tank heater is powered
by high voltage and is available with different input voltages (rated
voltage). The heater is mounted on the footstep on the right-hand
side.
000656
The tank heater can be equipped with an adjustable thermostat that

keeps the temperature at a constant level. The thermostat is mounted
directly on the heating element and can be adjusted with a knob on
the junction box.
Tank heater, replacement
CAUTION
The tank heater is connected to high voltage (110 - 400
V).
High voltage.
Installation and reconnection of the tank heater may
only be performed by personnel authorised for work
with high voltage.
NOTE
Safety.
3 Drain the machine of hydraulic oil. Use a pumping device.

10 Common hydraulics – Tank heater 10:29
4 Remove the two screws that hold the plastic cover.

5 Unplug the electric cables from the connections.
6 Remove the lock nut which holds the wiring harness in the heater.
7 Remove the heater from the machine.

8 Replace the heater.

10:30 10 Common hydraulics – Hydraulic oil cooler
10.6.2 Hydraulic oil cooler

Hydraulic oil cooler, description
The hydraulic oil cooler is the through-flow type with an electric

cooling fan. The oil is cooled when it passes through the cooler. The
fan starts when the oil temperature exceeds 60 °C and stops when
the temperature drops below 50 °C.
1 2
015367
6 5 4 3
Hydraulic oil cooler

1. Cooling fan
2. Cooling element
3. Intake
4. Outlet
5. Sensor hydraulic oil temperature
6. Thermal bypass valve
10.6.3 Sensor hydraulic oil temperature

Sensor, hydraulic oil temperature, description
Sensor, hydraulic oil temperature (B776) senses the temperature of

the hydraulic oil before it reaches the cooler. The sensor is located by
the plate in the hydraulic oil tank (by the suction line).
Sensor hydraulic oil temperature (B776) is supplied with voltage by

and sends voltage signal proportional to oil temperature to Control
unit general (ECU790).
The signal can be checked from the diagnostics menu, see section 8
Control system, group 8.4.1.1 View inputs, menu 3, ECU 790 input
K2:21.
015373

10 Common hydraulics – Make-contact (closing switch), cooling fan 10:31
Sensor, hydraulic oil temperature, replacement
NOTE
Safety.
2 Drain the oil from the hydraulic oil tank.
3 Detach the electrical connectors from the sensor.
4 Replace the sensor.
10.6.4 Make-contact (closing switch), cooling fan

Make-contact (closing switch), cooling fan,
description
At a certain temperature the make-contact (closing switch) sends out a

signal to the cooling fan that then starts.
See figure at Hydraulic oil cooler, description, page 10:30.
10.6.5 Cooling fan

Cooling fan, description
The cooling fan is located behind/below the fuel tank on the inside
of the hydraulic oil cooler. The cooling fan draws air from outside of
the machine through the cooler.
The fan is activated by the hydraulic oil temperature sensor, see

Sensor, hydraulic oil temperature, description, page 10:30.
015372

10:32 10 Common hydraulics – Thermal bypass valve
10.6.6 Thermal bypass valve

Thermal by-pass valve, description
The thermal bypass valve is temperature-controlled and is fitted on

the inlet to the hydraulic oil cooler. (See also the figure at Hydraulic oil
cooler, description, page 10:30.)
The oil can pass straight through the valve at low oil temperatures.
At a certain temperature the valve closes completely thereby forcing
the oil through the cooler's cooling element.
015374
10.6.7 Breather filter hydraulic oil tank

Breather filter hydraulic oil tank, description
A breather filter of insert type is mounted on the hydraulic oil tank
to protect the tank from impurities. On the top of the filter housing
is an indicator that shows when the filter is clogged and needs to
2 be changed.
The breather filter cleans moisture and dust from the air that passes
from the tank\qs breather.
1
3
015371
1. Filling point
2. Breather filter
3. Sight glass

10 Common hydraulics – High-pressure filter 10:33

The oil is cleaned when it is forced out and through the filter insert,
which is a fibreglass cartridge, and then onward.
There is a bypass valve that protects the insert between the inlet
and outlet in the filter head. If resistance through the filter surface
becomes too great, the bypass valve opens a passage past the insert.
The bypass function opens if the oil is viscous (cold or incorrect
viscosity) or if the filter insert is clogged by dirt. Accordingly, the
1 valve's opening area becomes progressively greater with the pressure
drop, i.e. the contamination level increases.
High-pressure filters must be replaced in accordance with the interval

in the lubrication schedule as well as in connection with work on the
hydraulic system.
NOTE
When the filter is clogged, the oil is directed past the filter without
015370
cleaning. It is therefore very important to replace the filter at the

prescribed interval.
10.6.9 Hydraulic oil

Hydraulic oil, safety
NOTE
Safety.
Hydraulic oil, description

Lubrizol is added to the hydraulic oil with the lubrication of the brake
discs in mind. See section F Technical data, and Oil and lubricant
recommendations.

See Gear pump with fixed displacement, description, page 10:14.


10:34 10 Common hydraulics – Other
10.7 Other
10.7.1 Hydraulic cylinders
Fault tracing, leakage
Fault tracing, leakage
CAUTION
All fault tracing should be carried out with as low a
pressure in the system as possible so that the leakage
can be detected. High pressure causes the seals to
close tighter, which prevents detection of leaks.
1. Carefully check the source of the leakage before taking any

action. It may be possible to rectify the fault without disassembly.
2. Check for external leakage:
• At cylinder face end welds
• At sleeve coupling welds
• Between cylinder barrel and cylinder head
This could be due to a defective O-ring or damaged O-ring
sealing surfaces.
• Between cylinder head and piston rod
This could be due to a damaged piston rod or damaged or
worn piston rod seal.
3. Check for internal leakage. Pressurise the cylinder and check
whether the piston sinks back.
This could be due to a worn piston seal.
1. Piston rod
2. Scraper
3. Cylinder head
4. Piston rod seal
5. O-ring with support ring
6. Cylinder barrel
7. Sleeve coupling
8. Welded cylinder end face
9. Piston
10. Piston seal, double-acting
11. Example of weld

10 Common hydraulics – Hydraulic cylinders 10:35
Dismantling of cylinders
CAUTION
Before dismantling always check that the piston rod
is clean and free from all residual paint. Also check
that connections and couplings are free from burrs and
impact marks.
Make sure that the chamfer up to the chromium surface
of the piston rod is free from burrs and residual paint.
1 Remove the cylinder from its mounting and undo the connections.
2 Plug the cylinder connections and hoses without delay.
3 If the cylinder is opened - observe the strictest cleanliness!
Inspection of surfaces
Inspect the sealing surfaces. Always bearing mind the function of the
seals and the type of sealing surfaces they have. See the following
descriptions:
• O-ring groove, internal and external
• piston rod seal in the cylinder head
• sealing groove on the piston
• cylinder barrel surface
• piston rod surface. The piston rod is chromium plated with a layer
thickness of 20-50 my. Slight damage to the chromium plating may
not necessarily cause leakage directly.
• all slide surfaces (dynamic surfaces), e.g. cylinder barrel and
piston rod. These are always the hardest to seal.
CAUTION
When fitting the cylinder head:
Fit the cylinder head absolutely straight, ideally by hand
and do not hit with a mallet. If a mallet must be used,
use a plastic or rubber mallet and tap gently.
If the cylinder head is fitted crooked, the sealing lip
of the piston rod seal could be damaged, making an
improper seal. This applies to all types of piston rod
seals.

10:36 10 Common hydraulics – Hydraulic cylinders
Function and removal of the seals

Piston rod seal
2 Piston rod seal
The piston rod seal is the seal that sits in the groove in the cylinder
1 head and seals against the piston rod. This seal is very exposed to
wear since it is both a dynamic and a static seal, i.e. it seals against a
moving surface on the piston rod while the sealing surface with the
cylinder head is fixed. There are different types of piston rod seals:
• Single V-seal
3 • Pre-stressed V-seal with support ring
• Compressible seal
The single V-seal has a V-shaped section with two lips that seal
4 in opposite directions. The hydraulic pressure acts in the V-shape,
6
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 screwdriver on a sealing surface can have a
devastating effect and cause major leakage.
001497
5
1. Hydraulic pressure
2. Seal lip pressed out toward piston rod
3. Seal lip pressed inward toward cylinder head
4. Sealing surface, piston rod
5. Sealing surface, cylinder head
6. Screwdriver

2 The pretensioned V-seal also has an O-ring in the seal's V-shaped

space. The O-ring creates a strong seal at low hydraulic pressure
1 since the O-ring already presses the sealing lips out toward the
sealing surfaces when unloaded. It is just as sensitive to damage
as the V-seal. Examine in the same manner. To remove, use a
screwdriver to prise the seal outward and bend it up (see illustration).
It is extremely important that the screwdriver is always inserted in
the V-shape so that it cannot touch and thereby damage a sealing
3 surface. A mark from a screwdriver on a sealing surface can have a
7 devastating effect and cause major leakage.
6 4
001498
5
6. Screwdriver
7. O-ring
The compressible piston rod seal consists of a solid rubber profile
2
and provides a larger sealing surface than the V-seals. To remove,
use a screwdriver to prise the seal outward and bend it up (see
1 illustration). With this type of seal with sealing surfaces that cover so
much of the seal groove, it is particularly important that marks are
3
not made with the screwdriver.
6
4
5
001499
6. Screwdriver

Support ring and O-ring

Support ring and O-ring
The support ring and O-ring combination is used for sealing between
two fixed surfaces, such as between cylinder barrel and cylinder head.
The purpose of the support ring is to lend rigidity to the O-ring so that
3 it is not deformed. The O-ring is pressed against the support ring and
the 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. Support ring
Scraper
Scraper
øD+10
1 The purpose of the scraper is to scrape the piston rod clean and
prevent impurities from entering the cylinder barrel.
The scraper must be fitted with a special fitting tool. This tool must
have a greater outer diameter than the scraper so that the press force
2 against the scraper ceases precisely when the scraper is pressed into
its position. If the scraper were to be pressed in further, the metal
capsule would be deformed (see lower illustration), which would
4 impair the function of the scraper.
3 To prevent the scraper from bottoming in its recess in the cylinder

head, the recess is slightly deeper than the width of the scraper.
øD
6
001496
1. Correct assembly tool

2. Scraper, correctly fitted
3. Cylinder head
4. Clearance between scraper and bottom of
cylinder head recess
5. Incorrect assembly tool
6. Deformed scraper

A screwdriver can be used for removal. This must always be applied

1 against the outer edge of the scraper (see illustration). Carefully tap
the screwdriver down between the scraper and the cylinder head and
2 then prise out the scraper. Polish away any damage to the cylinder
head.
CAUTION
No tool may be applied from the inside. This could
3 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-seal it is always the long side that seals
2
against the fixed surface and the short side that seals against the
moving surface.
1 To remove, use a screwdriver to prise the seal outward and bend it

up (see illustration). It is extremely important that the screwdriver is
always inserted in the V-shape so that it cannot touch and thereby
damage a sealing surface. A mark from a screwdriver on a sealing
surface can have a devastating effect and cause major leakage.
3
6 4
002370
5
2. Seal pressed out toward cylinder barrel
3. Seal pressed in toward piston
4. Sealing surface, cylinder barrel
5. Sealing surface, piston
6. Screwdriver

The seal must always be fitted as a single assembly together with

the support ring.
Always assemble by hand. No tools should be used as they could

easily damage the surface of the piston.
To facilitate assembly the seal can be heated in hot water to make it

soft.
Lubricate with hydraulic oil.
002950
Double-acting piston seal
Double-acting piston seal
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 caution when fitting the piston in the cylinder barrel, making
2
002951
sure that the seal is not damaged by the cylinder barrel threads.
1. Variable sealing surface to cylinder barrel

2. Fixed sealing surface with piston
3. Guide ring
4. Support ring
5. Piston head
6. Cylinder barrel
Dismantling:
1 Remove guide rings and support rings.
2 Move the seal body over to one side of the sealing groove.
3 Press up the material so that there is a gap between seal and

piston.
4 Without damaging the surface of the piston - cut off the seal with
a knife.
5 Carefully examine the seal to find any damage that could cause
leakage. This will be easier if you bend the seal sharply bit by bit
and feel over the sealing surface with a fingernail.
Assembly:
1 All double-acting piston seals are of similar design: a middle seal
body, then support rings and farthest out guide rings.
2 First fit the seal body, then the support rings and finally the guide
rings - all must be done by hand without tools to avoid damage.

Repairing the piston rod surface

A small impact mark on a piston rod may be sufficient to cause
leakage. 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 2 3 1 Locate the damage using your fingertips and fingernails.
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.
4 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:
• fill the damage with weld metal, use chromium or stainless
steel electrodes
• remove all slag completely
• file the weld down to the same level as the chrome
• polish evenly using emery cloth.
002952
1. Piston rod
2. Chromium plating
3. Impact mark
4. Highly-polished hammer

Dismantling the steering cylinders

It can prove extremely difficult to extract the piston rod from the cylinder
barrel on steering cylinders. This is because the O-ring in the cylinder
head fastens in the lock ring groove in the cylinder barrel. It is therefore
best to remove the O-ring before trying to withdraw the piston rod from
the cylinder.
1 Unscrew the end washer at the cylinder head.
2 Unscrew the connecting nipple for the hydraulic hose.
3 Insert the piston rod with piston crown until the O-ring is visible
through the nipple hole.
4 Bend the end of a length of heavy-duty steel wire, piano wire or
similar into the shape of a hook. Use this to snag the O-ring.
5 Pull the O-ring up slightly and hold it with a pair of needle-nose
pliers.
6 Continue to pull the O-ring out through the hole.
7 Hold the O-ring steady and cut it with a knife.
8 Rotate the piston rod while pulling the O-ring out through the hole.
9 Remove the lock ring from the cylinder barrel.
10 Carefully extract the piston rod from the cylinder barrel.
002953

11:1
11 Common electrics
Contents 11 Common electrics

11 Common electrics ............................................................................................11:3
11.1 Controls and instruments ............................................................................... 11:3
11.1.1 Hour meter ................................................................................................ 11:3
11.2 Electric protection .......................................................................................... 11:4
11.2.1 Battery disconnector ................................................................................. 11:4
11.2.2 Fuses ........................................................................................................ 11:5
11.3 Batteries......................................................................................................... 11:7
11.3.1 Start battery............................................................................................... 11:7
11.4 Alternator ....................................................................................................... 11:9
11.4.1 Alternator................................................................................................... 11:9
11.5 Distribution of electricity ............................................................................... 11:10
11.5.1 Voltage feed ............................................................................................ 11:11
11.5.2 Electronic box.......................................................................................... 11:12
11.5.3 Control units ............................................................................................ 11:27
11.5.4 Operation, electrical system ................................................................... 11:39
11.5.5 Cable harness ......................................................................................... 11:39
11.6 Communication ............................................................................................ 11:40
11.6.1 CAN bus .................................................................................................. 11:41
11.6.2 Redundant CAN bus ............................................................................... 11:43
11.6.3 CAN bus, driveline/axle ........................................................................... 11:44

11:2

11 Common electrics – Common electrics 11:3
11 Common electrics
11.1.1 Hour meter
Hour meter, replacement, Spirit Delta
2 Remove the screws that hold the panel in place.

3 Lift away the panel.
008341
4 Unplug the connector from the operating time recorder.

5 Remove the two screws on the rear piece of the operating time
recorder.
6 Replace the hour meter.

11:4 11 Common electrics – Electric protection
11.2 Electric protection

11.2.1 Battery disconnector
Battery disconnector, description
The positive terminal of the series-connected batteries is connected
to the machine's electrical system via the battery disconnector. This is
used to cut off all power from the batteries to the machine's electrical
system.
IMPORTANT
Never switch off the voltage with the battery
disconnector when the engine is running. This could
damage the alternator.
The battery disconnector must not be used as control
breaker!
1
015376
1. Battery disconnector location
Battery isolator, replacement

2 Open the cover concealing the battery.
3 Disconnect the negative cable and then the positive cable from
the battery.
WARNING
Be careful to keep the positive and negative cables
apart to avoid short circuiting.

11 Common electrics – Fuses 11:5
4 Fold back the rubber protectors on the battery disconnector.

5 Remove the two nuts and release the cables from the battery
isolator.
015767 6 Remove the two screws which hold the battery isolator in the
bracket.
7 Replace the battery isolator.
015768
11.2.2 Fuses
Fuses, description
The main fuses splits the machine\qs voltage feed in smaller parts
to maintain as many functions as possible in case of damage in the
cabling.
Circuit fuses are grouped in fuse holders that are located in the
electrical distribution box in the cab.

11:6 11 Common electrics – Fuses
Fuses, changing
Checking and replacement of main fuses:
2 Remove the plastic cover.
3 Check and replace the fuses if necessary. The fuses are 25 A.
4 Switch on the system voltage again.
1
015670
1. Main fuses (25 A)

2. Battery disconnector
Checking and replacement of fuses:

2 Remove the cover over the electrical distribution box in the cab.
3 Remove the cover from the fuse holder.
4 Check that fuses are intact. Replace when needed.

The fuse plate gives information about each fuse.

11 Common electrics – Batteries 11:7
11.3 Batteries
11.3.1 Start battery
Start battery, description
The two series-connected batteries are located behind a cover lid (by
the fuel tank) on the left-hand side of the machine.
The battery's negative terminal is connected to the frame and the

positive terminal is connected to the battery isolator.
The batteries are charged by the alternator, see Alternator,

WARNING
Battery electrolyte contains corrosive sulphuric acid.
Risk of corrosive injuries! Health hazard!
Use protective glasses and protective gloves when
working with the batteries. Immediately remove any
electrolyte on bare skin. Wash with soap and plenty of
water. If the electrolyte has found its way into your
eyes, rinse immediately with lots of water and contact
a doctor immediately.
WARNING
015667
Risk of explosion!
Personal injury!
During charging, hydrogen gas forms around the
batteries. Sparks could ignite the hydrogen gas,
causing an explosion. Disconnect the battery with the
battery disconnector.
WARNING
Short-circuiting of battery.
Risk of explosion! Fire hazard! Risk of personal injury!
The battery's terminals must not be connected to each
other or to common grounding point (frame).

11:8 11 Common electrics – Start battery
Start battery, replacement

2 Disconnect the cables from the battery terminals. Disconnect the

negative cable first.
3 Replace batteries.
4 Connect the cables to the battery terminals. Connect the negative
cable last of all.
NOTE
Take great care when reconnecting the cables to prevent short
circuiting.
015667

11 Common electrics – Alternator 11:9
11.4 Alternator
11.4.1 Alternator
Alternator, description
The alternator generates current for the batteries during operation.
The alternator produces AC current and has an integrated charge
regulator.
The alternator is belt driven by the engine. Any faults are indicated
by the warning lamp for low battery charging.
014036
Alternator, replacement
See Supplier documentation for the engine.

11:10 11 Common electrics – Distribution of electricity
11.5 Distribution of electricity

Distribution of electricity, general
This section describes the distribution of electric power and
communication between the control units.
System communication has three main sections:

• Power supply of control units
• Redundant CAN bus communication (a control unit can drop away
without the system losing all functionality)
See Redundant CAN bus, description, page 11:43.
• CAN bus communication for drive train (the drive train has its own
communication system)
See CAN bus drive train (ECU 793, ECU 794), description, page
11:44.

11 Common electrics – Voltage feed 11:11
11.5.1 Voltage feed

1 3
S144
+ + 4
F51-1
M
2 6
M
F54-1 F54-2 F54-3 F54-4

G
7
10
12 8
K315-1,2
11
9
13
F58-1
015473
F58-2 F58-3 F58-4
1. Two series-connected 12 V batteries. 8. Fuse, power supply engine

2. Auxiliary start connector 9. Fuse, power supply after-treatment system
3. Battery disconnector 10. Main fuses
4. Hydraulic pump cab tilting 11. Ignition
5. Fuses, engine help function 12. Ignition relay
6. Starter motor 13. Fuses, fuse box
7. Alternator
11.5.1.1 Battery voltage, connection 30 voltage
Battery voltage, connection 30 voltage, description

The voltage before the ignition key lock is normally known as 30
voltage. The voltage is always approximately 24 V, even if the ignition
is switched off (ignition key lock in position 0).
This voltage is connected to the cab tilting pump (4), which means
that the cab can be tilted without having to switch the ignition on. The
voltage is supplied via fuses (5) to the engine's auxiliary functions, such
as pre-heating and fuel injection. The starter motor (5) and alternator
(6) are connected directly to the battery (via the battery disconnector).

11:12 11 Common electrics – Electronic box
11.5.1.2 Ignition voltage, connection 15 voltage

Ignition voltage, connection 15 voltage, description
The voltage after the ignition key lock is normally known as 15 voltage.
Voltage is only 24 V if the ignition is switched on (ignition key lock in
position 1). Otherwise, the voltage is 0 V.
The current is distributed by means of the ignition relay (12) and is then
transferred to the other functions in the machine via the four fuse boxes
(13) located in the distribution box behind the operator in the cab, see
Electrical distribution box, description, page 11:12.
11.5.1.3 Frame connections

Frame connections, description
Power supply takes place with cable harnesses (cables) which are
drawn across the machine.
A grounding point on the frame acts as a central ground connection,
also for the starter motor. From here the ground cable is routed to a
common point in the electronic box, to which the ground cables from
the electrical consumers are connected.
11.5.2 Electronic box

Electrical distribution box, description
The electronic box is located to the left behind the driver's seat in
the cab. The electronic box contains fuse holders, relays, diodes,
grounding points and terminal blocks.
All mini relays (20 A/10 A) and micro relays (10 A/5 A) have quenching
diodes. In addition to these there are two mini relays (40 A) which work
as main relays. The two main relays have no quenching diodes and
have slightly different contact pins compared with other relays.
All relays are the flat pin type relay. However, the size of the pin differs
between the different types (6.3 and 9.5 mm on the main relay, 6.3 mm
on other mini relays and 4.8 and 6.3 mm on the micro relay).
NOTE
Changing between relay types is not permitted.
Sockets for relays and terminal boxes.
4 Sockets for relays and terminal boxes.

2 1
A C 3 5 The sockets to relays and terminal boxes are shown in the illustration
1 2 6 4 as well as numbering and location of the different pins.
5 9 7
3 8
87 2 3
87A 1
B D 5
86 85 4 6
7 9
010673
30 8
Sockets seen from cable side with pin numbering for:

A Micro relay
B Mini relay
C Terminal box (socket housing)
D Terminal box (pin housing)

11 Common electrics – Electronic box 11:13
1 2 3 4 5 6 7
9 10 11 12 13 14 15
009109
16 17
Electronic box
In addition to the following positioning, see table Connecting terminal
boxes and Section E. Schedules under Common electrics, Component
list for post number etc.
1. Relay, interval wiper 10. Screw, holder and strap
2. Relay, ignition 11. Socket, relay 5-pin
3. Micro relays 12. Socket, relay 9-pin
4. Fuse holder 58-2 13. Blink module, 200 W, 24V
5. Fuse holder 58-3 14. Mini relay
6. Fuse holder 58-4 15. Fuse holder 58-1
7. Fuse holder 16. Cable shoe (to ground), washer and screw
8. Socket housing with 9 pins 17. Fitting plate
9. Circuit board with diodes

1 2 3 4 5 6 7
9 10 11 12 13 14 15
008571
16 17
Electrical distribution box, machine equipped with turnable driver's

seat option.
In addition to the following positioning, see table Connecting terminal
boxes and Section E. Schedules under Common electrics, Component
list for post number etc.
1. Relay, interval wiper 10. Screw, holder and strap
2. Relay, ignition 11. Socket, relay 5-pin
3. Micro relays 12. Socket, relay 9-pin
4. Fuse holder 58-2 13. Blink module, 200 W, 24V
5. Fuse holder 58-3 14. Mini relay
6. Fuse holder 58-4 15. Fuse holder 58-1
7. Fuse holder 16. Cable shoe (to ground), washer and screw
8. Socket housing with 9 pins 17. Fitting plate
9. Circuit board with diodes
Connecting terminal boxes

The following table describes the connecting terminal boxes numbered
in the illustration above the fuse box. (X is the sign for connecting
terminal box in the wiring diagram).
NOTE
The table shows all available functions. The functions used
on a specific machine may vary depending on which engine or
driveline/axle, control system and optional equipment the machine is
equipped with.

Number Main function Pin/Detailed function

X1 Cable cab - steering wheel 1. Gear selector
Gear selector 2. Gear selector
3. Optional forward/reverse selector, supply
4. Gear selector control, supply
5. -
6. Reverse
7. Neutral position
8. Forward
9. Forward/reverse control, supply
X2 Cable cab - steering wheel 1. Switch direction indicator, supply
Direction indicator/high-low beam 2. Direction indicator, left
3. Direction indicator, right
4. Switch headlamp flasher, supply
5. Switch high/low beam, supply
6. Low beam
7. High beam
8. -
9. -
X3 Cable cab - steering wheel 1. Lever for wiper, washer, horn, supply
Horn, windscreen wipers, windscreen washer 2. Horn, supply
3. Pump windscreen washer, supply
4. Interval windscreen wipers, supply
5. Relay windscreen wipers, supply
6. Forward/reverse alternative place standard lever,
supply
7. Forward/reverse alternative place
8. Warning lamp Air filter/exhaust filter (Unicat)
9. Forward/reverse alternative place
X5 Cable cab - right instrument panel 1. Switch lighting, supply
Switches lighting, hazard warning flasher, 2. Switch high/low beam, supply
actuator ventilation
3. Rear lights, position light, supply
4. Warning lamp, Hazard
7. Switch actuator ventilation, ground
8. Switch actuator ventilation
9. Switch hazard light before ignition, supply
X6 Cable frame 1. Direction indicator front left, supply
Lighting 2. High beam front, supply
3. Low beam front, supply
4. Reverse alarm front, supply
5. Direction indicator front right, supply
6. Position light front, supply
7. Rear light front, supply
8. Break light front, supply
9. Reverse alarm, ground


X7 Cable cab - steering wheel panel 1. Glow ignition signal
Ignition key lock, display 2. Start motor, signal
3. Ignition key lock, supply
4. Signal to main relay on/off
5. -
6. ECU 795, supply
7. -
8. -
9. Ignition key lock P-position
X8 Cable cab - left instrument panel 1. Indication central lubrication
Elevate/lower seat, working lights 2. Working lights roof, extra
3. Working lights roof, extra
4. Condenser unit, supply
5. Elevate/lower seat, ground
6. Elevate/lower seat, supply
7. Supply position (side) light
8. Work lights frame, signal
9. Switch work lights frame
X9 Cable cab - steering wheel panel 1. Switch rear intermittent wiper, supply
Rear and roof wiper 2. Switch rear wiper, supply
3. Switch rear intermittent wiper
4. Switch rear wiper
5. EDU 795, ground
6. Switch roof intermittent wiper
7. Switch roof wiper
8. Switch roof wiper, supply
9. Switch roof intermittent wiper, supply
X10 Cable cab - right instrument panel 1. Switch pause heater
Right instrument panel 2. Pause heater, signal
3. Motor seat up/down
4. Motor seat up/down
5. -
6. Hour counter, signal
7. Reverse alarm on/off
8. Reverse alarm on/off
9. Hour counter, ground
X11 Cable cab - steering wheel panel 1. Indicator light, high beam
Steering wheel panel 2. -
3. Indicator light direction indicator, supply
4. Indicator light, direction indicator
5. Indicator light high beam, ground
6. Inching on/off
7. Inching on/off
8. Warning lamp, charging
9. -


X12 Cable cab - front panel 1. Fan, supply
Fan, wiper motor front 2. AC on/off
3. Temperature sensor AC, signal
4. Condenser unit, FlexCab
5. Windscreen wiper front, ground
6. Windscreen wiper, front
9. Fan motor, ground
X13 Cable cab - left instrument panel 1. Switch working lights mast, supply
Left instrument panel: Work lights, seat 2. Switch working lights roof, supply
heating, revolving beacon
4. Working lights, mast
5. Working lights roof
6. Rotating hazard light on
7. Switch seat heating, supply
8. Seat heat
9. Switches lights, ground
X14 Cable cab - panel + seat 1. Switch parking brake
2. Parking brake, signal
3. Seat switch, signal
4. Parking brake, indication
5. Seat heating, ground
6. Seat switch, supply
7. Position switch, rotating driver seat forward
8. Seat heating, supply
9. Position switch, rotating driver seat rearward
X15 Cable cab - frame 1. Working lights mast, supply
Fuel and air filer sensors, washer pump, 2. Working lights mast, ground
working lights mast
3. Air filter sensor, ground
4. Solenoid valve for deactivation of hydraulics, ground
5. Washer pump, supply
6. Washer pump, ground
7. Solenoid valve deactivation of hydraulics
8. Air filter sensor
9. -
X16 Cable cab - frame 1. -
Gearbox 2. -
3. -
4. -
5. -
6. -
7. Speed sensor
8. Speed sensor
9. Speed sensor


X17 Cable cab ECU792 - frame 1. ECU 792, supply
Engine, transmission 2. -
3. ECU 792, supply
4. Travel direction selector (forward/reverse) on left
armrest on
5. -
6. -
7. -
8. -
9. ECU 792, ground
X18 Cable cab - frame 1. D+ from generator
Engine 2. Stop signal, engine (VOLVO)
3. Signal to hour meter
4. Ignition on
5. Starter motor signal
6. ECU 794 ground (VOLVO)
7. Feed ECU 794 (VOLVO)
8. -
9. Magnetic coupling AC
X19 Cable cab - frame 1. -
Actuator/water level 2. -
3. -
4. -
5. -
6. -
7. -
8. Coolant Level Switch
9. Coolant water level 5 V ref
X20 Cable cab - frame 1. PWM lift/down D796:K2.3, load
Electric servo 2. PWM Valves lift D796:K2.10, supply
3. PWM Lift/up D796:K2.4, load
4. PWM Tilt/out D796:K2.5, load
5. PWM Valves tilt D796:K2.10, supply
6. PWM Tilt/in D796:K2.6, load
7. PWM Side shift/left D796:K2.7, load
8. PWM Valves side shift D796:K2.10, supply
9. PWM Side shift/right D796:K2.8, load
X21 Cable cab - frame 1. PWM spreading/out D796:K2.11, load
Electric servo 2. PWM Valves fork position D796:K2.10, supply
3. PWM spreading/in D796:K2.12, load
4. PWM Option/out D796:K2.13, load
5. PWM Valves option D796:K2.10, supply
6. PWM Option/in D796:K2.14, load
7. -
8. -
9. -


X22 Cable cab - frame 1. Central lubrication
Central lubrication, rear main beams, alarm 2. Central lubrication
reverse driving
3. Central lubrication
4. Central lubrication, ground
5. High and low beam, VBFS rear, ground
6. Low beam VBFS rear, supply
7. High beam VBFS rear, supply
8. Alarm reverse driving, supply
9. Alarm reverse driving, ground
X23 Cable cab - frame 1. Direction indicator rear left, supply
Lighting 2. Brake lights rear, supply
3. Rear lights, supply
4. Ground
5. Direction indicator rear right, supply
6. Revolving beacon, supply
7. Working lights
8. Headlamps, ground
9. Frame working lights, ground
X24 Cable roof 1. Condenser, ground
Condenser, pressure sensor AC, roof wiper 2. AC, signal on
3. AC, supply condenser
4. Pressure sensor AC, supply
5. Pressure sensor AC, signal
6. Roof windscreen wiper
X25 Cable roof 1. Radio, 12 V supply
Radio, interior lightning 2. Radio memory, 12 V supply
3. Option
4. Option
5. Interior lightning cab, supply
6. Option
7. Option
8. Option
9. Radio, interior lightning, ground
X26 Cable roof 1. Extra working lights roof
Reversing light, working light roof, rotating 2. Extra working lights roof
beacon
3. Roof working lights, feed
4. Roof working lights, feed
5. Back-up lights
6. Revolving beacon
7. Option
8. Reversing light, ground
9. Working lights roof, ground


X27 Cable under cab 1. Compressor, supply (opt)
Compressor air supplied seat 2. Temp water, pause heat (opt)
3. Reverse, additional dir. selector (OPT)
4. Forward, additional dir. selector (OPT)
5. Supply, additional dir. selector (OPT)
6. Compressor, air supplied seat, ground
7. Switch Seat turned 40 deg (OPT)
8. Switch, Hydraulics disable (OPT)
9. Switch return, Hydraulics disable (OPT)
X28 Cable under cab 1. Pressure switch low brake pressure
Brake pressure, inching 2. Pressure switch low brake pressure, ground
3. Pressure switch brake pedal/inching
4. Pressure switch brake pedal/inching
5. Pressure switch brake pedal, brake light, supply
6. Pressure switch brake pedal, brake light
7. Brake light Hydrostatic drive
8. Brake light Hydrostatic drive
9. Horn, supply
X29 Cable under cab 1. Actuator ventilation, supply
Actuator ventilator, indicator turnable driver's 2. Ventilation actuator, ground
seat
3. Signal actuator, 0 V = rotating left, 24 V = rotating
right
4. Compressor horn, supply
5. Compressor horn, ground
6. Seat position potentiometer turnable driver's seat
9. Switch seat position turnable driver's seat
X30 Cable under cab 1. Valve Y636-1 steering forward, rotating driver's seat
Valves steering, valves rotating driver's seat, 2. Valve Y636-2 steering rearward, rotating driver's
pause heating seat
3. Valves Y636-1, Y636-2, ground
4. -
5. Brake rotating driver's seat
6. Brake rotating driver's seat
7. Water pump pause heating +
8. Water pump pause heating -
9. Water temperature sensor, pause heating
X31 Cable under cab 1. Potentiometer accelerator pedal, signal
Accelerator pedal standard and rotating 2. 5 V analogue reference accelerator pedal
driver's seat, idle switch
3. 0 V analogue reference accelerator pedal
4. Potentiometer brake pedal, signal
5. Accelerator pedal 2
6. Brake pedal channel 2
7. Brake pedal 2
8. -
9. -


X32 Cable frame 1. Solenoid valve parking brake
Parking brake, oil cooler, lifting height 2. Solenoid valve parking brake
3. Pressure switch, parking brake
4. Pressure switch, parking brake
5. Hydraulic oil cooler, temperature switch
6. Hydraulic oil cooler +
7. Hydraulic oil cooler -
X33 ECU 790 1. Gear changing 1:st
2. Gear changing 2:nd
3. Switch parking brake, signal
4. Parking brake pressure, signal
5. Inching/declutch
6. Reverse
7. Seat orientation, seat facing forward
8. Forward
9. Brake light hydrostatic transmission
X34 ECU 790 automatic gearing 1. Starter motor
2. Ignition shut off
3. Horn
4. Forward
5. Reverse
6. Seat contact
7. ECU 790, supply +24 V
8. ECU 790, supply +24 V
9. ECU 790, ground
X35 ECU 790 revolution sensor/high pressure 1. Revolution sensor, frequency input
sensor, hydrostatic transm./lift sensor
2. Revolution sensor, frequency 0 V reference
3. 5 V reference hydrostatic transmission high
pressure sensor
4. 0 V reference hydrostatic transmission high
pressure sensor
5. High pressure sensor forward
6. High pressure sensor reverse
7. Lift sensor 5 V reference
8. Lift sensor 0 V reference
9. Lifting lever sensor 0.5 - 4.5 V
X36 ECU 790 monitoring sensors 1. Fuel level
2. 0-reference rheostat
3. Hydraulic oil temperature
5. -
7. Outside temperature
8. -
9. Pressure sensor, lift cylinder


X37 ECU 790 1. Seat turned 40 deg.
2. -
3. -
4. -
5. -
6. Tilt pin sensor signal
7. -
8. -
9. -
X38 ECU 790 accelerator pedal 1. Accelerator
2. Brake pedal
3. Turn seat CW
4. Overload protection (opt)
5. Load cell right
6. 5 V reference
7. 0 V reference
8. Parking brake ON
9. Low rotation speed, seat orientation
X39 Hydraulic joystick 1. Hydraulic joystick, side shift
2. Hydraulic joystick, auxiliary function
3. Hydraulic joystick, fork spreading
4. Hydraulic joystick, side shift
5. Hydraulic joystick, auxiliary function
6. Hydraulic joystick, fork spreading
7. -
8. -
9. -
X40 ECU 790 monitoring scale 1. Turn seat CCW
2. Seat turned output
3. -
4. Low brake pressure
5. Coolant level
6. Back-up lights
7. Key position 3
8. 0 V reference
9. Load cell left
X41 ECU 792 joystick control/mini-wheel 1. Valve mini steering wheel right
2. Valve mini steering wheel left
3. Valve mini steering wheel right
4. Position steering axle
5. Position steering axle 5 V analogue reference
6. Position steering axle 0 V analogue reference
7. Valve mini steering wheel left
8. -
9. -


X42 ECU 792 joystick control/mini-wheel 1. Position of linear lever ECU 792: K1:31
2. Position of linear lever 5 V ref ECU 792: K1:1
3. Position of linear lever 0 V ref ECU 792: K1:14
4. Mini-wheel channel A
5. Mini-wheel channel B
6. Indicator guide wheel
7. Indicator guide wheel, supply
8. Indicator guide wheel, ground
9. -
X43 ECU 790 joystick control/mini-wheel 1. Switch horn, supply / switch alternative steering,
mini-wheel
2. Spreading/spreading input ECU 790:k1:20
3. 5th function pos input ECU 790:k1:21
4. Switch forward/reverse selector 3 forward
5. Switch forward/reverse selector 3 reverse
6. Horn
7. Indication lamp mini-steering On/off, ground
X44 ECU 793 1. ECU 793, Supply
2. ECU 793, Supply
3. -
4. -
5. -
6. -
7. ECU 793, ground
8. ECU 793, ground
9. ECU 793, ground
X45 ECU 790 1. -
2. -
3. -
4. -
5. -
6. -
7. Speed sensor, supply
8. 0 V reference K2:2
9. Speed sensor K2:1
X46 ECU796 electrical servo linear levers 1. Linear lever lift D796:K1.9, signal
2. Linear lever tilt D796:K1.10, signal
3. Linear lever side shift D796:K1.11, signal
4. Linear lever fork position D796:K1.12, signal
5. Linear lever optional hydraulic function D796:K1.13,
signal
6. Linear lever 10V analogue reference D796:K1.27
7. Linear lever 0V analogue reference D796:K1.26
8. Emergency stop hydraulic functions, supply
9. Emergency stop hydraulic functions


X47 Supply ECU 796, paper functions, electronic 1. D796:K1.1, supply +24 V
scale
2. Emergency stop hydraulic functions, supply
3. CAN D796:K1.7, supply +24 V
4. -
5. Stop lowering sensor, ground
6. Switch paper functions, supply
7. D796 K1:30 Hydraulics disable
8. D796:K2.1, ground
9. D796:K1.14/K1.28, ground
X48 Cable panels 1. 12 V
2. Ground
3. Reading-lamp
4. 12 V before ignition
5. 12 V
6. AC compressor ECC
9. Ground
X49 Not used 1. -
2. -
3. -
4. -
5. -
6. -
7. -
8. -
9. -
X50 Cables converter, rear wipers 1. Rear windscreen wipers
2. Rear windscreen wipers
3. Rear windscreen wipers
4. Rear windscreen wipers, ground
5. 12 V converter, supply
6. 12 V converter, ground
7. 12 V
8. -
9. -
X51 ECU 792 joystick control/mini-wheel 1. -
2. Mini-wheel/Joystick control on/off ECU 792:K1:2
3. Gear up ECU 792:K1:4
4. Gear down D792:K1:5
5. -
6. -
7. -
8. Alternative steering on ECU 792:K1:40
9. -


X52 Electronic scale 1. Scale, supply
2. Scale, signal left
3. Scale, 0 V reference
4. Motor elevate/lower seat column
5. Motor elevate/lower seat column
6. -
7. -
8. -
9. Scale, signal right
X53 Steering wheel panel 1. -
2. Seat turn CCW
3. Seat turn CW
4. Switch seat rotation supply
5. -
6. -
7. -
8. -
9. -
X54 Electric motor seat turning 1. Low speed
2. CW
3. CCW
4. -
5. Supply turning motor
6. -
7. -
8. -
9. -
X60 Supply cab 1. Supply 24 V
2. Supply 24 V
3. Supply 24 V
4. Supply 24 V
5. Ground
6. Ground
7. Ground
8. Ground
9. Supply 24 V
X70 ECU 796 paper functions 1. Switch paper functions, supply +24V
2. -
3. Switch automatic clamping D796:1.36
4. Switch shift hydraulic function D796:1:40
5. Switch vertical positioning D796:1.32
6. Switch locking upper arm D796:1.37
7. -
8. -
9. -


X71 ECU 796 indicator lights, sensor tilt 1. Indicator light, paper handling unit K2:10, supply
angle/elevation height
2. Red Lamp D796:K3:14
3. Yellow lamp D796:3:13
4. Green lamp D796:3:12
5. 0 V analogue reference sensor tilt angle/elevation
speed K1:26
6. 10 V analogue reference sensor tilt angle/elevation
speed K1:27
7. Side shift/upper arms up/down D796:K3:15
8. Analogue input elevation height K1:16
9. Analogue input tilt angle K1:17
X72 ECU 796 pressure sensor paper handling unit, 1. Pressure sensor, paper handling unit, supply
switch extender
2. Pressure right clamp P1
3. Pressure right clamp P2
4. Pressure sensor, paper handling unit, ground
5. Extender inner position
6. Pressure left clamp P2
7. Pressure left clamp P1
8. Valve, upper arms off
9. Supply valve, upper arms off
X73 ECU 796 switch preselection elevation height 1. Switch preselection elevation height, supply
2. Switch preselection elevation height D796:1.31
3. Increase preselected elevation height D796:1.33
4. Decrease preselected elevation height D796:1.34
5. Switch clamping pressure K1:22
6. 10 V reference switch clamping pressure K1:27
7. 0 V reference switch clamping pressure K1:26
8. -
9. -
X74 ECU 796 sensor lowering stop 1. Sensor, lowering stop, supply +24 V
2. Sensor, lowering stop K1:41, signal
3. Valve, extender/rotation, side shift/rotation
4. Sensor, lowering stop, ground
5. Valve clamp pressure 1
6. Supply clamping valves
7. Laser
8. Supply laser, switch hydraulic functions
9. Valve clamp pressure 2
X75 ECU 790 Seat rotation 1. 5 V ref K1:35
2. Input, seat position K1:37
3. 0 V ref K1:36
4. Output, seat turning brake
5. Input, seat turn CCW
6. Input, seat Turn CW
7. Right Pedal 40/180 deg
8. Left pedal channel 2
9. Left pedal 40/180 deg

11 Common electrics – Control units 11:27

X77 ECU 796 key switch forced handling, paper 1. -
functions
2. Key switch forced handling paper functions, supply
3. -
4. -
5. -
6. -
7. Key switch, forced handling
8. -
9. -
X81 Cable, roof working lights 1. -
2. -
3. Reversing light left
4. Reversing light right
5. Revolving beacon roof, ground
11.5.3 Control units

Control units, location
1 2 3 4
5
014465
1. Steering control unit (ECU 792) 4. Control unit terminal (EDU 795)
2. Control unit hydraulics (ECU 796) 5. Transmission control unit (ECU 793)
3. Control unit general (ECU 790) 6. Control unit engine (ECU 794)

11:28 11 Common electrics – Control units
11.5.3.1 Control unit terminal (EDU 795)
Control unit terminal (EDU 795), description

The terminal, which comprises a display and function keys located on
the steering wheel panel, is program controlled and can carry out most
individual functions depending on the program it is equipped with.
The display is a graphical LCD display with a resolution of 128 * 64

points and with background lighting.
F
Beside the display are ten red LEDs that are connected together.
N They used to alert the operator that there is new information on the
R display.
R To enable management of the system are six function keys.

1 2 3
008884
4 5
Control unit terminal (ECU 795), specification

PIN-out (connections)
Contact: Number Type of input/output Function

K1:1 RS232 0-ref RS232 0-ref
K1:2 RS232 RxD RS232 RxD
K1:3 RS232 TxD RS232 TxD
K1:4 CAN Shield CAN Shield
K1:5 CAN 2 - CAN 2 low (J1939)
K1:6 CAN 2 + CAN 2 high (J1939)
K1:7 + 24 V, CPU Right + 24 V Right (Battery +24V)
K1:8 + 24 V, CPU Left + 24 V Left (Battery +24V)
K1:9 Power supply 0 V Battery minus
K1:10 CAN 1 DATA, - Right Redundant CAN - right
K1:11 CAN 1 DATA, + Right Redundant CAN + right
K1:12 CAN 1 DATA, - Left Redundant CAN - left
K1:13 CAN 1 DATA, + Left Redundant CAN + left
K1:14 Digital output (buzzer) Buzzer
NPN
Control unit terminal (EDU 795), replacement

2 Transfer using the Kalmar Smart Link parameters from the old
display before it is removed. More information about Kalmar
Smart Link is available under section 8 Control system, group
8.6 Software.
3 Remove the centre cover from the steering wheel.
4 Remove the steering wheel and steering panel covers, see section
lever, replacement.
5 Unplug the connector from the terminal.

6 Remove the two screws securing the terminal to the steering

wheel cover.
7 Replace the terminal.
9 Download parameters and software to the new display, using
Kalmar Smart Link.
NOTE
After the replacement of EDU 795, the correct program must be
downloaded with Kalmar Smart Link. All parameters must be
downloaded (with settings and calibrations). Contact Cargotec
for information.
11.5.3.2 Control unit general (ECU 790)
Control unit general (ECU 790), description

Indication lights, general control unit (ECU 790)
Control unit general (ECU 790) is located next to the electrical
A B C D
distribution box behind the operator in the cab.
The indication lamps have the following meanings:
Table Indication lights, general control unit (ECU 790)

ECU 792 ECU 796 ECU 790
Green (Power) Battery voltage OK
Green (System) Internal 5 VDC OK
Amber (Mode) Software check, flashes 0.5 Hz if the program is
0007760
OK, flashes 5 Hz if no program is downloaded,

fixed light glow if set-up mode
Red (Status) Activated if error occurs.
A ECU 792
B ECU 796
C ECU 790 Functions in KCS:
D Electronic box • Monitoring

• ETC (Electronic Throttle Control) - Used for/by Monitoring
functions (rpm limitation), for hydrostatic drive
• Scale
• Rotating driver's seat
• Automatic engine stop 5 minutes after the driver's seat is vacated
(five minutes is the normal default setting, but the time can be
changed by a service technician authorised by Kalmar).
Control unit general (ECU 790), specification


K1:1 Analogue in +24 V Battery +24V, 16 - 36 V
K1:2 CAN DATA, + Left Redundant CAN + left
K1:3 CAN DATA, - Left Redundant CAN - left
K1:4 CAN DATA, + Right Redundant CAN + right
K1:5 CAN DATA, -Right Redundant CAN - right
K1:6 CAN Shield CAN Shield


K1:7 +24V Redundant power Redundant feed left
supply
K1:8 +24V Redundant power Redundant feed right
supply
K1:9 Digital input Gear selector input 1 / Brake active (2-pedal hydrostatic)
K1:10 Digital input Gear selector input 2 / side shift, pressure switch F3 active
(hydrostatic)
K1:11 Digital input Switch, turnable driver's seat (reverse)
K1:12 Digital input Forward direction selector lever
K1:13 Digital input Reverse direction selector lever
K1:14 Digital input Parking brake, sensor pressure switch, 0V = parking brake active, 24V
= parking brake released
K1:15 Digital input Declutch / Tilt, pressure switch F2 active (hydrostatic)
K1:16 Digital input Speed limitation 2, 0V = activated, 24V = inactivated
K1:17 Digital input Ignition key lock position 3, start
K1:18 Digital input Operator's seat turned 40 degrees / Turnable driver seat button CCW
(forward)
K1:19 Digital input Seat sensor, NC or NO logic, programmed with Kalmar Smart Link
K1:20 Digital input Spreading, pressure switch F4 (hydrostatic)
K1:21 Digital input End position damping, Fork function 5 pressure switch (hydrostatic)
K1:22 Digital input Low brake pressure, sensor accumulator tank
K1:23 Digital input Switch for parking brake, 0V = parking brake active, 24V = parking
brake released
K1:24 5 V ref 5 V ref
K1:26 Analogue input 0-5V Right pedal (throttle pedal)
K1:27 Analogue input 0-5 V Left pedal (throttle/brake)
K1:29 Analogue input 0-5 V Scale, chain tensioner left
K1:30 Analogue input 0-5 V Scale, chain tensioner right
K1:31 Analogue input 0-5 V Power cell, shaft tilt cylinder
K1:37 Analogue input 0-5 V Turnable driver seat sensor position 0-5V (Spirit Delta Space)
Turnable driver seat position, resistor network 4.5-2.5-0.5V (Spirit
Delta)
K1:38 Analogue input 0-5 V 0 V = normal level, 5 V = low level
K1:39 Analogue input 0-5 V Right pedal (throttle pedal)
Turnable driver's seat (180) / turnable driver's seat (40)
K1:40 Analogue input 0-5 V Left pedal (throttle/brake)
Turnable driver's seat (180) / turnable driver's seat (40).
Inching with turnable driver's seat (40).
K1:41 Analogue input 0-5 V Left pedal channel 2, ZF inching sensor
K1:42 Analogue input 0-5 V
K2:2 0V pulse 0 V Pulse in
K2:4 0V pulse 0 V Pulse in


K2:5 Encoder channel A
K2:6 Encoder channel B
K2:7 0 V pulse encoder
K2:8 Rheostat (0-200 Ohm) Fuel level, LPG level
K2:9 0V 0 V rheostat in
K2:10 Digital output 1-255 min stop, 24V for stop on.
The conditions are that the parking brake switch is on and the seat
sensor is not operated.
K2:11 Digital output Motor turnable driver seat, CCW (forward)
K2:13 Digital output Hydraulic motor PDC
K2:14 Digital output Parking brake valve, 24V = released parking brake
K2:15 Digital output
K2:16 RS232 RX Programming port, D-sub 9 pin
K2:17 RS232 TX Programming port, D-sub 9 pin
K2:18 RS232 0V Programming port, D-sub 9 pin
K2:19 Temperature/Analogue
input
input
K2:21 Temperature/Analogue Temperature, hydraulic oil
input
input
K2:23 PWM low side driver Turnable driver seat, low speed
(mA)
K2:24 PWM low side driver Turnable driver seat, high = brake released
(mA)
K2:25 PWM high side driver Pump forward EDC
(mA)
K2:26 PWM high side driver Pump reverse EDC
(mA)
K2:27 PWM low side driver Hydraulic motor PDC
(mA)
K2:28 PWM low side driver
(mA)
K2:29 Digital output Motor turnable driver seat, CW (reverse)
K2:30 Analogue output Spare, Sauer-Danfoss valve
K2:31 Analogue output Spare, Sauer-Danfoss valve
K2:33 Not used
K2:34 Not used
K2:35 Not used
K2:36 Not used
K2:37 Not used
K2:38 High driver digital out Turnable driver seat, forward position
K2:39 High driver digital out Start motor activated when 24V


K2:40 High driver digital out Back-up lights
K2:41 High driver digital out Turnable driver seat, reverse position
K2:42 Battery 0 V
Control unit general (ECU 790), replacement

2 Remove the covers behind the driver's seat.
3 Transfer using the Kalmar Smart Link parameters from the existing
control unit before it is removed. More information about Kalmar
8.6.1 Kalmar Smart Link.
4 Unplug the connectors from the control unit.
5 Remove the two screws securing the control unit.

6 Replace the control unit.
8 Download parameters and software to the new control unit, using
Kalmar Smart Link.
NOTE
After the replacement of ECU 790, the correct program must be
for information.

11.5.3.3 Control unit hydraulics (ECU 796)
Control unit hydraulics (ECU 796), description

Indicator lights control unit ECU 796
Control unit hydraulics (ECU 796) is located next to the electrical
A B C D
distribution box the operator in the cab.
Table Indicator lights control unit ECU 796

ECU 792 ECU 796 ECU 790
All LEDs give constant light for 3 seconds when started up.
Green Power, constant light at 22-28 VDC, flashing
outside these limits
0007760
Amber CAN bus communication and application OK
Red Flashes if the supply voltage to the PWM board is
less than 12 VDC.
A ECU 792
B ECU 796
D Electronic box • Electric servo
Hydraulics control unit (ECU 796), specification


K1:1 Voltage feed Battery +24V, 16 - 36 V
K1:2 CAN DATA, + Left Redundant CAN + left
K1:3 CAN DATA, - Left Redundant CAN - left
K1:4 CAN DATA, + Right Redundant CAN + right
K1:5 CAN DATA, -Right Redundant CAN - right
K1:6 CAN, 0 - Ref CAN Shield
K1:7 Redundant feed Redundant feed left +24 V
K1:8 Redundant feed Redundant feed right +24 V
K1:9 Analogue input 1, 0-10V Hydraulic function 1 / Joystick left y-coordinate
K1:10 Analogue input 2, 0-10V Hydraulic function 2 / Joystick left x-coordinate
K1:11 Analogue input 3, 0-10V Hydraulic function 3 / Joystick right y-coordinate
K1:12 Analogue input 4, 0-10V Hydraulic function 4 / Joystick right x-coordinate
K1:13 Analogue input 5, 0-10V Hydraulic function 5
K1:14 Battery 0 V Battery 0 V
K1:15 Battery +24 V Battery +24 V
K1:16 Analogue input 5, 0-10V Lift height
K1:17 Analogue input 6, 0-10V Tilt angle
K1:18 Analogue input 7, 0-10V Clamping pressure P1 right
K1:19 Analogue input 8, 0-10V Clamping pressure P2 right
K1:20 Analogue input 9, 0-10V Clamping pressure P1 left
K1:21 Analogue input 10, 0-10V Clamping pressure P2 left
K1:22 Analogue input 11, 0-10V Chosen clamping pressure 1, 2, 3, 4
K1:23 Temperature input 1 Not used


K1:26 0-Ref output Not used
K1:27 Ref +10V Not used
K1:28 Battery 0-Ref Not used
K1:30 Digital input 1 Control breaker
K1:31 Digital input 2 Lift height preselection (PLH) ON/OFF
K1:32 Digital input 3 Vertical hold ON/OFF
K1:33 Digital input 4 Increase lift height preselection (PLH)
K1:34 Digital input 5 Decrease lift height preselection (PLH)
K1:35 Digital input 6 Joystick T1-1 switch for 5:th function
K1:36 Digital input 7 Automatic clamping/opening
K1:37 Digital input 8 Upper arm locked
K1:38 Digital input 9 Extender in inner position
K1:39 Digital input 10 Override all paper functions
K1:40 Digital input 11 Shift hydraulic functions: Side shift to lifting/lowering upper arm
pair, side shift or extender to rotation
K1:41 Digital input 12 Optic stop lower sensor attachment, paper function
K1:42 Not used Not used
K2:1 Battery 0-Ref Voltage feed, 0 V
K2:3 PWM low-side driver out 1 Valve hydraulic function 1A/Lower
(mA)
K2:4 PWM low-side driver out 2 Valve hydraulic function 1B/Lift
(mA)
K2:5 PWM low-side driver out 3 Valve hydraulic function 2A/Tilt out
(mA)
K2:6 PWM low-side driver out 4 Valve hydraulic function 2B/Tilt in
(mA)
K2:7 PWM low-side driver out 5 Valve hydraulic function 3A/Side shift left
(mA)
K2:8 PWM low-side driver out 6 Valve hydraulic function 3B/Side shift right
(mA)
K2:9 24 V in Voltage feed, 24 V DC (in to ECU, PWM section)
K2:10 24 V out Voltage feed, 24 V DC (out to valves)
K2:11 PWM low-side driver out 7 Valve hydraulic function 4A/spreading out
(mA)
K2:12 PWM low-side driver out 8 Valve hydraulic function 4B/spreading in
(mA)
K2:13 PWM low-side driver out 9 Valve hydraulic function 5A/Extra 5A
(mA)
K2:14 PWM low-side driver out 10 Valve hydraulic function 5B/Extra 5A
(mA)
K2:15 PWM low-side driver out 11 P&P valve upper arms shut off
(mA)
K2:16 PWM low-side driver out 12 -
(mA)


K3:1 Battery 0-Ref Voltage feed, 0 V
K3:3 Desired current value Clamping pressure valve 1, current
K3:4 Desired current value Start pump, digital output (ECE 50-90)
K3:5 Desired current value Pump speed via converter 24/10V (ECE 50-90)
K3:6 Desired current value Speed limitation (ECE 50-90)
K3:7 Desired current value Driving interlock (ECE 50-90)
K3:8 Desired current value Laser
K3:9 24 V in Voltage feed, 24 V DC (in to ECU, PWM section)
K3:10 24 V out Voltage feed, 24 V DC (out to valves)
K3:11 PWM desired current value Clamping pressure valve 2, current
K3:12 PWM desired current value Green lamp, clamping pressure OK
K3:13 PWM desired current value Yellow lamp, vertical hold
K3:14 PWM desired current value Red lamp (overload, extender out, override etc.)
K3:15 PWM desired current value Valve shift side shift to lifting/lowering upper arm pair
K3:16 PWM desired current value Valve shift side shift or extender to rotation
Control unit hydraulics (ECU 796), replacement



Kalmar Smart Link.
NOTE
for information.
11.5.3.2 Control unit steering (ECU 792)

Control unit steering (ECU 792), description
Indicator lights, control unit ECU 792
Control unit steering (ECU 792) is located next to the electrical
A B C D
distribution box behind the operator in the cab.
Table Indicator lights, control unit ECU 792

ECU 792 ECU 796 ECU 790
Green (Power) Battery voltage OK
Green (System) Internal 5 VDC OK
Amber (Mode) Software check, flashes 0.5 Hz if the program is
0007760
OK, flashes 5 Hz if no program is downloaded,

fixed light glow if set-up mode
Red (Status) Activated if error occurs.
A ECU 792
B ECU 796
D Electronic box • Joystick control with feedback

• Joystick control without feedback
• Mini-wheel
Control unit steering (ECU 792), specification


K1:2 Digital input 0 Mini-wheel/joystick control on/off
K1:3 Digital input 1 Sensor, steering wheel movement (for joystick control/mini-steering
wheel)
K1:4 Digital input 2 Upshift gear (manual shifting)
K1:5 Digital input 3 Downshift gear (manual shifting)
K1:6 PWM high side driver Steering valve, right


K1:7 PWM high side driver Steering valve, left
K1:8 Analogue input 2, Feedback current Steering valve, right
config 1= 0-3030mA
K1:9 Analogue input 3, Feedback current Steering valve, left
config 1= 0-3030mA
K1:10 Analogue input 2,
Config 0=0-5V Config
2= 0-152mA
K1:11 Analogue input 3,
Config 0=0-5V Config
2= 0-152mA
K1:12 Frequency input 4
K1:13 RS232 0V Serial port 0V, D-sub 9 pin, pin 5
K1:15 Battery 0 V Battery 0 V
K1:20 RS232 Tx Serial port Tx, D-sub 9 pole pin 3
K1:21 RS232 Rx Serial port Rx, D-sub 9 pole pin 2
K1:22 PWM output 2
K1:23 Analogue input 4, 0-5V
K1:24 PWM output 3
K1:26 PWM output 4
K1:27 PWM output 5
K1:28 Battery +24 V
K1:29 Battery 0 V
K1:30 Reference thermistor
K1:31 Analogue input 6, 0-5V Joystick
K1:32 Analogue input 7, 0-5V Sensor, steering axle
K1:35 Analogue 8, 0-5 V Mini-wheel potentiometer sensor channel A
K1:36 Analogue 9, 0-5 V Mini-wheel potentiometer sensor channel B
K1:37 CAN High CAN bus high +
K1:38 CAN Low CAN bus low -
K1:39 CAN screen 0V
K1:40 Digital output 0 Mini-wheel/joystick control and lamp on
K1:41 Digital output 1
K1:42 Battery +24 V Battery +24 V

Control unit steering (ECU 792), replacement


Kalmar Smart Link.
NOTE
for information.
Transmission control unit (ECU 793), description

See section 2 Transmission, group 2.8.1 Transmission control unit
(ECU 793).
Control unit engine (ECU 794), description

See section 1 Engine, group 1.9.1 Control unit engine (ECU 794).

11 Common electrics – Operation, electrical system 11:39
11.5.4 Operation, electrical system

Operation, electrical system, description
The fuse box and supply to the circuits are activated when the ignition
key lock is turned to ignition position.
11.5.5 Cable harness

Cables, description
The cables are drawn in a cable harness along the side of the frame
and held in place with straps and rubber clamps.
There are very few joints in the cables between the consumers and the
fuse box. The intention is to reduce the risk of faults.
Connectors, description
See Electrical distribution box, description, page 11:12.

11:40 11 Common electrics – Communication
11.6 Communication
Communication, description
The central components in the bus communication are the control
units that manage the control of machine functions. These units work
together and all communication, control signals or signal information is
sent via data buses.
The premise behind the bus network is that a signal is sent out by a
transmitter and that the control units requiring information consider it.
Connection is suitably performed with a 2-lead pair-twisted bus cable

with impedance of 120 Ohm (30 winding/metre).
CAN J1939 250kb/s
CAN H CAN H
120 Ohm*
ECU 793 ECU794
TRANSMISSION ENGINE
CAN L CAN L
CAN L CAN H
K1:5 K1:6
K1:13 L+ K1:10 R-
EDU 795
TERMINAL
K1:12 L- K1:11 R+
K1:4 R+ K1:5 R- K1:2 L+ K1:3 L-
RED CAN 125kb/s

K1:2 L+ K1:4 R+
ECU 796 ECU 790

HYDRAULIC GENERAL
K1:3 L- K1:5 R-
K1:37 + K1:38 -
ECU 792
008448
STEERING
* The built-in resistor in control unit engine (ECU 794) is used in some
engines.

11 Common electrics – CAN bus 11:41
11.6.1 CAN bus

CAN bus, description
1 2 Communication between the control units takes place using so-called
"CAN buses" (Controller Area Network) based on the ISO 11898
standard and CAN specification 2.0B.
The CAN bus is a fast control bus with logical hardware circuits. A
120 ohm 120 ohm
simple technology that is highly reliable (low error frequency), which
is a requirement for control signals to be able to regulate systems
based on varying conditions and requirements.
CAN specifies:
5 5 • that the signal traffic is carried by "twisted pair" cables.
3 • that termination resistors (position 1) are necessary (adapted to
4 cables' impedance) so that the pulse train (position 4) should
obtain a sharp signal.
2
U [V]
• that the signal valve is given as the potential difference between

the cables, CAN + and CAN - (position 2 and 3).
3 • form of signal messages.
000026
t [S]
Messages are sequential and signal is high (voltage

high) or low (voltage low).
1. Termination resistor (120 ohm)
2. CAN + (voltage high)
3. CAN - (voltage low)
4. Pulse
5. Control unit
Message
Message
A
There are two types of messages:
• CAN Standard, has identity field of 11 bits
B C D E F G • CAN Extended, has identity field of 29 bits
000027
t [S] CAN works in messages sent in frames of 8 bytes (64 bits). A

complete message is approx. 100 bits long. The illustration depicts
Messages are sequential and signal is high (voltage how a message is structured.
high) or low (voltage low).
Start bit (B)
A Length message
B Start bit Indicates that the transmission of a frame, i.e. a message, is now
beginning.
C Identity field/Priority
D Control field (length of data segment) Identity field (C)
E Data segment Indicates what kind of information the message contains, e.g.
F Checksum for error detection measurement information on engine speed.
G Acknowledge bit Does not indicate address to control unit. CAN does not work with
addressing. All control units receive messages and send them on.
Control field (D)
Indicates how the length of the data segment that follows.
Data segment (E)

Contains the information to be conveyed to control units in the network.
Checksum for error detection (F)
Calculates a checksum for the message. This makes it possible for the
receiving control unit to detect errors in the sent message.

11:42 11 Common electrics – CAN bus
Acknowledge (G)
The transmitting control unit sets a bit to logical one (1) when the
message is sent. The first control unit to receive the message sends it
on and sets the bit to logical zero (0).
Communication
Communication
The CAN network consists of control units and segments. The

segment (bus) is a twisted pair cable that leads CAN + and CAN -
signal levels from control unit to control unit.
3,5 V
Each control unit measures the potential difference of its two inputs.
The potential difference generates logical zero and logical one. The
illustration depicts an approved interval according to the standard for
U [V]
potential levels. CAN + has a recommended value of 3.5 V and CAN

0,5 V - has 1.5 V. As a worst case scenario, the potential difference can be
only 0.5 V and still be approved. In practice, a potential difference of
2 V is recommended for reliable communication.
1,5 V A pulse train can only be observed using an oscilloscope, NOT with
a digital multimeter.
When a message is sent, all control units in the network listen.

Messages are saved in the control unit and relevant information is
000028
processed. The control unit that receives the message first confirms
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
listen and wait until the bus is available. If two messages are to be
sent simultaneously then the sending of the message with the lowest
priority (highest value in identity field) is concluded. This means that
messages do not need to be re-sent in the event of a communication
conflict but only in the event of a bus error (erroneous message).
The CAN bus exchanges around 100 messages per second in the
network.
Different bus systems can be used e.g. random sending or primary

(master) / secondary (slave).
HLP High Layer Protocol

CAN only specifies messages and how communication shall take
place, i.e. one protocol. In order to manage the network the CAN
protocol needs to be supplemented by a HLP which specifies:
• flow control
• transport of data above a length of 8 bits in 8 bit messages
(division)
• how control units are addressed in the network
• how bits in the message's data field should be interpreted

11 Common electrics – Redundant CAN bus 11:43
11.6.2 Redundant CAN bus

Redundant CAN bus, description
Communication between ECUs is managed by a so-called "redundant
CAN bus system", which is a network for managing different nodes of
different types in a common CAN bus system.
The network is based on one node being central, in this case EDU
795, and the controlling unit (master). Other nodes in the network are
secondary (slaves) and manage dedicated areas e.g. hydraulic units.
A condition for communication is that the ignition voltage is active.
The following occurs:

• Most suitable route for an enclosed communication system is
analysed.
• Communication is established segment for segment.
NOTE
The number of active segments depends on the number of control
units that are active in the machine in question, which depends on
the machine's equipment level (option).
• Termination resistors in the control nodes ensure communication

segment by segment. This is indicated as a rapid clicking sound
when starting (key to position I in the ignition key lock) that can be
heard in the operator's station.
• When all nodes and segments have closed loops then the
communication is established in the system.
The communication loop can be disrupted by cable damage for

example, and then communication is established via an alternative
route (not applicable to ECU 793 and ECU 794). At the same time an
exclamation mark in the panel for warning and indicator lights indicates
that the communication loop is broken in some segment.
The control system can manage the loss of one segment (not
applicable to ECU 793 and ECU 794). If several segments fail
then one or several of the communication nodes are lost and work
independently, but usually with limited capacity to perform their
function. This is indicated by an error code in the display (EDU 795).

11:44 11 Common electrics – CAN bus, driveline/axle
Technical specification:
• 11 bit identity field
• 125 kbit/s
• Termination 120 Ohm (in the ECUs)
11.6.3 CAN bus, driveline/axle

CAN bus drive train (ECU 793, ECU 794), description
E G The drive train CAN bus is based on the SAE J1939 standard where
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.
EDU 795 D F
The engine and transmission control units come from the respective
engine and transmission suppliers.
The machine can be ordered with different models of gearbox and

with different engine alternatives. These alternatives use the standard
and therefore the messages for each variant are built up on the same
structure.
A condition for communication is that the ignition voltage is active.
The following occurs:

• Control units are started
010643
• The CAN bus is ready for communication

A B C
Technical specification:
A Redundant CAN bus
• 29 bit identity field
B CAN bus drive-train
• 250 kbit/s
C Termination resistor (120 ohm)
• Termination 120 Ohm (in wiring network)
D Control unit, engine
E Engine control
F Control unit, transmission
G Transmission control

D:1
D Error codes
Contents D Error codes

D Error codes ........................................................................................................ D:3
1 Engine................................................................................................................. D:8
2 Transmission ................................................................................................... D:30
8 Control system ................................................................................................ D:52
9 Frame, body, cab and accessories ................................................................ D:61
9.4 Heating, ventilation and air conditioning ....................................................... D:61

D:2

D Error codes – Error codes D:3
D Error codes
Error codes, explanation
The error codes are explained in table form for Engine, Transmission
as well as Control system. They are sorted according to error code
number.
The error code table has the following information:

• Code, error code\qs number, shown in field C on display.
C • Description, explanation of the error code and when it\qs
generated.
D E
• Limitation, in case of certain error codes certain functions are
impaired or limited to protect the machine and operator.
B
000389
• Action, information of what should be checked to find the cause

of the error code.
B. Error code level (symbol)
C. Error code number
D. Error cause (symbol)
E. Function (symbol)

D:4 D Error codes – Error codes
Error code menu, description

The control and monitoring system's display is divided into four fields
C where the information is shown (see figure to the left).
• Field B: Error code level is shown with a symbol.
D E
• Field C: Shows error code.
B • Field D: Shows type of error.
000389
• Field E: Indicates which function is affected by error code.
• Book symbol means that information is available in the operator's
manual.
Field B: Error code level
Field B: Error code level
C
The control and monitoring system gives error code information in
D E three levels which are indicated with a symbol in the lower left corner
(B) on the display unit.
• Stop
000350
Indicates a serious malfunction that may jeopardise the operator's

safety or cause machine failure. The error code must be rectified
immediately. Stop working with the machine and contact service
immediately.
The error code is shown automatically on the display.
• Warning
C Indicates malfunction in machine that should be taken care of as
soon as possible. After the finished work shift with the machine,
D E contact service as soon as possible.
The error code is shown automatically on the display.
000351
• Information
C Information for the operator that something should be taken care
of, for example, low fuel level. Rectify the cause of the error code
D E as soon as possible.
000352
Field C: Error code number

Field C: Error code number
C
The control and monitoring system gives error codes from three
D E sub-systems:
• Machine:
B
000389
Shown with error code number XXX on display.
• Engine
XX/YY Shown with code 1200 and error code number SPN: XXX and
FMI: XXX (position D) in display. SPN means Suspect Parameter
D Number and is an indication of the failed component and FMI
means Failure Mode Identifier and are an indication of what type
of fault the component have.
B
001343
NOTE
If several error codes are generated from the motor then these are
shown as rolling, i.e. all active error codes are displayed with about
a 1 second interval in the same field.

• Transmission:
XXX/YY Shown with code 900 and error code number SPN: XXX and
FMI: XXX (position D) in display. SPN means Suspect Parameter
D Number and is an indication of the failed component and FMI
means Failure Mode Identifier and are an indication of what type
of fault the component have.
B
001344
NOTE
If several error codes are generated from the transmission then
these are shown as rolling, i.e. all active error codes are displayed
with about a 1 second interval in the same field.
Field D: Type of error
Field D: Type of error
1 2 3
1. Temperature too high/too low.
2. Incorrect signal to solenoid.
3. Incorrect hydraulic pressure
4. Incorrect sensor signal.
4 5 6 5. Incorrect signal from lever.
6. Too high/too low level.
000879

D:6 D Error codes – Error codes
Field E: Affected function
1 2 3 Field E: Affected function
Field E: Indicates which function is affected by the error code.

1. Battery voltage.
2. Hydraulic functions.
4 5 6
3. Communication.
4. ECU hardware defect.
5. Lift up/down.
6. Forks tilt.
7 8 9
7. Forks side shift.
8. Forks spreading.
9. Levelling.
10 11 12 10. Motor.
11. Coolant engine.
12. Engine oil.
13. Oil pressure engine.
13 14 15 14. Transmission.
15. Oil pressure transmission.
16. Hydrostatic transmission.
17. Pedal.
16 17 18
18. Brake system.
19. Time.
20. Electronic scale.
21. Fuel.
19 20 21
22. Steering.
23. Clamping attachment.
24. Emergency stop.
22 23 24 25. Turnable driver's seat.

26. Air or particle filter.
27. Fuel economy.
28. Parking brake.
25 26 27
28
007010

Reading out error code
WARNING
A stop alarm indicates a fault in the machine that may
affect the safety of the operator and others in the
vicinity, or which could cause a breakdown. - Read the
error code, switch off the engine and take the necessary
remedial action in accordance with the error code table.
A warning and information alarm indicates a fault
of such a nature that the work does not have to be
stopped. The machine's capacity may be limited and
certain functions may not work. - Carry out remedial
action in accordance with the error code table as soon
as possible.
1 Stop the machine and identify the error code level and the specific
error code number, see section Error code menu, description,
page D:4. Stop the engine in the event of a stop alarm, or allow
the engine to run in the event of a warning or information alarm.
NOTE
If several error codes are generated from the motor then these
are shown as rolling, i.e. all active error codes are displayed
with about a 1 second interval in the same field.
2 The error code is shown automatically on the display.

C Note all error codes.
D E Scroll through the error codes by pressing the Reset function key
(Reset, R). If the error codes are still active then they are shown
after a certain time, which may be different depending on the type
B
000389
of alarm. The error code information disappears as soon as its

cause has been rectified.
Deactivate display of error codes by pressing the Reset (R)
function key:
• In the event of Stop: If the cause of the fault remains, the
error code will reappear within one minute.
• In the event of Warning or Information: If the cause of the
error code remains, the error code will reappear within three
minutes.
• If the cause of the error code is gone, error code display will
automatically deactivate within 30 seconds.
3 Park the machine in a suitable location.
For error code level "STOP" Stop the engine.
For error code level "WARNING" or "INFORMATION" Leave the
engine running or switch the machine off.
4 Read the information for the error code/error codes in the error
code table and perform the recommended actions.
5 Restart the engine and check in the display that error codes are
gone according to step 2.

D:8 1 Engine – Engine
1 Engine
Error codes engine, general
When contacting engine supplier, use the supplier code.
• Display indicates error code as shown in the machine, in
accordance with SAE J1939 in SPN/FMI.
• The supplier code indicates the error code in accordance with the
engine manufacturer's specification.
Table Specifications FMI
FMI Description SAE-text

0 Too high value. Data valid, but higher than normal operating range.
1 Too low value. Data valid, but lower than normal operating range.
2 Incorrect data. Intermittent or incorrect data.
3 Electrical problem. Abnormally high voltage or short-circuit to higher voltage.
4 Electrical problem. Abnormally low voltage or short-circuit to lower voltage.
5 Electrical problem. Abnormally low current or open circuit.
6 Electrical problem. Abnormally high current or short-circuit to ground.
7 Mechanical problem. Incorrect response from mechanical system.
8 Mechanical problem or electrical Abnormal frequency.
problem.
9 Communication error. Abnormal update rate.
10 Mechanical problem or electrical Abnormally wide variations.
problem.
11 Unknown malfunction. Non-identifiable malfunction.
12 Component error. Incorrect unit or component.
13 Incorrect calibration. Values outside calibration values.
14 Unknown malfunction. Special instructions.
15 Unknown malfunction. Reserved for future use.
16 Too high value. Data valid, but higher than normal operating range. Moderately
severe level.
17 Too low value. Data valid, but below normal operating range: The least serious level.
18 Too low value. Data valid, but below normal operating range: Moderately severe
level.
19 Communication error. Received network data in error.
20-30 Reserved for SAE assignment.
31 FMI is not available or the condition that Not available or condition exists.
is identified by the SPN exists.

1 Engine – Engine D:9
Error codes engine

Table Error codes engine (engine alternative Volvo TAD761VE)
Description Limitation Action
Display Supplier
code
51/3 PID51/3 Position sensor accelerator - Check the cable harness
pedal, abnormally high voltage between control unit and
or short-circuit to higher component.
voltage.
Check the sensor.
pedal, abnormally low voltage between control unit and
or short-circuit to lower voltage. component.
Check the sensor.
pedal, abnormally low power between control unit and
or open circuit. component.
Check the sensor.
91/9 PID91/9 Signal from accelerator pedal, - Check the cable harness
communication error. between control unit and
component.
Check the sensor.
94/1 PID94/1 Sensor fuel pressure, low fuel No limitation. Check the fuel level.
pressure.
Open all fuel taps and check for
leakage.
Check whether pressure can
be built up with the hand pump.
Measure the fuel pressure.
Replace all fuel filters (pre- and
fine filter).
Check that no fuel hose is
pinched or kinked.
Remove and clean the pressure
reducing valve on the fuel
transfer pump.
94/3 PID94/3 Sensor fuel pressure, No limitation. Check the cable harness
abnormally high voltage or between control unit and
short-circuit to higher voltage. component.
Check the sensor.
94/5 PID94/5 Sensor fuel pressure, No limitation. Check the cable harness
abnormally low power or between control unit and
open circuit. component.
Check the sensor.
94/7 PID94/7 Sensor fuel pressure, - -
mechanical defect.
97/0 PID97/0 Water in fuel. No limitation. Drain water separator.
Check the switch for the water
in the fuel.
Check the cable harness
between control unit and
component.
97/3 PID97/3 Sensor water in fuel, No limitation. Check the cable harness

Display Supplier
code
97/4 PID97/4 Sensor water in fuel, No limitation. Check the cable harness
abnormally low voltage or between control unit and
short-circuit to lower voltage. component.
98/1 PID98/1 Low oil level engine. Warning indication. Check the oil level in the engine.
Check that there is no oil
leakage.
Check the sensor.
98/3 PID98/3 Oil level sensor engine, No limitation. Check the cable harness
Check the sensor.
normally low voltage or between control unit and
Check the sensor.
abnormally low power or open between control unit and
circuit. component.
Check the sensor.
100/1 PID100/1 Low oil pressure in the engine. Reduced engine power or Check the engine oil level and
engine shutdown. oil quality.
Change the engine oil and oil
filter.
Check that there is no leakage.
Check the sensor.
100/3 PID100/3 Sensor oil pressure, No limitation. Check the cable harness
Check the sensor.
Check the sensor.
100/18 PID100/1 Sensor oil pressure, too low - -
8 value.
105/0 PID105/0 Too high booster temperature. Reduced engine power. Check that the engine
temperature is normal.
Check the coolant level.
Clean the intercooler and
radiator.
Check the sensor.
105/4 PID105/4 Sensor booster temperature, No limitation. Check the cable harness
Check the sensor.
105/5 PID105/5 Sensor booster temperature, No limitation. Check the cable harness
Check the sensor.

Display Supplier
code
105/16 PID105/1 Sensor booster temperature, Reduced engine power. Check that the engine
6 too high value. temperature is normal.
Check the coolant level.
Clean the intercooler and
radiator.
Check the sensor.
106/0 PID106/0 High booster pressure. Reduced engine power. Check the Wastegate valve
function.
Check the sensor.
Check that the compressor unit
in the turbo is correct according
to engine specification.
106/3 PID106/3 Sensor booster pressure, The engine jerks more than Check the cable harness
abnormally high voltage or normal during acceleration between control unit and
short-circuit to higher voltage. or increased load. component.
Check the sensor.
106/5 PID106/5 Sensor booster pressure, The engine jerks more than Check the cable harness
abnormally low power or open normal during acceleration between control unit and
circuit. or increased load. component.
Check the sensor.
106/16 PID106/1 Sensor booster pressure, too - -
6 high value.
107/0 PID107/0 Low air pressure. No limitation. Change the air filter.
107/3 PID107/3 Sensor air pressure, No limitation. Check the cable harness
Check the sensor.
107/4 PID107/4 Sensor air pressure, - -
abnormally low voltage or
short-circuit to lower voltage.
Check the contact pressure in
sleeves 15 and 29 in the engine
connector A.
Check the sensor.
intermittent or incorrect data. between control unit and
component.
Replace the engine control unit
(EMS 2).
(EMS 2).

Display Supplier
code
(EMS 2).
110/0 PID110/0 High coolant temperature. Reduced engine power. Check the coolant level.
Check that radiator is clean.
Check drive belts' adjustment.
Check the impeller on the
coolant pump.
Check if there is air in coolant
system.
If the coolant level is low,
pressure test the cooling system
to find leakage.
Check the pressure valve in the
coolant tank.
Check or replace the coolant
thermostat.
Check the sensor for the coolant
temperature.
Clean the coolant system.
110/4 PID110/4 Sensor coolant temperature, No limitation. Check the cable harness
Check the sensor.
110/5 PID110/5 Sensor coolant temperature, No limitation. Check the cable harness
circuit. component.
Check the sensor.
110/16 PID110/1 Sensor coolant temperature, - -
6 too high value.
111/1 PID111/1 Low coolant level. Reduced engine power. Check the coolant level; fill if
necessary.
Bleed the coolant system.
If the coolant level is low,
pressure test the cooling system
to find leakage.
Check the pressure valve in the
coolant tank.
Check the wiring to the sensor.
Check the sensor.
111/3 PID111/3 Sensor coolant level, No limitation. Check the cable harness
111/5 PID111/5 Sensor coolant level, - -
abnormally low power or
open circuit.

Display Supplier
code
153/0 PID153/0 Too high crankcase ventilation The engine is switched off. Check whether crankcase
pressure. ventilation is clogged. Clean the
crankcase ventilation system.
component.
Check the sensor for the
crankcase pressure.
Measure the crankcase
pressure.
Check for wear or damage to the
cylinder liner, piston or piston
rings.
153/3 PID153/3 Sensor crankcase ventilation No limitation. Check the cable harness
pressure, abnormally high between control unit and
voltage or short-circuit to component.
higher voltage.
Check the sensor.
153/5 PID153/5 Sensor crankcase ventilation No limitation. Check the cable harness
pressure, abnormally low between control unit and
power or open circuit. component.
Check the sensor.
158/1 PID158/1 Low battery voltage, CIU, The engine may be difficult Check the battery cables.
line short circuited to ground, to start.
Check/charge the batteries.
defective alternator or battery.
Check alternator and alternator
belt.
158/3 PID158/3 Low battery voltage, CIU, No limitation. Check the system voltage from
abnormally high voltage or the control unit.
short circuit to higher voltage.
158/4 PID158/4 Low battery voltage, CIU, No limitation. Check the system voltage from
abnormally low voltage or short the control unit.
circuit to lower voltage.
intermittent or incorrect data.
abnormally low voltage or
short-circuit to lower voltage.
abnormally low power or
open circuit.
172/4 PID172/4 Sensor air temperature, No limitation. Check the cable harness
Check the sensor.
172/5 PID172/5 Sensor air temperature, No limitation. Check the cable harness
circuit. component.
Check the sensor.

Display Supplier
code
175/0 PID175/0 High engine oil temperature. Reduced engine power. Check the oil level in the engine.
Check the coolant level and
engine temperature.
Check that no leakage occurs.
Check the sensor.
Clean the oil cooling system and
check the overflow valve for the
oil cooler.
175/4 PID175/4 Sensor oil temperature, No limitation. Check the cable harness
Check the sensor.
Check the contact pressure
in the sleeve 31 in engine
connector A and the sleeve 10
in engine connector B.
Check the sensor.
175/16 PID175/1 Sensor oil temperature, too Reduced engine power. Check the oil level in the engine.
6 high value.
Check the coolant level and
engine temperature.
Check that no leakage occurs.
Check the sensor.
Clean the oil cooling system and
check the overflow valve for the
oil cooler.
190/16 PID190/1 Engine speed too high value. No limitation. Ease off throttle or select higher
6 gear.
Investigate the cause of the high
speed when the engine has
been stopped.
354/3 PID354/3 Relative humidity, abnormally Hygrometer shows 50%. Check the cable harness
high voltage or short-circuit to between control unit and
higher voltage. component.
Check the sensor.
354/5 PID354/5 Relative humidity, abnormally Hygrometer shows 50%. Check the cable harness
low power or open circuit. between control unit and
component.
Check the sensor.
442/4 PPID272/ Humidity compensation for air - -
4 temperature, abnormally low
voltage or short circuit at a
lower voltage.
442/5 PPID272/ Humidity compensation for air - -
5 temperature, abnormally low
power or open circuit.

Display Supplier
code
608/9 PPID132/ Signal from accelerator pedal, The engine is running at Check that the throttle
9 abnormal update rate. idle. If the accelerator pedal potentiometer is connected
is first released and then correctly.
pressed again, the engine
may be forced to run with
the help of the idle switch.
component.
Check the function of the throttle
potentiometer.
608/9 PPID98/9 Motor synchronisation, No limitation. Check the communication
acknowledgement, abnormal cables to the DCU/CIU.
update rate.
Check the power cable between
the motor control unit and
DCU/CIU.
Make sure the DCU/CIU are
programmed for the correct
engine type.
608 SID250 J1708 communication bus, No limitation. Check all data links between
defect. DCU/CIU and EMS 2.
Check that sleeves 22 and 37
in the connector for CIU are
undamaged.
620/3 SID232/3 +5 V voltage feed sensor No limitation. Check voltage feed to the
engine, abnormally high sensors that triggered the error
voltage or short circuit to the codes.
higher voltage.
Check the sensor cables.
Check the sensors.
620/4 SID232/4 +5 V voltage feed sensor No limitation. Check voltage feed to the
engine, abnormally low voltage sensors that triggered the error
or short circuit to the lower codes.
voltage.
Check the sensors.
626/3 PID45/3 Sensor inlet air heater, Preheater relay never Check the cable harness
abnormally high voltage or activated, starting problems between control unit and
short-circuit to higher voltage. in cold weather. component.
White smoke with cold-start.
626/4 PID45/4 Sensor inlet air temperature, Preheater relay does not Check the cable harness
abnormally low voltage or close by, preheater fuse will between control unit and
short-circuit to lower voltage. trip. component.
Inlet air is hot.
626/5 PID45/5 Sensor inlet air heater, Preheater relay never Check the cable harness
abnormally low power or open activated, starting problems between control unit and
circuit. in cold weather. component.
White smoke with cold-start. Check the contact pressure in
sleeve 25 and in sleeve 7 in the
engine connector B.
628/2 SID240/2 Memory error in engine control, The engine does not start. Reprogram the control unit.
irregular signal.
Replace the control unit.
628/12 SID240/1 Memory error in engine control, - -
2 defective unit or component.

Display Supplier
code
629/8 SID254/8 Engine control unit, internal No limitation. Search for short-circuit in the
fault. feeder cables to the CIU throttle
potentiometer.
Reprogram the control unit that
has triggered the error code.
629/12 SID254/1 Control unit engine, defective No limitation. Search for short-circuit in the
2 unit or component. feeder cables to the CIU throttle
potentiometer.
Reprogram the control unit that
has triggered the error code.
630/2 SID253/2 Electrical fault engine The engine does not start. Reprogram the control unit.
(EEPROM), intermittent or
Replace the control unit if the
incorrect data.
fault persists.
2 (EEPROM), defective unit
or component.
fault persists.
4 (EEPROM), Special
instructions.
fault persists.
636/2 SID21/2 Sensor rotation speed The engine takes longer to Check the cable harness
camshaft, irregular signal. start than normal. between control unit and
component.
Check the sensor and its
connection.
636/3 SID21/3 Sensor camshaft speed, The engine takes longer to Check the cable harness
abnormally high voltage or start than normal. between control unit and
installation.
636/8 SID21/8 Sensor speed, camshaft, The engine takes longer to Check the cable harness
abnormal frequency. start than normal. between control unit and
component.
Check sensor installation.
Try to locate the source of the
disturbance.
Check and clean the sensor.
637/2 SID22/2 Sensor rotation speed flywheel, The engine takes longer to Check the cable harness
no signal. start than normal. between control unit and
component.
connection.
637/3 SID22/3 Sensor flywheel speed, Engine runs unevenly with Check the cable harness
abnormally high voltage or increased risk of high fuel between control unit and
short-circuit to higher voltage. consumption and smoking. component.
installation.

Display Supplier
code
637/8 SID22/8 Sensor speed, flywheel, The engine takes longer to Check the cable harness
abnormal frequency. start than normal. between control unit and
component.
Check sensor installation. Try
to locate the source of the
disturbance.
Check and clean the flywheel
sensor.
639/2 SID231/2 Communication error control Engine switched off: engine Check all data links between
unit engine (J1939). cannot be started. DCU/CIU and EMS2.
Engine running: the engine Check that connections 11 and
can only be stopped by 12 in the connector in the CIU
using the emergency stop. are not damaged.
Instrument and warning
lamps stop working.
639/9 PSID201/ Communication error control No communication with the Check all data links between
9 unit engine (J1939). engine control unit. DCU/CIU and EMS2.
Open circuit or short circuit
between DCU/CIU and EMS2,
via the engine's connector.
647/3 SID33/3 Cooling fan control abnormally - -
high voltage or short-circuit to
higher voltage.
647/4 SID33/4 Cooling fan control, abnormally - -
low voltage or short-circuit to
lower voltage.
647/5 SID33/5 Cooling fan control, abnormally - -
low power or open circuit.
651/3 SID1/3 Injector cylinder 1, abnormally Engine only runs on 5 Check the cable harness
high voltage or short-circuit to cylinders, sounds rough and between control unit and
higher voltage. has reduced power. component.
low voltage or short-circuit to cylinders, sounds rough and between control unit and
lower voltage. has reduced power. component.
low power or open circuit. cylinders, sounds rough and between control unit and
has reduced power. component.
all sleeves for injection units in
the motor connector A.
651/12 SID1/12 Injector cylinder 1, defective. Engine only runs on 5 Check the cable harness
cylinders, sounds rough and between control unit and
Check the wiring to the injector.

Display Supplier
code

Display Supplier
code
677/0 PPID3/0 Start relay on the starter motor, - -
too high value.
677/3 PPID3/3 Start relay on the starter motor, The engine does not start. Check the connection and
abnormally high voltage or function of the ignition key lock.
Engine starts immediately
short circuit to higher voltage.
when ignition is turned on. Check the cable harness
component.
Check the start button on DCU.
677/4 PPID3/4 Start relay on the starter motor, The engine does not start. Check the ignition cable.
abnormally low voltage or short
Engine starts immediately Check the connection and
circuit to lower voltage.
when ignition is turned on. function of the ignition key lock.
component.

Display Supplier
code
677/5 PPID3/5 Start relay on the starter motor, The engine does not start. Check the ignition cable.
abnormally low power or open
Engine starts immediately Check the start relay on the
circuit.
when ignition is turned on. starter motor.
in sleeve 29 in the engine
connector B.
677/10 PPID3/10 Start relay on the starter motor, - -
abnormally large fluctuations.
729/3 SID70/3 Sensor preheating, abnormally Fuse for short circuit in Check the cable harness
high voltage or short-circuit to cable trips. between control unit and
higher voltage. component.
Check the function of the relay.
Check the heating coil.
729/4 SID70/4 Sensor preheating, abnormally Preheating cannot be Check the function of the relay.
low voltage or short-circuit to activated, starting problems
lower voltage. in cold weather.
component.
729/5 SID70/5 Sensor preheating, abnormally Preheating cannot be Check the preheater fuse.
low power or open circuit. activated, starting problems
in cold weather.
component.
Check the heating coil.
858/3 PSID82/3 AdBlue external filter heater, No limitation. Check the cable harness
cable short circuited to voltage. between control unit and
component.
Check the component.
cable open circuit or short between control unit and
circuited to ground. component.
859/3 PSID107/ AdBlue external filter heater, No limitation. Check the cable harness
3 cable short circuited to voltage. between control unit and
component.
4 abnormally low voltage or between control unit and
5 cable open circuit or short between control unit and
975/3 SID26/3 Fan speed, abnormally high - -
voltage or short-circuit to higher
voltage.

Display Supplier
code
1080/3 SID211/3 +5V voltage feed sensor No limitation. Check voltage feed to the
engine, abnormally high sensors that triggered the error
voltage or short circuit to the codes.
higher voltage.
Check the sensors.
1080/4 SID211/4 +5V voltage feed sensor No limitation. Check voltage feed to the
engine, abnormally low voltage sensors that triggered the error
or short circuit to the lower codes.
voltage.
Check the sensors.
1136/0 PPID55/0 ECU-temperature, control unit No limitation. Check if the ambient
too hot. temperature is high.
Check the control unit's
installation. The recommended
ambient temperature is 50 °C.
Change the control unit.
1136/4 PPID55/4 ECU temperature, abnormally No limitation. Change the control unit.
low voltage or short-circuit to
lower voltage.
1136/5 PPID55/5 ECU temperature, abnormally No limitation. Change the control unit.
low power or open circuit.
1184/0 PID173/0 High exhaust temperature. Reduced engine power. Make sure the exhaust pipe
has not been damaged and that
there are no restrictions.
Check the sensor.
Check the exhaust system's
back pressure.
1184/4 PID173/4 Sensor exhaust temperature, No limitation. Check the cable harness
Check the sensor.
1184/5 PID173/5 Sensor exhaust temperature, No limitation. Check the cable harness
circuit. component.
sleeves 18 and 44 in the engine
connector B.
Check the sensor.
1184/16 PID173/1 Sensor exhaust temperature, - -
6 too high value.
1188/3 SID32/3 Wastegate drive circuit, No limitation. Check the cable harness
Replace the component.

Display Supplier
code
circuit. component.
in sleeves 38 in the engine
connector B.
1231/2 PSID232/ CAN2 J1939 communication No AdBlue additive. Check the cable harness
2 link, intermittent or incorrect between control unit and
data. component.
1231/2 PSID248/ CAN3 communication link, No AdBlue additive. Check the cable harness
2 intermittent or incorrect data. between control unit and
component.
1231/9 PSID229/ CAN-frames from UDS/ACM, No AdBlue additive. Check the cable harness
9 timeout. between control unit and
component.
1675/0 PPID3/0 Starter motor output power - -
(Penta), data valid, but above
normal operating range.
(Penta), abnormally high
voltage or short-circuit to
higher voltage.
(Penta), abnormally low
voltage or short-circuit to lower
voltage.
(Penta), abnormally low power
or open circuit.
(Penta), mechanical problem
or electrical problem.
1761/1 PPID278/ After-treatment reagent, level, Temperature shows 20 °C. Fill AdBlue.
1 low level, limited cooling
Check sensor.
capacity.
1761/3 PPID278/ After-treatment reagent, level Temperature shows 20 °C. Fill AdBlue.
3 SCH.
Check sensor.
1761/5 PPID278/ After-treatment reagent, level, - -
5 abnormally low power or open
circuit.
11 unknown error.
18 too low value.
2061/8 PSID77/8 AdBlue ECU EEPROM, No limitation. Check the system voltage.
abnormal frequency.
Check fuses for EATS.

Display Supplier
code
2061/8 PPID273/ After-treatment reagent, Warning indication and Fill AdBlue.
14 pressure, heating defect. reduced engine power.
Check AdBlue filter.
Check AdBlue hoses.
Check the wiring and
connections.
2061/12 PSID77/1 AdBlue ECU EEPROM, No limitation. Check the system voltage.
2 defective unit or component.
2061/13 PPID278/ After-treatment reagent, level, No limitation. -
13 values outside calibration
values.
2061/14 PPID385/ AdBlue ECU-voltage, internal SCR-system does not start. Check the system voltage.
14 supply, critical error.
2791/3 PPID19/3 Internal EGR status, IEGR cannot be activated. Check the cable harness
In the event of failure on
short circuit to higher voltage. component.
the IEGR function, the
2791/4 PPID19/4 Internal EGR status, proportion of nitrogen
abnormally high voltage or oxides in exhaust
short circuit to higher voltage. emissions becomes high
and over-revving of the
2791/5 PPID19/5 Internal EGR-status, turbocharger is possible. Check the cable harness
sleeves 30, 57 and 60 in the
engine connector B.
Check the coil on IEGR.
2791/7 PPID19/7 Internal EGR-status, incorrect Check the operation of the
response from mechanical solenoid valve on IEGR.
system.
Check the engine's oil pressure.
2988/3 PPID332/ Thermostat, abnormally high No limitation. Check the cable harness
3 voltage or short-circuit to higher between control unit and
voltage. component.
Check the cold start valve.
2988/4 PPID332/ Thermostat, abnormally low No limitation. Check the cable harness
4 voltage or short-circuit to lower between control unit and
voltage. component.
2988/5 PPID332/ Thermostat, abnormally low No limitation. Check the cable harness
5 power or open circuit. between control unit and
component.
in sleeves 34 in the engine
connector B.
3031/0 PPID274/ After-treatment reagent, No AdBlue added. Check the wiring and
0 tank temperature, too high connections.
temperature.
3031/1 PPID274/ After-treatment reagent, No AdBlue added. Check the wiring and
1 tank temperature, too low connections.
temperature.

Display Supplier
code
3031/4 PPID274/ After-treatment reagent, tank No AdBlue added. Check the wiring and
4 temperature, cable short connections.
circuited to ground.
3031/5 PPID274/ After-treatment reagent, tank No AdBlue added. Check the wiring and
5 temperature, open circuit. connections.
3051/11 PSID90 SCR-system performance, no - -
identifiable error.
3226/2 PPID270/ NOx-sensor exhaust outlet, Reduced engine power. Check the cable harness
2 short circuited cable, between control unit and
intermittent or incorrect data. component.
Check the sensor.
Check fuse.
3226/7 PPID270/ NOx-sensor exhaust outlet, Reduced engine power. Check the cable harness
7 mechanical problem. between control unit and
component.
Check the sensor.
Check fuse.
3241/4 PPID386/ Exhaust temperature sensor No limitation. Check the cable harness
4 #1, abnormally low voltage or between control unit and
Check the sensor.
3241/5 PPID386/ Exhaust temperature sensor No limitation. Check the cable harness
5 #1, cable open circuit or short between control unit and
Check the sensor.
3361/3 PSID89/3 AdBlue metering valve, short No AdBlue added. Check the wiring and
circuit to battery. connections.
3361/4 PSID89/4 AdBlue metering valve, short No AdBlue added. Check the wiring and
circuit to ground. connections.
3361/5 PSID89/5 AdBlue metering valve, open No AdBlue added. Check the wiring and
circuit. connections.
3361/7 PSID89/7 AdBlue metering valve, valve No AdBlue added. Check the wiring and
or hose clogged. connections.
3361/10 PSID89/1 AdBlue metering valve, valve No AdBlue added. Check the wiring and
0 jammed. connections.
3361/14 PSID89/1 AdBlue metering valve, frozen No AdBlue added. Check the wiring and
4 too many times. connections.
3363/3 PSID75/3 AdBlue tank heating valve, No limitation. Check the cable harness
intermittent or incorrect data. between control unit and
component.
Check the sensor.
Check the sensor.
Check the sensor.

Display Supplier
code
3464/3 PSID7/3 Actuator motor accelerator - -
control, abnormally high
voltage or short-circuit to
higher voltage.
control, abnormally low voltage
or short-circuit to lower voltage.
control, abnormally low power
or open circuit.
control, defective unit or
component.
3511/3 PSID77/3 AdBlue ECU EEPROM. ECU No limitation. Check the system voltage.
internal feed high.
3511/4 PSID77/4 AdBlue ECU EEPROM. ECU No limitation. Check the system voltage.
internal feed low.
13 pressure, values outside reduced engine power.
calibration values.
Check AdBlue hoses.
connections.
3522/16 PSID91/1 AdBlue, consumption, too high No limitation. Check for leakage in the
6 value. SCR-system.
3522/18 PSID91/1 AdBlue, consumption, too low No limitation. Check for leakage in the
8 value. SCR-system.
1 pressure, leakage. reduced engine power.
Check AdBlue hoses.
connections.
4 pressure, cable short circuited reduced engine power.
to ground.
Check AdBlue hoses.
connections.
5 pressure, open circuit. reduced engine power.
Check AdBlue hoses.
connections.
7 pressure, accumulated error. reduced engine power.
Check AdBlue hoses.
connections.

Display Supplier
code
9 communication error. reduced engine power.
Check AdBlue hoses.
connections.
10 mechanical problem or reduced engine power.
electrical problem.
Check AdBlue hoses.
connections.
13 pressure, values outside reduced engine power.
calibration values.
Check AdBlue hoses.
connections.
4337/0 PPID275/ Reagent filter temperature, too No AdBlue added. Check the wiring and
0 high temperature. connections.
4337/1 PPID275/ Reagent filter temperature, No AdBlue added. Check the wiring and
1 too low temperature, electrical connections.
heating not possible.
4337/2 PPID275/ Reagent filter temperature, out No AdBlue added. Check the wiring and
2 of operating range. connections.
4 cable short circuited to ground. connections.
5 open circuit. connections.
4354/3 PSID103/ AdBlue ECU hose heater 1, No limitation. Check the cable harness
component.
Check component.
Check component.
Check component.
4354/14 PSID103/ AdBlue ECU hose heater 1, No limitation. No limitation.
14 special instructions.
4355/3 PSID84/3 AdBlue ECU hose heater 2, No limitation. Check the cable harness
cable short circuited to voltage. between control unit and
component.
Check component.
Check component.

Display Supplier
code
Check component.
4355/14 PSID84/1 AdBlue ECU hose heater 2, No limitation. No limitation.
component.
Check component.
Check component.
Check component.
4356/14 PSID102/ AdBlue ECU hose heater 3, No limitation. -
component.
Check component.
Check component.
Check component.
4374/0 PSID87/0 AdBlue pump motor speed, too No AdBlue added. Check the wiring and
high-speed. connections.
4374/1 PSID87/1 AdBlue pump motor speed, too No AdBlue added. Check the wiring and
low-speed. connections.
4374/10 PSID87/1 AdBlue pump motor speed, no No AdBlue added. Check the wiring and
0 signal from pump. connections.
4376/3 PSID105/ AdBlue directional control No limitation. Check the wiring and
3 valve, short circuit to battery. connections.
4 valve, short circuit to ground. connections.
5 valve, open circuit. connections.
7 valve, mechanical problem. connections.
4811/1 PPID8/1 Oil pressure piston cooling, too - -
low value.
4811/2 PPID8/2 Oil pressure piston cooling, - -
incorrect data.

Display Supplier
code
abnormally high voltage or
short-circuit to higher voltage.
abnormally low power or open
circuit.
4811/18 PPID8/18 Oil pressure piston cooling, too - -
low value.
5246/0 PSID46/0 Inducing level, Inducing level Warning indication and Check the cable harness
3, 4 or 5. reduced engine power. between control unit and
component.
Check the sensor.
5246/15 PSID46/1 Inducing level, Inducing level Warning indication and Check the cable harness
5 1 or 2. reduced engine power. between control unit and
component.
Check the sensor.
5246/16 PSID46/1 Inducing level, too high value. - -
6
5394/17 PSID90/1 SCR-system performance, Warning indication, error Check AdBlue quality.
7 metering error. message on display and
reduced engine power.
520192/ PPID8/1 Low oil pressure piston Reduced engine power. Check piston cooling pressure
1 cooling, engine has reduced again.
Error code deactivated at
performance.
engine speed below 1000 Replace the monitor for
rpm. piston cooling pressure if the
measurement shows that the
piston cooling pressure is
correct.
520192/ PPID8/3 Sensor oil pressure piston No limitation. Check the cable harness
3 cooling, abnormally high between control unit and
voltage or short-circuit to component.
higher voltage.
520194 PPID4 Starter motor input sensor. The engine does not start. Check the connection and
function of the ignition key lock.
Engine starts immediately
when ignition is turned on. Check the cable harness
component.
520195/ PPID6/5 Sensor ignition off (stop Engine cannot be shut Check the connections and
5 request), abnormally low down. cables are not damaged.
power or open circuit.
520195/ PPID6/18 Sensor ignition off (stop - -
18 request), too low value.
520233/ PSID85/3 AdBlue ECU main relay, cable No limitation. Check the cable harness
3 short circuited to voltage. between control unit and
component.
Check the sensor.
520223/ PSID85/4 AdBlue ECU main relay, No limitation. Check the cable harness
Check the sensor.

Display Supplier
code
520223/ PSID85/5 AdBlue ECU main relay, cable No limitation. Check the cable harness
5 open circuit or short circuited between control unit and
to ground. component.
Check the sensor.
520223/ PSID85/6 AdBlue ECU main relay, No limitation. Check the cable harness
6 abnormally high current or between control unit and
short-circuit to ground. component.
Check the sensor.

D:30 2 Transmission – Transmission
2 Transmission
Error codes transmission
In the event of serious faults in the transmission the control unit
uses four conditions with reduced functionality in order to protect the
transmission from damage. These are:
• "Substitute clutch control".
In this mode the operator can use the machine as usual. However,
gear shifting and change of direction is not under the control of
normal modulation. The control unit uses the default values for
the modulation of the clutches.
• "Limp home".
In this mode, the operator can use one of the transmission gears
in each direction, and in some cases only in one direction. To
continue to drive in the event of a fault with the "Limp home"
restriction, the machine must be stopped to a standstill and the
gear selector moved to neutral before the gear can be selected
again.
• "Transmission shut down".
In this mode, the transmission is permanently in neutral as the
solenoid valves for the clutches and parts of the power supply to
the transmission are shut off. Park the machine and switch off
the engine.
• "TCU shut down".
In this mode, the transmission is permanently in neutral as all
solenoid valves and all power supplies to the transmission are shut
off. Park the machine and switch off the engine.
ZF code
SPN/FMI (hex)
5000/12 11 Logical error at gear range signal. Transmission Check the cables from ECU793 to
is locked in gear control.
ECU793 detected a wrong signal
neutral position
combination for the gear range. Check signal combinations of gear
("transmission shut
control positions for gear range.
Possible reasons: down").
• Cable from gear control to
ECU793 is defective.
• Cable is defective and has
contact with battery voltage or
vehicle ground.
• Gear control is defective.
5010/12 12 Logical error for travel direction Transmission Check the cables from ECU793 to
selector signal. is locked in gear control.
neutral position
ECU793 detected a wrong signal Check signal combinations of gear
("transmission shut
combination for the direction. control positions F-N-R.
down").
Possible reasons:
• Cable from gear control to
vehicle ground.

2 Transmission – Transmission D:31
ZF code
SPN/FMI (hex)
5020/12 13 Logical error in the engine's After neutral position Restart ECU 793 by switching the
reduction unit. has been selected, ignition off and back on.
ECU793 shifts to
The TCU detects no reaction when Check the engine's reduction unit.
"limp home" mode.
the engine's reduction unit is active.
5040/12 15 Logical error for travel direction Transmission Check the cables from ECU793 to
selector signal 2 from gear selector. locked in neutral gear control 2.
("transmission shut
ECU793 detected a wrong signal Check signal combinations of gear
down") when extra
combination for the direction. control positions F-N-R.
travel direction
Possible reasons: selector is used.
• Cable from gear control 2 to
vehicle ground.
5050/12 16 Logical error at shaft connection. - Check the cable from ECU793
to the sensor for feedback shaft
Feedback shaft connection
connection.
measured by ECU793 and output
signal from shaft connection do not Check the signals from the sensor
match. for feedback shaft connection.
Possible reasons:
• The shaft cannot be engaged
or disengaged due to
mechanical problems
• One of the cables from the
sensor for feedback shaft
connection to ECU793 is
defective.
5110/3 25 Short circuit to battery voltage or ECU793 uses default Check the cable from ECU793 to
open circuit at transmission sump temperature. the sensor.
temperature sensor input.
Check the connectors.
The measured voltage is too high.
Check the temperature sensor.
Possible reasons:
contact with battery voltage.
• Cable has no connection to
ECU793.
• Temperature sensor has an
internal defect.
• Connector pin has contact with
battery voltage or is defective.

ZF code
SPN/FMI (hex)
5110/4 26 Short circuit to ground at ECU793 uses default Check the cable from ECU793 to
transmission sump temperature temperature. the sensor.
sensor input.
The measured voltage is too low.
Possible reasons:
contact with vehicle ground.
internal defect.
vehicle ground.
5120/3 27 Short circuit to battery voltage ECU793 uses default Check the cable from ECU793 to
or open circuit at retarder/torque temperature. the sensor.
converter temperature sensor
input.
Possible reasons:
ECU793.
internal defect.
5120/4 28 Short circuit to ground at ECU793 uses default Check the cable from ECU793 to
retarder/torque converter temperature. the sensor.
temperature sensor input
Possible reasons:
internal defect.
vehicle ground.
5130/3 29 Short circuit to battery voltage ECU793 uses default Check the cable from ECU793 to
or open circuit at parking brake values. the sensor.
sensor input.
Check the parking brake sensor.
Possible reasons:
ECU793
internal defect

ZF code
SPN/FMI (hex)
5130/4 2A Short circuit to ground at the ECU793 uses default Check the cable from ECU793 to
parking brake sensor's input. values. the sensor.
The measured voltage is too low. Check the connectors.
Possible reasons: Check the parking brake sensor.
• Sensor has an internal defect.
vehicle ground.
5135/3 2C Short circuit to battery voltage or ECU793 uses default Check the cable from ECU793 to
open circuit in DLM TRACTION values. the sensor.
ADJUST DASHBOARD DEVICE
INPUT
Check DLM Traction Adjust
dashboard device.
Possible reasons:
1. Cable is defective and has
2. Cable has no connection to
ECU793.
3. Sensor has an internal defect.
4. Connector pin has contact with
5135/4 2D Short circuit to ground at DLM ECU793 uses default Check the cable from ECU793 to
traction adjust dashboard device values. the sensor.
input.
Check DLM Traction Adjust
Possible reasons: dashboard device.
internal defect.
vehicle ground.
5137/3 2E Short circuit to battery voltage or ECU793 uses default Check the cable from ECU793 to
open circuit at DLM wheel angle values. the sensor.
sensor input.
Check the DLM wheel angle sensor.
Possible reasons:
ECU793.

ZF code
SPN/FMI (hex)
5137/4 2F Short circuit to ground at DLM ECU793 uses default Check the cable from ECU793 to
wheel angle sensor input. values. the sensor.
The measured voltage is too low. Check the connectors.
Possible reasons: Check the DLM wheel angle sensor.
internal defect.
vehicle ground.
5313/12 2B Inching sensor signal incorrect. In inching mode: Check the cable from ECU793 to
ECU793 shifts to the sensor.
The measured voltage from CCO
neutral.
and CCO2 signals are incorrect. Check the connectors.
Not inching: No
Possible reasons: Check the sensor.
change and normal
• Cable is defective. operation.
5140/3 31 Short circuit to battery voltage or The transmission is Check the cable from ECU793 to
open circuit at engine speed input. limited in accordance the sensor.
with "Substitute
ECU793 measures a voltage Check the connectors.
clutch control".
higher than 7.00 V at speed input
Check the speed sensor.
pin.
Possible reasons:
ECU793.
• Speed sensor has an internal
defect.
• Connector pin has contact
with battery voltage or has no
contact.
5140/4 32 Short circuit to ground at engine The transmission is Check the cable from ECU793 to
speed input. limited in accordance the sensor.
with "Substitute
ECU793 measures a voltage less Check the connectors.
clutch control".
than 0.45 V at speed input pin.
Possible reasons:
• Cable/connector is defective
and has contact with vehicle
ground.
defect.

ZF code
SPN/FMI (hex)
5140/12 33 Logical error at engine speed input. The transmission is Check the cable from ECU793 to
limited in accordance the sensor.
ECU793 measures an engine
with "Substitute
speed over a threshold and the Check the connectors.
clutch control".
next moment the measured speed
is zero.
Check the sensor gap.
Possible reasons:
Restart ECU 793 by switching the
ignition off and back on.
and has poor contact.
defect.
• Sensor gap is the wrong size.
open circuit at turbine speed input. limited in accordance the sensor.
with "Substitute
clutch control". If
there is an error in the Check the speed sensor.
pin.
tachometer sensor
Possible reasons: output signal then the
transmission control
unit activates "limp
home".
ECU793.
defect.
contact.
5150/4 35 Short circuit to ground at turbine The transmission is Check the cable from ECU793 to
with "Substitute
clutch control". If
Possible reasons: tachometer sensor
output signal then the
transmission control
unit activates "limp
ground.
home".
defect.
5150/12 36 Logical error at turbine speed input. The transmission is Check the cable from ECU793 to
ECU793 measures a turbine speed
with "Substitute
over a threshold and at the next Check the connectors.
clutch control". If
moment the measured speed is
zero.
tachometer sensor
Possible reasons: output signal then the
transmission control Restart ECU 793 by switching the
unit activates "limp ignition off and back on.
home".
defect.

ZF code
SPN/FMI (hex)
open circuit at internal speed input. limited in accordance the sensor.
with "Substitute
clutch control".
pin.
Possible reasons:
ECU793.
defect.
contact.
5160/4 38 Short circuit to ground at internal The transmission is Check the cable from ECU793 to
with "Substitute
clutch control".
Possible reasons:
ground.
defect.
5160/12 39 Logical error at internal speed The transmission is Check the cable from ECU793 to
input. limited in accordance the sensor.
with "Substitute
ECU793 measures a internal Check the connectors.
clutch control".
speed over a threshold and at the
is zero. Check the sensor gap.
Possible reasons: Restart ECU 793 by switching the
1. Cable/connector is defective
2. Speed sensor has an internal
defect.
3. Sensor gap is the wrong size.

ZF code
SPN/FMI (hex)
5170/3 3A Short circuit to battery voltage or The transmission is Check the cable from ECU793 to
open circuit at output speed input. limited in accordance the sensor.
with "Substitute
clutch control". If
pin.
turbine speed sensor
Possible reasons: then the transmission
control unit activates
"limp home".
ECU793.
defect.
contact.
5170/4 3B Short circuit to ground at output The transmission is Check the cable from ECU793 to
with "Substitute
clutch control". If
Possible reasons: turbine speed sensor
then the transmission
"limp home".
ground.
defect.
5170/12 3C Logical error at output speed input. The transmission is Check the cable from ECU793 to
ECU793 measures an output
with "Substitute
speed over a threshold and at the Check the connectors.
clutch control". If
is zero.
turbine speed sensor
Possible reasons: then the transmission
control unit activates Restart ECU 793 by switching the
"limp home". ignition off and back on.
defect.
5180/2 3E Output speed zero does not match The transmission is Check the sensor signal of output
other speed signals. limited in accordance speed sensor.
with "Substitute
If the transmission is not in neutral Check the sensor gap of output
clutch control". If
and shifting has finished, ECU793 speed sensor.
there is an error in the
measures output speed zero and
turbine speed sensor Check the cable from ECU793 to
turbine speed or internal speed not
then the transmission the sensor.
equal to zero.
Restart ECU 793 by switching the
Possible reasons: "limp home".
defect.

ZF code
SPN/FMI (hex)
5260/9 54 DCT1 exceeded time limit. Check the display computer.
Timeout of CAN message DCT1 Check cable to CAN bus.
from display computer.
Check the cable for the display
Possible reasons: computer.
• Interference on CAN bus.
• CAN cable/connector is
defective.
• CAN cable/connector is
defective and has contact
to vehicle ground or battery
voltage.
5270/9 E5 DISPID1_time limit exceeded. ECU793 selects Check the display computer.
parameter settings
Timeout of CAN message DISPID1 Check cable to CAN bus.
with ID0.
from display computer.
Check the cable for the display
Transmission limited
Possible reasons: computer.
in accordance with
1. Interference on CAN bus. "limp home".
2. CAN cable/connector is
defective.
3. CAN cable/connector is
defective and has contact
to vehicle ground or battery
voltage.
5390/2 61 AEB Request signal. Last setting is Check I/O control unit.
retained.
CAN signal for AEB request is Check cable to CAN bus.
incorrect.
Check cable to I/O control unit.
Possible reasons:
• I/O control unit is incorrect.
• Interference on CAN bus.
5480/3 71 Short circuit to battery voltage at Control unit Check the cable from ECU793 to
clutch K1. transmission the gearbox.
activates "limp
The measured resistance value of Check the connectors from ECU793
home". In the event
the valve is out of limit, voltage at to the gearbox.
of an ongoing fault on
K1 valve is too high.
another gear, control Check regulator resistance.
Possible reasons: unit transmission
Check internal wiring harness of the
activates "TCU
• Cable/connector is defective gearbox.
shutdown".
and has contact to battery
voltage.
• Regulator has an internal
defect.

ZF code
SPN/FMI (hex)
5480/4 72 Short circuit to ground at clutch K1. Control unit Check the cable from ECU793 to
transmission the gearbox.
The measured resistance value of
activates "limp
the valve is out of limit, voltage at Check the connectors from ECU793
home". In the event
K1 valve is too low. to the gearbox.
Possible reasons: another gear, control Check regulator resistance.
unit transmission
• Cable/connector is defective Check internal wiring harness of the
activates "TCU
and has contact with vehicle gearbox.
shutdown".
ground.
and has contact to another
regulator output of the
ECU793.
defect.
5480/5 73 Open circuit at clutch K1. Control unit Check the cable from ECU793 to
activates "limp
the valve is out of limit. Check the connectors from ECU793
home". In the event
to the gearbox.
Possible reasons: of an ongoing fault on
unit transmission
and has no contact to ECU793. Check internal wiring harness of the
activates "TCU
gearbox.
• Regulator has an internal shutdown".
defect.
activates "limp
home". In the event
activates "TCU
shutdown".
voltage.
defect.
activates "limp
home". In the event
unit transmission
activates "TCU
shutdown".
ground.
ECU793.
defect.

ZF code
SPN/FMI (hex)
activates "limp
home". In the event
to the gearbox.
unit transmission
activates "TCU
gearbox.
defect.
activates "limp
home". In the event
activates "TCU
shutdown".
voltage.
defect.
activates "limp
home". In the event
unit transmission
activates "TCU
shutdown".
ground.
ECU793.
defect.
5500/5 79 Open circuit at clutch K3 Control unit Check the cable from ECU793 to
activates "limp
home". In the event
to the gearbox.
unit transmission
activates "TCU
gearbox.
defect.

ZF code
SPN/FMI (hex)
activates "limp
home". In the event
activates "TCU
shutdown".
voltage.
defect.
activates "limp
home". In the event
unit transmission
activates "TCU
shutdown".
ground.
ECU793.
defect.
activates "limp
home". In the event
to the gearbox.
unit transmission
activates "TCU
gearbox.
defect.
clutch KV, forward clutch. transmission the gearbox.
activates "limp
home". In the event
KV valve is too high.
activates "TCU
shutdown".
voltage.
defect.

ZF code
SPN/FMI (hex)
5520/4 85 Short circuit to ground at clutch KV, Control unit Check the cable from ECU793 to
forward clutch. transmission the gearbox.
activates "limp
home". In the event
KV valve is too low.
activates "TCU
shutdown".
ground.
ECU793.
defect.
5520/5 86 Open circuit at clutch KV, forward Control unit Check the cable from ECU793 to
clutch. transmission the gearbox.
activates "limp
home". In the event
the valve is out of limit. to the gearbox.
unit transmission
activates "TCU
and has no contact to ECU793. gearbox.
shutdown".
defect.
clutch KR, reverse clutch. transmission the gearbox.
activates "limp
home". In the event
KR valve is too high.
activates "TCU
shutdown".
voltage.
defect.
5530/4 88 Short circuit to ground at clutch Control unit Check the cable from ECU793 to
KR, reverse clutch. transmission the gearbox.
activates "limp
home". In the event
KR valve is too low.
activates "TCU
shutdown".
ground.
ECU793.
defect.

ZF code
SPN/FMI (hex)
5530/5 89 Open circuit at clutch KR, reverse Control unit Check the cable from ECU793 to
clutch transmission the gearbox.
activates "limp
home". In the event
the valve is out of limit. to the gearbox.
unit transmission
activates "TCU
and has no contact to ECU793. gearbox.
shutdown".
defect.
5535/3 8B Short circuit to battery voltage at - Check the cable from ECU793 to
DLM transversal output. the gearbox.
ECU 793 detected incorrect voltage Check the connectors from ECU793
on the output that appears to be a to the gearbox.
short circuit to battery voltage.
Check regulator resistance.
Possible reasons:
• The unit has an internal fault.
voltage.
5535/4 8A Short circuit to ground at DLM Output will be Check the cable from ECU793 to
transversal output. activated until the gearbox.
ECU793 is switched
off even if the fault
goes away (loose
short circuit to machine ground.
connection). Check regulator resistance.
Possible reasons:
ground.
5536/3 8E Short circuit to battery voltage at - Check the cable from ECU793 to
DLM indicator lamp output. the unit.
Possible reasons:
voltage.

ZF code
SPN/FMI (hex)
5536/5 8F Open circuit DLM indicator lamp - Check the cable from ECU793 to
output. the unit.
short circuit for this output.
Possible reasons:
• The cable is defective and has
no contact to ECU793.
• Cable/connector has no
connection to ECU793.
5545/3 D8 Short circuit to battery voltage at - Check the cable from ECU793 to
DLM longitudinal output. the valve.
Possible reasons:
voltage.
5545/4 D7 Short circuit to ground at DLM Output will be Check the cable from ECU793 to
longitudinal output. activated until the valve.
ECU793 is switched
off even if the fault
goes away (loose
connection). Check regulator resistance.
Possible reasons:
vehicle ground.
5560/5 93 Open circuit for connection to relay - Check the cable from ECU793 to
reverse alarm. the reverse alarm unit.
ECU 793 detected incorrect voltage Check the connectors from the
on the output that appears to be a reverse alarm unit to ECU793.
Check reverse alarm unit resistance.
Possible reasons:
• The reverse alarm unit has an
internal defect.

ZF code
SPN/FMI (hex)
5570/3 95 Short circuit to battery voltage at - Check the cable from ECU793 to
relay start lock-out. the start lock-out relay.
ECU 793 detected incorrect voltage Check the connectors from the start
on the output that appears to be a lock-out relay to ECU793.
Check relay start lock-out
Possible reasons: resistance.
• Start lock-out relay has an
internal defect.
voltage.
5570/4 94 Short circuit to ground for relay - Check the cable from ECU793 to
start lock-out. the start lock-out relay.
ECU 793 detected incorrect voltage Check the connectors from the start
on the output that appears to be a lock-out relay to ECU793.
Check relay start lock-out
internal defect.
vehicle ground.
5570/5 96 Open circuit at start lock-out relay. - Check the cable from ECU793 to
the start lock-out relay.
ECU 793 detected incorrect voltage
on the output that appears to be a Check the connectors from the start
short circuit for this output. lock-out relay to ECU793.
Possible reasons: Check relay start lock-out
resistance.
internal defect.
5620/3 A6 Short circuit to battery voltage at - Check the cable from ECU793 to
warning signal output. the warning unit.
on the output that appears to be a warning unit to ECU793.
Check the warning unit's resistance.
Possible reasons:
• Warning unit has an internal
defect.
voltage.

ZF code
SPN/FMI (hex)
5620/4 A4 Short circuit to ground at warning - Check the cable from ECU793 to
signal output. the warning unit.
Possible reasons:
defect.
vehicle ground.
5620/5 A5 Open circuit at warning signal - Check the cable from ECU793 to
output. the warning unit.
Possible reasons:
defect.
5660/2 B1 Slipping at clutch K1. Control unit Check pressure at clutch K1.
transmission
ECU793 calculates a different Check main pressure in the system.
activates "limp
speed for closed clutch K1. If this
home". In the event Check sensor gap at internal speed
calculated value is outside the
of an ongoing fault on sensor.
range, ECU793 interprets this as
another gear, control
slipping. Check sensor gap at output speed
unit transmission
sensor.
Possible reasons: activates "TCU
shutdown". Check signal at internal speed
• Low pressure at clutch K1.
sensor.
• Low main pressure.
Check signal at output speed
• Wrong signal at internal speed sensor.
sensor.
Replace clutch.
• Wrong signal at output speed
sensor.
• Wrong sensor gap size.
• Clutch is defective.

ZF code
SPN/FMI (hex)
transmission
activates "limp
unit transmission
sensor.
sensor.
sensor.
Replace clutch.
sensor.
transmission
activates "limp
unit transmission
sensor.
sensor.
sensor.
Replace clutch.
sensor.
transmission
activates "limp
unit transmission
sensor.
sensor.
sensor.
Replace clutch.
• Wrong signal at turbine speed
sensor.

ZF code
SPN/FMI (hex)
5680/2 B5 Slippage at clutch KV, forward Control unit Check pressure at clutch KV.
clutch. transmission
Check main pressure in the system.
activates "limp
ECU793 calculates a different
speed for closed clutch KV. If this
range, ECU793 interprets this as Check sensor gap at output speed
unit transmission
slipping. sensor.
activates "TCU
Possible reasons: shutdown". Check signal at internal speed
sensor.
• Low pressure at clutch KV.
sensor.
• Wrong signal at internal speed
Replace clutch.
sensor.
sensor.
5685/2 B6 Slippage at clutch KR, reverse Control unit Check pressure at clutch KR.
clutch. transmission
Check main pressure in the system.
activates "limp
ECU793 calculates a different
speed for closed clutch KR. If this
range, ECU793 interprets this as Check sensor gap at output speed
unit transmission
slipping. sensor.
activates "TCU
Possible reasons: shutdown". Check signal at internal speed
sensor.
• Low pressure at clutch KR.
sensor.
• Wrong signal at internal speed
Replace clutch.
sensor.
sensor.
5700/0 B7 Overtemp sump - Cool down machine.
ECU793 measured a temperature Check the oil level.
in the oil sump that is over the
allowed threshold.
5730/0 BA Differential pressure oil filter. - Check the oil filter.
ECU793 measured a voltage at the Check the cable from ECU793 to
differential pressure sensor outside the differential pressure sensor.
the permissible limits.
Check the sensor for differential
Possible reasons: pressure (measure resistance).
• The oil filter is contaminated.
or cable/connector has contact
to battery voltage or machine
ground.
• The sensor for differential
pressure is defective.

ZF code
SPN/FMI (hex)
5745/15 BC Overspeed output. -
ECU793 measures an transmission
output speed above the defined
threshold.
5751/0 C0 Engine torque or engine power -
overload.
ECU793 calculates an engine
torque or engine power above the
defined thresholds.
5752/0 C1 Transmission output torque -
overload.
ECU793 calculates an transmission
output torque above the defined
threshold.
5755/15 C2 Transmission input torque overload Programmable: No WARNING!
reaction or shift to
ECU793 calculates an transmission
neutral.
input torque above the defined
threshold.
5760/0 C3 Overtemp converter output. - Cool down machine.
ECU793 measured oil temperature Check the oil level.
at the converter output that is over
the allowed threshold.
5770/3 C4 Short circuit to ground at status - Check the cable from ECU793 to
indication joystick. status indication joystick.
ECU 793 detected incorrect voltage Check the connectors from status
on the output that appears to be a indication joystick to ECU793.
Check status indication joystick
• Status indication joystick has
an internal defect.
vehicle ground.
5770/4 C5 Short circuit to battery voltage at - Check the cable from ECU793 to
status indication joystick. status indication joystick.
an internal defect.
voltage.

ZF code
SPN/FMI (hex)
5770/5 C6 Open circuit at status indication - Check the cable from ECU793 to
joystick. status indication joystick.
an internal defect.
5810/3 D1 Short circuit to battery voltage at See error codes no. Check cables and connectors to the
power supply for sensors. 25 to 2C. sensors supplied from AU1. Check
the power supply to pin AU1 (should
ECU793 measures more than 6 V
be approx. 5 V).
at pin AU1 (5 V sensor supply).
Error codes no. 25 to no. 2C may
be a reaction of this fault.
5810/4 D2 Short circuit to ground at power See error codes no. Check cables and connectors to the
supply for sensors. 25 to 2C. sensors supplied from AU1. Check
the power supply to pin AU1 (should
ECU793 measures less than 4 V at
be approx. 5 V).
the pin AU1 (5 V sensor supply).
Error codes no. 25 to no. 2C may
be a reaction of this fault.
5820/3 D4 High voltage at battery. Transmission control Check power supply battery.
unit activates "TCU
Measured voltage at power supply Check cables from batteries to
shutdown".
is higher than: ECU793.
• 18 V (12 V device) Check connectors from batteries to
ECU793.
• 32.5 V (24 V device).
5820/4 D3 Low voltage at battery Transmission control Check power supply battery.
unit activates "TCU
Measured voltage at power supply Check cables from batteries to
shutdown".
is lower than: ECU793.
• 10 V (12 V device) Check connectors from batteries to
ECU793.
• 18 V (24V device).
5830/2 D5 Error at value power supply VPS1. Transmission control Check fuse.
unit activates "TCU
ECU793 switched on VPS1 and Check cables from gearbox to
shutdown".
measured VPS1 is off or ECU793 ECU793.
switched off VPS1 and measured
Check the connectors from the
VPS1 is still on.
gearbox to ECU793.
Possible reasons:
Replace ECU793.
• Cable or connectors are
defective and have contact
with battery voltage.
with vehicle ground.
• Permanent power supply KL30
missing.
• ECU793 has an internal defect.

ZF code
SPN/FMI (hex)
5840/2 D6 Error valve power supply VPS2. Transmission control Check fuse.
unit activates "TCU
ECU793 switched on VPS2 and Check cables from gearbox to
shutdown".
measured VPS2 is off or ECU793 ECU793.
switched off VPS2 and measured
Check the connectors from the
VPS2 is still on.
gearbox to ECU793.
Possible reasons:
Replace ECU793.
• Permanent power supply KL30
missing.
• ECU793 has an internal defect.
5860/3 E3 Short circuit to battery voltage at - Check the cable from ECU793 to
display output. the display.
ECU793 sends data to the display Check the connectors at the display.
and always measures a high
Replace display.
voltage level on the connector.
Possible reasons:
• Display has an internal defect.
5860/4 E4 Short circuit to ground at display - Check the cable from ECU793 to
output. the display.
ECU793 sends data to the display Check the connectors at the display.
and always measures a high
Replace display.
voltage level on the connector.
Possible reasons:
• Display has an internal defect.
5880/2 E6 Illegal ID request via CAN. Transmission in
neutral position.
Transmission control
unit activates "TCU
shutdown".
5890/2 F1 General EEPROM fault. - Replace ECU793.
ECU793 cannot read non-volatile Often shown together with error
memory. code F2.
Possible reason:
• ECU793 is defective.

D:52 8 Control system – Control system
ZF code
SPN/FMI (hex)
5900/13 F2 Configuration lost. Transmission control Reprogram the correct configuration
unit activates "TCU for the machine (e.g. with cluster
ECU793 has lost the correct
shutdown". control unit,...).
configuration and cannot control
the transmission.
Possible reasons:
• Interference while saving data
on non-volatile memory.
• ECU793 is brand new or from
another vehicle.
5910/13 F3 Application error. Transmission control Replace ECU793.
unit activates "TCU
Something in this application is This fault occurs only if an
shutdown".
wrong. technician did something wrong in
the application of the machine.
5930/7 F5 Clutch fault. Transmission control ECU793 also shows the affected
unit activates "TCU clutch on the display.
AEB was not able to adjust clutch
shutdown".
parameters.
Possible reason:
• One of the AEB values is out
of limit.
5930/13 F6 Clutch adjustment data lost or Default values = 0 for Execute AEB clutch calibration
inching pedal calibration data lost. AEB offsets used. or inching pedal calibration; see
section 2 Transmission, group 2.8
ECU793 was not able to read No inching mode
Transmission control system.
correct clutch adjustment available.
parameters.
Possible reason:
• Interference while saving data
on non-volatile memory.
• ECU793 is brand new.
8 Control system
Error codes machine
Code Description Limitation Action
1 Time for service interval has been Make maintenance according to
exceeded. service schedule. Activate new
service interval with service interval
code.
10 Communication fault ECU 790. Operation not possible. Check the power supply to the ECU
790. Check the CAN bus for breaks.
11 Communication, defective cable Operation not possible. Check the cable between ECU 790
between ECU 790 - EDU 795. and EDU 795.
Short-circuit or open circuit.
12 Communication fault ECU 793. Check the cable between ECU 793
and EDU 795.

8 Control system – Control system D:53

13 Communication fault ECU 794. Check the cable between ECU 794
and EDU 795.
14 Communication ECU 796, not Check the power supply to the ECU
responding. 796. Check the CAN bus for breaks.
15 Communication, defective cable ECU Check cable.
795 - ECU 796.
16 Communication, defective cable ECU Check cable.
796 - ECU 790.
17 Memory error, check sum EDU 795. Operation not possible. Restart ECU 795. Download
program. If the problem persists,
Display not in function.
replace ECU 795.
18 Communication ECU 792, not Check the power supply to the ECU
responding. 792. Check the CAN bus for breaks.
301 Voltage supply error ECU 790. Reduction of engine speed. Check the fuse in accordance with
the manual. Measure the battery
Supply voltage below 14 or above 33
voltage or check the acid level.
V for 5 s.
303 Reference voltage error, 5V, ECU Reduction of engine speed. Measure 5 V reference. Possible
790. sensor fault or short-circuit to battery
minus.
Reference voltage below 4,5 or above
5,5 V for 50 ms.
304 Defective sensor for electric scale. Possible cable open circuit. Check
cable from frame to mast.
Signal below 0.20V for 5s.
305 Defective speed sensor. Reduction of engine speed. Examine the installation of the sensor
and cable to this. Search for open
Machine speed above 40 km/h for
circuit or open conductor. Important
one second or too fast change of
that the distance between sensor and
speed (2 km/h at 20ms).
cam disc is correct, contact Cargotec.
Measure output signal with
oscilloscope.
306 Defective engine rev sensor. Reduction of engine speed. Check that the sensor is securely
screwed into the flywheel housing so
Engine speed above 3500 rpm for 1s
that the correct distance to the ring
or too fast change of speed (150 rpm
gear is obtained. On the front edge of
at 20 ms).
the sensor is a flange that must abut
against the flywheel housing. Also
check the cable to the sensor if there
is open circuit or open conductors.
Measure output signal with
oscilloscope.
307 Defective gear selector. Reduction of engine speed. Check for physical damage or cable
open circuit.
Logical fault or unexpected input from
lever.
320 Defective sensor for hydrostatic drive Reduction of engine speed. Check connector on pressure sensor
pressure (forward). mounted on hydraulic pump.
Signal below 0.20V or above 4.80V
for 2s.
321 Defective sensor for hydrostatic drive Reduction of engine speed. Check connector on pressure sensor
pressure (reverse). mounted on hydraulic pump.
for 2s.


322 Defective hydraulic pressure sensor Engine speed does not increase Check connector on pressure sensor.
for lift lever. when using lift lever.
for 2s.
323 Short-circuit or open circuit on output Reduction of engine speed. Measure the valve's resistance. Must
signal EDC valve pump (forward). not be less than 15 ohm. Check
with the data sheet from the valve
manufacturer.
signal EDC valve pump (reverse). not be less than 15 ohm. Check
manufacturer.
signal PDC valve hydraulic motor. not be less than 15 ohm. Check
manufacturer.
350 Battery voltage low. Check the alternator and charging
circuit. Measure the acid level and
Battery voltage below 23 V if engine
charge the battery if necessary. If the
is running for 12 s.
problem persists, replace one or both
batteries.
351 Battery voltage high. Check the alternator's 24V output.
Check cabling.
Battery voltage above 30 V for 10 s.
352 Fuel level low. Activity can be continued. Fill with fuel.
Less than 15 % for 40 s.
353 Defective sensor fuel level. Activity can be continued. Check the sensor's resistance. It
should be between 0 and 73 ohm.
354 Coolant level low. Reduction of engine speed. Fill with refrigerant.
Low level for 40 s.
355 Hydraulic oil temperature high. Do not use hydraulic functions before
the temperature has fallen below 70
Hydraulic oil temperature above 100
°C. Hydraulic fluid may burn if above
°C for 40 seconds.
100 °C.
356 Defective sensor hydraulic oil Activity can be continued. Check the sensor's resistance. It
temperature. should be approx. 8.5 kOhm at 0 °C
and 290 Ohm at 100 °C.
If value is above 138 °C or below -30
°C.
357 Brake system, accumulator pressure Reduction of engine speed. Stop the machine. Check the
low. accumulator.
The brake pressure is low for ten
seconds. The pressure can be low
for 60 seconds during starting.
370 Engine particulate filter. Time to Regenerate particulate filter in 30
regenerate particulate filter in 30 minutes.
minutes.
371 Engine particulate filter. Time to Reduction of engine speed. Regenerate particulate filter.
clean.
372 High pressure in the particulate filter. Reduction of engine speed. Regenerate particulate filter.
Pressure high for 1 minute.
380 Defective accelerator LF (Left Front). Reduction of engine speed. Check cable and physical installation
of pedal. Calibrate pedal.
Accelerator pedal signal below 0.2
V or above 4.8 V or 0.3 V out of
calibrated values for 500 ms.


381 Defective accelerator RF (Right Reduction of engine speed. Check cable and physical installation
Front). of pedal. Calibrate pedal.
382 Defective accelerator LR (Left Rear). Reduction of engine speed. Check cable and physical installation
of pedal. Calibrate pedal.
383 Defective accelerator RR (Right Reduction of engine speed. Check cable and physical installation
Rear). of pedal. Calibrate pedal.
384 Defective servo motor for injector Reduction of engine speed. Check cable and physical installation
pump engine. of pedal. Calibrate pedal.
Servo feedback above 4.8 V or 0.5 V
out of calibrated values for 500 ms or
too fast change of feedback.
390 Defective valve to variable pump for Measure the valve's resistance. It
Optimum Lift, short circuit or open should not be less than 10 ohm.
circuit at terminal K2:28. Check with the data sheet from the
valve manufacturer.
400 Fault in sensor for turnable driver's Only driving with driver's seat in Measure the signal with a multimeter
seat. forward direction is possible. or use the built-in diagnostic system
in the KCS to check whether the
Faulty sensor or open circuit on signal
signal is within the permissible limits.
cable. Signal below 0.3 V or above
4.7 V for 200 ms. Mechanical sensor Use the diagnostic menus (KCS,
fault. monitoring) to investigate K1:37.
401 Overload lift and tilt according to Speed limitation. Put down and lift lighter loads.
calibrate table.
Machine capacity exceeded.
402 Parking brake error. Parking brake doesn't release. Check the parking brake pressure
after the valve. Check switch parking
Parking brake valve or parking brake
brake.
switch out of order.
404 Coolant level sensor error. Check cable from sensor and make
sure coolant level is ok.
Signal from sensor below 0.2V or
above 4.8V.
405 Seat turning sensing logic error. Possible to turn seat but with Check cables and connections to
limitations. seat sensing logic.
Signal from sensor below 0.2V or
above 4.8V.
406 Error from power cell, gudgeon pin, Overload protection disabled. Overload protection is deactivated.
tilt cylinder. Do not overload the machine.
Replace sensor.
Sensor signal below 0.1V or above
4.8V for 10s.
601 Voltage supply error, ECU 796. Measure battery voltage. Check fuse
58-4 no. 6 (5 A).
V.
602 Memory error, check sum ECU 796. Restart ECU 796. Download
program. If the problem persists,
replace ECU 796.
603 Reference voltage 10V error, ECU Measure 10V reference between
796. X46.7 (0V) and X46.6 (10V).
Reference voltage below 9 or above
11 V for 50 ms.


604 Voltage supply error PWM outputs, Hydraulics not working. Switch off the hydraulic functions.
ECU 796. Check if the electric servo control
switch is depressed.
V for 5s. Measure battery voltage. Check fuse
58-4 no. 7 (10 A).
605 Communication error XA-PWM, K2. Hydraulic functions not working. Re-start ECU 796. If that does not
help, replace ECU 796.
606 Communication error XA-PWM, K3. Hydraulic functions not working. Re-start ECU 796. If that does not
help, replace ECU 796.
610 Error, input signal from lever for Hydraulic function 1 not working. Check the potentiometer fitting and
hydraulic function 1. cable. The signal voltage should be
between 0-10 V.
Signal from sensor below 0.6 V or
above 9.4 V for 100 ms.
between 0-10 V.
between 0-10 V.
between 0-10 V.
between 0-10 V.
615 Short-circuit or open circuit for main Hydraulic function 1 not working. Measure the valve's resistance. Must
valve hydraulic function 1A at terminal not be less than 15 ohm. Check
K2:3. with the data sheet from the valve
manufacturer.
valve hydraulic function 1B at terminal not be less than 15 ohm. Check
manufacturer.
manufacturer.
manufacturer.
manufacturer.
manufacturer.
manufacturer.


manufacturer.
manufacturer.
manufacturer.
626 Defective sensor for tilt control. Tilt control not working. Switch off tilt control.
Signal below 0.5 V or above 9.5 V for Check the potentiometer fitting and
100 ms. cable.
627 Defective sensor for preselected Preselected lifting height not Switch off preselected lifting height.
lifting height. working.
Signal below 0.5 V or above 9.5 V for
100 ms.
628 CTX communication error. The Only manual clamping function is CTX clamping controller inoperative.
clamping controller is not responding. possible. Select manual clamping control.
Check cable to clamping controller.
630 Fault in pressure sensor P1 for Clamping pressure is estimated Check the cable for the pressure
automatic clamping unit. to be the set value. Warning! sensor on the clamping unit.
There is no automatic increase in
Signal below 0.5V or above 10.5V for Check the pressure sensor.
clamping pressure.
2s.
631 Fault in pressure sensor P2 for Clamping pressure is estimated Check the cable for the pressure
automatic clamping unit to be the set value. Warning! sensor on the clamping unit.
Signal below 0.5V or above 10.5V for Check the pressure sensor.
clamping pressure.
2s.
632 Short circuit or open circuit in Clamping prevented. Measure the valve's resistance. It
hydraulic valve at terminal K3:3. should not be less than 15 ohms.
Check with the manufacturer's data
sheet. Check the cable connected to
the valve.
633 Short circuit or open circuit in Clamping prevented. Measure the valve's resistance. It
clamping pressure valve, on/off. should not be less than 15 ohms.
the valve.
634 Short circuit or open circuit in valve Not possible to shut off left side. Measure the valve's resistance. It
for left clamping arm, on/off. should not be less than 15 ohms.
the valve.
635 Short circuit or open circuit in valve Not possible to shut off right side. Measure the valve's resistance. It
for right clamping arm, on/off. should not be less than 15 ohms.
the valve.
636 Short circuit or open circuit in upper Not possible to shut off upper left Measure the valve's resistance. It
left clamping arm valve on/off. side. should not be less than 15 ohms.
the valve.


637 Short circuit or open circuit in middle Not possible to shut off middle Measure the valve's resistance. It
right clamping arm valve on/off. right side. should not be less than 15 ohms.
the valve.
638 Short circuit or open circuit in middle Not possible to shut off middle left Measure the valve's resistance. It
left clamping arm valve on/off. side. should not be less than 15 ohms.
the valve.
639 Short circuit or open circuit in upper Not possible to shut off upper right Measure the valve's resistance. It
right clamping arm valve on/off. side. should not be less than 15 ohms.
the valve.
642 Fault in pressure sensor for opening Clamping prevented. Check the cable for the pressure
clamping unit. sensor for opening the clamping unit.
Signal below 0.5 V or above 10.5 V Check the pressure sensor.
for 2s.
643 Fault in pressure sensor for closing Clamping prevented. Check the cable for the pressure
clamping unit. sensor for closing the clamping unit.
for 2s.
644 Switch for selecting left or right Not possible to shut off left or right Check the switch.
clamping unit. side.
Check the cable connected to the
switch.
645 Overload Speed reduction to max 1 km/h.
646 Short circuit or open circuit in upper Clamping on left side not possible. Measure the valve's resistance. It
left bypass valve on clamp. should not be less than 15 ohms.
the valve.
647 Short circuit or open circuit in middle Clamping on left side not possible. Measure the valve's resistance. It
left bypass valve on clamp. should not be less than 15 ohms.
the valve.
648 Short circuit or open circuit in left Clamping on left side not possible. Measure the valve's resistance. It
sequence valve on clamp. should not be less than 15 ohms.
the valve.
650 Short circuit or open circuit in upper Clamping on right side not Measure the valve's resistance. It
right bypass valve on clamp. possible. should not be less than 15 ohms.
the valve.
651 Short circuit or open circuit in middle Clamping on right side not Measure the valve's resistance. It
right bypass valve on clamp. possible. should not be less than 15 ohms.
the valve.
652 Short circuit or open circuit in right Clamping on right side not Measure the valve's resistance. It
sequence valve on clamp. possible. should not be less than 15 ohms.
the valve.


654 Pressure sensor P3 left long arm Clamping on left side not possible. Check the cable for the pressure
fault, paper clamp. sensor for P3 left long arm.
Check the pressure sensor.
655 Pressure sensor P3 left short arm Clamping on left side not possible. Check the cable for the pressure
fault, paper clamp. sensor for P3 left short arm.
656 Pressure sensor P3 right long arm Clamping on right side not Check the cable for the pressure
fault, paper clamp. possible. sensor for P3 right long arm.
657 Pressure sensor P3 right short arm Clamping on right side not Check the cable for the pressure
fault, paper clamp. possible. sensor for P3 right short arm.
658 Pressure select switch fault. Clamp pressure one is selected. Check the switch bracket and cable.
The signal voltage should be between
0.2-9.8 V.
659 Pressure sensor P1 on left arm fault, Clamping pressure is estimated Check the cable for the pressure
paper clamp. to be the set value. Warning! sensor.
clamping pressure.
for 2s.
660 Pressure sensor P2 on left arm fault, Clamping pressure is estimated Check the cable for the pressure
clamping pressure.
for 2s.
661 Pressure sensor P1 on right arm fault, Clamping pressure is estimated Check the cable for the pressure
clamping pressure.
for 2s.
662 Pressure sensor P2 on right arm fault, Clamping pressure is estimated Check the cable for the pressure
clamping pressure.
for 2s.
900 Error code from transmission control Depending on type of fault. See Error codes transmission, page
unit. SPN and FMI code are shown D:30.
if available.
1200 Error code from engine control unit. Depending on type of fault. See Error codes engine, page D:9.
SPN and FMI code are shown if
available.
1501 Defective sensor for feedback Steering turns off automatically. Check potentiometer and wiring from
steering. sensor wheel angle. The signal
should be between 0.5 and 4.5 V.
100 ms or mechanical sensor fault.
1502 Defective steer lever. Steering turns off automatically. Check potentiometer and wiring from
sensor wheel angle. The signal
should be between 0.5 and 4.5 V.
100 ms or mechanical sensor fault.
1503 Defective mini steering 2-channel Steering turns off automatically. Check the wiring. Measure the
potentiometer. potentiometer channels 1 and 2
(oscilloscope required).
Unexpected input signal from
potentiometer. Signal value below
0.2 V or above 4.8 V.
1504 Short-circuit or open circuit on output Steering turns off automatically. Measure the valve's resistance. Must
signal for right steering valve. not be less than 15 ohm. Check
manufacturer.


1505 Short-circuit or open circuit on output Steering turns off automatically. Measure the valve's resistance. Must
signal for left steering valve. not be less than 15 ohm. Check
manufacturer.
1506 Voltage supply error, ECU 792. Reduction of engine speed. Check the fuse in accordance with
the manual. Measure the battery
voltage or check the acid level.
V for 5s.
1507 Reference voltage 5V error, ECU 792. Reduction of engine speed. Measure 5 V reference. Possible
sensor fault or short-circuit to battery
Reference voltage below 4.5 or above
minus.
5.5 V for 50 ms.
1508 Incorrect value from alternative Steering turns off automatically. If the machine is equipped with
steering. The steering wheels do not turnable driver's seat then the
turn in the expected direction. position of the seat must be checked.
1509 Short-circuit or open circuit on output Steering turns off automatically. Check the wiring to the control valve
signal to steering valve. Control for steering.
signal outside valid range or internal
Check the voltage for the control
fault in the steering valve.
valve for steering, it must be 15-85%
of the supply voltage.
Check the control valve for steering
for mechanical damage.
1510 Unreasonable value from wheel angle Steering turns off automatically. Switch the ignition off and on.
sensor.
If the fault remains then the wheel
angle sensor must be calibrated,
section 8 Control system, group
8.5.4.2 Calibrate feedback joystick
control.
If that does not help then check
the wiring and sensor. A further
calibration may be required in
accordance with the above.
1511 Wheel angle sensor indicates Steering turns off automatically. Check the wheel angle sensor's
no movement for steering with installation.
mini-wheel/joystick control.

9 Frame, body, cab and accessories – Frame, body, cab and accessories D:61
9 Frame, body, cab and

accessories
9.4 Heating, ventilation and air
conditioning
ECC: Reading out error code
A B C
NOTE
In case of an error code, perform the recommended actions
according to the error code table to find the problem.
If there is a fault in any sensor, or if the pressure monitor has tripped,

A UT O
MODE
"ERROR" will be flashed on the display.
Keep the auto button (position E) depressed for a few seconds to

003708
show the current fault(s) as text on the display.

E F
Scroll through the error messages with the temperature buttons (A
A Scrolling between error messages and B). The selected error message is indicated with an arrow on
B Scrolling between error messages the display.
C Resetting the pressure monitor The fault cause is indicated with a left arrow (position F).
D -
The pressure monitoring is reset with the button for reducing speed
E Auto mode (C). Hold the button depressed for a few seconds to reset.
F Fault cause
Return by briefly pressing the auto button (position E).

D:62 9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
ECC: Error code table
Error Description Limitation Recommended action

Heatervalve The heater valve has failed or Pin 10 should have a Check the wiring harness. Is the
Open become disconnected. voltage of approx. 5 V heater valve connected? Change
all the time. Pin 9 should heater valve.
Heatervalve The heater valve has been shorted have a voltage of approx.
Short to ground. 0.9 V when fully closed
Heatervalve Is the heater valve stuck? and approx. 2.7 V when
Stuck fully open. Pin 8 should
have ground potential all
the time. Pin 6, when
valve is closing voltage
should be approx. 12 V,
when opening approx. 0
V, when stopped approx.
0 V. Pin 5, when valve
is closing voltage should
be approx. 0 V, when
opening approx. 12 V,
when stopped approx. 0
V.
Inside sensor The connection between ECC and Resistance should be Check wiring harness. Sensor
Open sensor has been broken. approx. 10 Kohm at 25 C. connected? Measure resistance.
Replace sensor.
Inside sensor The connection between ECC and
Short sensor has been shorted to ground.
Outside sensor The connection between ECC and Resistance should be Check wiring harness. Sensor
Replace sensor.
Outside sensor The connection between ECC and
Deicing sensor The connection between ECC and Resistance should be Check wiring harness. Sensor
Replace sensor.
Deicing sensor The connection between ECC and
Aftercoil sensor The connection between ECC and Resistance should be Check wiring harness. Sensor
Replace sensor.
Aftercoil sensor The connection between ECC and
AC system failure There is a problem with the ECC Control refrigerant charge. Control
system, either excess pressure or pressure switch. Refrigerant
insufficient refrigerant. The system leakage?
can be reset. Switch off, restart and
reset the error from the error menu
with the button for the fan down.

D:1
Contents E Schematics
Schematics......................................................................................................... D:3
Common hydraulics ........................................................................................ D:3
Hydraulic diagrams, compilation ................................................................ D:3
Hydraulic diagram A59056.0200 ................................................................ D:4
Hydraulic diagram A59056.0400 .............................................................. D:10
Hydraulic diagram A59067.0100 .............................................................. D:12
Common electrics ......................................................................................... D:13
Circuit diagram, description ..................................................................... D:13
Component designations ......................................................................... D:15
Circuit diagrams, compilation ................................................................... D:15

D:2

E Schematics – Schematics D:3
E Schematics
Common hydraulics
Hydraulic diagrams, compilation
Designation, draw. no, reference Functions included
Hydraulic diagram A59056.0200, page D:4 Hydraulic diagram steering and load handling (hydraulic servo)
Hydraulic diagram A59056.0100, page D:6 Hydraulic diagram steering and load handling (electric servo)
Hydraulic diagram A59056.0300, page D:8 Hydraulic diagram steering, mini-wheel/joystick control and load handling
(hydraulic servo)
Hydraulic diagram A59056.0400, page Hydraulic diagram steering, mini-wheel/joystick control and load handling
D:10 (electric servo)
Hydraulic diagram A59067.0100, page Hydraulic diagram brake system
D:12

D:4 E Schematics – Common hydraulics
Hydraulic diagram A59056.0200
13
6
7
5
18
5
4
12
4
19
11
8
17
15
14
3
2
10
1
015381 (A59056.0200 ve r.2)

16

E Schematics – Common hydraulics D:5
1. Directional control valve, turnable driver's seat

3. Control levers
4. Tilt cylinder
5. Lift cylinder
6. Side shift/spreading cylinder
7. Accumulator
8. Shuttle valve, steering and load handling.
9. Steering valve
10. Priority valve
11. Control valve load handling
12. Directional control valves for tilt and lift
13. Directional control valves for side shift and spreading
14. Shuttle valve, lift and tilt
15. Hydraulic oil filter
16. Hydraulic oil pump steering and load handling.
17. Hydraulic oil pump, lift, lower and tilt
18. Breather filter
19. Hydraulic oil tank

6
5
7
4
19
4
3
15
3
20
14
9
10
18
16
13
2
1
11
12
015380 (A59056.0100 ve r.2)

17


3. Tilt cylinder
4. Lift cylinder
6. Solenoid valve spreading in (Y6019) and out (Y6018)
7. Solenoid valve side shift left (Y6020) and right (Y6021)
8. Accumulator
11. Steering valve
12. Priority valve
13. Shuttle valve, lift/tilt
14. Solenoid valve lift (Y6005) and lower (Y6004)
15. Solenoid valve tilt in (Y6011) and out (Y6010)
19. Breather filter

13
6
5
7
5 4
20
12
4
11
3
19
21
17
14
2
1
15
18
015671 (A59056.0300 ve r.1)

16
10
9


3. Control levers
4. Tilt cylinder
5. Lift cylinder
7. Accumulator
10. Priority valve
12. Directional control valves for tilt and lift
13. Directional control valves for side shift and spreading
14. Shuttle valve, lift and tilt
15. Steering valve
16. Mini-wheel/joystick control
20. Breather filter

6
5
7
4
8
4 3
21
17
3
2
16
9
10
20
18
1
22
13
14
19
015672 (A59056.0400 ve r.1)

15
12
11


3. Tilt cylinder
4. Lift cylinder
6. Solenoid valve spreading in (Y6019) and out (Y6018)
7. Solenoid valve side shift left (Y6020) and right (Y6021)
8. Accumulator
12. Priority valve
13. Shuttle valve, lift/tilt
14. Steering valve
15. Mini-wheel/joystick control
16. Solenoid valve lift (Y6005) and lower (Y6004)
17. Solenoid valve tilt in (Y6011) and out (Y6010)
21. Breather filter

5
6
4
4
3
16
7
15
14
2
17
1
015383 (A59067.0100 ve r. 1)
12
11
13
10
1. Accumulator 10. Switch (NC), low brake pressure (S204)

2. Brake valve 11. Accumulator charging valve
3. Parking brake cylinder 12. Hydraulic oil filter
4. Brake cylinder 13. Hydraulic oil pump, brake system
5. Wheel brakes 14. Oil cooler
6. Distribution block 15. Thermal bypass valve
7. Make-contact (closing switch) brake light (S216) 16. Breather filter
8. NC switch disengagement (S220) 17. Hydraulic oil tank
9. Break contact (opening switch) parking brake (S200)

E Schematics – Common electrics D:13
Common electrics
Circuit diagram, description
A circuit diagram is divided into circuit names (drawing numbers) and
consists of a set of numbered pages.
The circuits and their contents are governed by the following set of
rules:
• 20015.0001 circuit drawings-post designations K-standard.
• K-standard 1: norms, rules
• K-standard 2: cables, general physical
• K-standard 5: Designation and marking system, item designations
circuit drawings
The following is an explanation of symbols and texts in a circuit

diagram:
Connectors
Connectors
-X M 6 7 4 m -X M 6 7 4 f
2 2
Connectors in the wiring start with an X followed by a number
and end with f = female or m = male. If a connector is connected
to a component then the component number is inherited into the
connector's number, e.g. XB72002Rm which is the connector for
Sensor, alignment front right (B7202R).
013017
-X 3 7 -2 0 1 Under the connector's number the pin is specified with numbers or

letters depending on the connector.
• X37-: All grounding points start with X37, e.g. X37-201, which is
a grounding point on the frame.
X37-A, X37-B, X37-C and X37-D are grounding points in
electronic box, cab.
Zero references are in the control units.
Components
+CHASSIS Components
-S220-2
Components are described with component number (S220-2) and
P
a short descriptive text. Components (sensors, switches, etc.) are
1 1 2 1 shown in standby mode i.e. de-energised mode or not mechanical
standby mode.
013018
DECLUTCH
3,0MPa • S indicates the type of component, see Component designations,
page D:15.
• 220 is component number and indicates the function the
component has.
• -2 indicates that it is the second component of this type for the
specific diagram.
Cable marking
A 01012 0525 W 212D

Cable marking
All cables are either white (ground signal) or grey (other wiring) and
A 01011 0524 W 212C labelled with numbers.
Cable numbering is interpreted as follows:

A 01010 0523 W 212B • 0525: the number on a cable can usually be traced to a pin in a
connector, in this example, connector X052 pin 5.
• W212: cables that start with W and serial number cannot be
A 01016 0527 W 212E traced directly to a connector.
• A01012: cables that start with A are in the electronic box in the
cab.
013019
W 212A
• W212D: cables that end with a capital letter are jointed in the
wiring from a main cable with the same number. Each joint will
have its own letter.

D:14 E Schematics – Common electrics
References
0 References
00816
1 An arrow symbol means that the circuit continues on another page in
/4 .0 _ 1 .B 1 5 1 the circuit diagram at the specified coordinates. Sometimes there are
013020
/9 .1 0 _ 1 .A 2
00816 also references for components that can then be part of a component
whose other parts are on a different diagram. In some cases there
is also a help text where the cable connects.
Example: /11.5_1.D3 means page 11.5_1 coordinate D3.

Connection to control unit
Connection to control unit
-X 4 1 1 Connections to control units are described as a table with two fields;
21 K 1 :2 1 A n a lo g In 0 -5 V +BO O M
-D 7 9 1 -1 the upper one shows the type of connection, the lower one has a
/0 .0 _ 4 .D 5
reference to the compilation of the control unit's connections. Together
013021
M E A S U R E P O IN T S C A L E with this there are descriptive texts that specify control unit and signal.
For more information about the different connection types on the

control units, see section 11 Common electrics, group 11.5.5 Wiring.
Fuses
Fuse boxes always start with 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
circuits that the various fuses protect.

Component designations
The components in circuit diagrams have a prefix and number, the
prefix describes the type of component, the number which component.
Component list with component number, prefix and designation is

provided as an appendix after the circuit diagrams.
Prefix Description
B Converter from non-electric to electric signals or vice versa. Example: inductive sensor.
D Binary element, delay unit, memory. Example: control unit.
E White light. Example: work lighting.
F Protective device. Example: fuse.
G Alternator, power supply device. Example: battery.
H Signal device. Example: horn, brake lights.
K Relay, contactor. Example: power relay ignition key lock.
M Motor. Example: electric motor.
P Measuring instrument, testing equipment. Example: hour meter.
R Resistor. Example: potentiometer.
S Electric switch for control circuit, selector. Example: switch.
X Outlet/socket, connecting device. Example: connection terminal.
Y Electrically controlled mechanical device. Example: solenoid valve, hydraulic valve.
Circuit diagrams, compilation

Circuit diagrams for basic machine has drawing number A49842.0100,
and are provided as an appendix in following order.
Sheet Designation
0.0-1 Circuit cross-reference ECU 790
1.0-A Circuit engine Volvo TAD650VE and TAD750VE
1.0-B Circuit engine Cummins
1.0-C Circuit engine Perkins/Caterpillar
1.0-D Circuit, Volvo TAD761VE engine
2.0-A1 Circuit, gear changing ECU 790
2.0-A2 Circuit, extra forward/reverse selector
2.0-A3 Circuit, gear changing, aut/ECU 793
2.0-A4 Circuit, gear changing, ECU 793
2.0-B1 Circuit, hydrostatic transmission
2.0-C1 Circuit, gear changing ZF
2.0-C2 Circuit, gear changing ZF
3.3 Circuit, differential lock

D:16 E Schematics – Common electrics
Sheet Designation
4.0-1 Circuit, cab
4.0-2 Circuit, cab, turnable driver's seat
4.0-3 Circuit, monitoring brake pressure
4.5 Circuit, parking brake
5.2-1A Circuit, control function
5.2-1B Circuit, control function, turnable driver's seat
5.2-2A Circuit, control function
5.2-2B Circuit, control function, turnable driver's seat
7.0-1 Circuit, servo and hydraulic functions
7.0-2 Circuit, servo and hydraulic functions
7.0-3 Circuit, servo and hydraulic functions, turnable driver's seat
7.0-4 Circuit, ECU 796, joystick
7.0-5A Circuit, ECU 796, joystick 2
7.0-5B Circuit, ECU 796, joystick 2 turnable driver's seat
7.0-6A Circuit, hydraulic joystick
7.0-6B Circuit, hydraulic joystick, turnable driver's seat
7.2-1 Circuit, paper functions
7.2-2A Circuit, sensors attachment
7.2-2B Circuit, valves attachment
7.2-3 Circuit, indication lamps
7.2-4 Circuit, switches paper functions
7.2-5A Circuit, stop lower
7.2-6 Circuit, Optispeed/rev/lift
7.10 Circuit, electronic scale
8.2-1 Circuit, data com. RED CAN
8.2-2 Circuit monitoring
8.2-3 Circuit sensors speed and engine rev.
8.2-4 Circuit data com. J1939
8.2-5 Circuit data com.
9.1 Circuit sensors/instruments
9.2 Circuit alcolock
9.3-1 Circuit, seat rotation
9.3-2 Circuit, electric seat rotation
9.3-3 Circuit, seat up/down
9.3-4 Circuit, throttle application
9.4-1 Circuit, ECC
9.4-2A Circuit heating/AC
9.4-2B Circuit heating/AC
9.4-3 Circuit heating/AC FlexCab
9.4-5 Circuit heating/AC
9.4-6 Circuit ECC fan
9.4-7 Circuit pause heater

Sheet Designation
9.5-1 Circuit, wipers
9.6-1 Circuit, headlights
9.6-2 Circuit, headlights
9.6-3A Circuit, headlights
9.6-3B Circuit, headlights, turnable driver's seat
9.6-4 Circuit, headlights, turnable driver's seat
9.6-5A Circuit, rear headlights, DCE90-
9.6-5B Circuit, rear headlights, DCE50-90
9.6-5C Circuit, rear headlights
9.6-6 Circuit working light
9.6-7 Circuit working light
9.6-8A Circuit working light
9.6-8B Circuit, work lights, turnable driver's seat
9.6-9 Circuit light, engine bay
9.8-1 Circuit, cab
9.8-2 Circuit, compressor horn
9.14–1 Circuit option
11.5-1 Circuit power supply
11.5-2 Circuit power supply, fuses
11.5-3 Circuit power supply, fuses
11.5-4 Circuit power supply, ECU 792
11.5-5 Circuit power supply, ECU 793
11.5-6 Circuit power supply, ECU/EDU

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E Schema - Komponentförteckning / E Schematics - List of Components
NUMBER CATEG SVENSKA ENGLISH

30 G Batteri Battery
32 A Kretskort elcentral Printed circuit board, Junction box
37 X Terminal stomanslutning Earthing terminal on chassis
39 X Terminal minusanslutning Terminal, negative terminal
51 F Säkringshållare 1-polig Fuse holder, 1-pole
62 F Batterihandske 2-polig Battery connector, 2-pole
64 F Batterihandske 4-polig Battery connector, 4-pole
72 X Stickuttag 2-polig Outlet, 2-pole
77 X Stickuttag 7-polig Outlet, 7-pole
78 X Stickuttag extra 7-polig Outlet, extra, 7-pole
100 S Strömställare ljus Switch, light
101 S Strömställare omk hel/halvljus Switch, main/dipped beam
102 S Strömställare dimljus Switch, fog light
103 S Strömställare fjärrljus Switch, distance light
104 S Strömställare lastljus Switch, mast lights
105 S Strömställare arbetsljus Switch, working lights
106 S Strömställare containerljus Switch, container light
107 S Strömställare park broms Switch, parking brake
108 S Strömställare centr smörjning Switch, central lubricator
109 S Strömställare varningsljus Switch, hazard lights
110 S Strömställare rot varningsljus Switch, rotating hazard beacon
111 S Strömställare fönsterhiss Switch, window regulator
112 S Strömställare kylanläggning (AC) Switch, air conditioner (AC)
113 S Strömställare styrning alt Switch, alternative steering
114 S Strömställare läsbelysning Switch, reading light
115 S Strömställare instr belysning Switch, instrument illumination
116 S Strömställare innerbelysning Switch, interior lighting
117 S Strömställare värme Switch, heating
118 S Strömställare fläktm värme Switch, heater fan
119 S Strömställare vindrutetorkare Switch, wiper
120 S Strömställare spolare Switch, washer
121 S Strömställare blackout Switch, blackout
122 S Strömställare nöd hydraulpump Switch, emergency hydraulic pump
123 S Strömställare backspegel Switch, observation mirror
124 S Strömställare kallstart Switch, cold start
125 S Strömställare avgasbroms Switch, exhaust brake
126 S Strömställare diff spärr/broms Switch, diff. Block
127 S Strömställare värmesystem diesel Switch, heating system diesel
128 S Strömställare kraftuttag sida Switch, power take off side
129 S Strömställare kraftuttag bak Switch, power take off rear
130 S Strömställare hög/lågväxel Switch, high/low gear
131 S Strömställare färdväljare fram Switch, gear selector forward
132 S Strömställare färdväljare bak Switch, gear selector rear
135 S Strömställare växelväljare Switch, gear shift
136 S Strömställare framhjuls styrning Switch, forward wheel steering
137 S Strömställare 4-hjuls styrning Switch, 4-wheel steering
138 S Strömställare crab styrning Switch, crab steering
139 S Strömställare defroster Switch, defroster
141 S Strömställare Stegbelysning Switch, Steplight
142 S Strömställare fot Switch, foot
143 S Strömställare sitsvärme Switch, seat heater
144 Q Batterifrånskiljare Battery disconnecting switch
145 S Strömställare AT-regulator Switch, AT-regulator
147 S Strömställare körvisare Switch, direction indicators
149 S Strömställare signalhorn Switch, horn
150 S Strömställare startlås/ellas Switch, main key switch
152 S Strömställare intervalltorkare Switch, intermittent wiper
156 S Strömställare kupevärmare Switch, cab heating

157 S Strömställare stoltilt Switch, seat tilt
158 S Strömställare dimbakljus Switch, rear fog light
159 S Strömställare extra fram/back väljare Switch, extra direction selector
160 S Strömställare komb fram/back Switch, combi-forward/reverse
161 S Strömställare komb signal, ljus hel/halv Switch, combi-horn, light main/dipped beam, washer,
spol,torkare m intervall körvisare wiper (intermittent), direction indicator
162 S Strömställare komb signal ljus hel/halv, Switch, combi horn, light main/dipped beam, washer,
spol, torkare m 2 int, fram/bacK wiper w 2int., forward/revers
163 S Strömställare start på 2-an Switch, start 2nd gear
165 S Strömställare stolvärme Switch, seat heater
166 S Strömställare låsning vändskiva Switch, interlocking of turntable
167 S Strömställare luftfjädring Switch, pneumatic springing
168 S Strömställare låsn stol Switch, interlocking of seat
169 S Strömställare stolsvändning Switch, reversible seat
170 S Strömställare förångare (LPG) Switch, evaporator (LPG)
171 S Strömställare v-skiva upp/ner Switch, fifth wheel up/down
172 S Strömställare v-skiva fr/back Switch, fifth wheel forward/reverse
173 S Strömställare v-skiva skevning Switch, fifth wheel, levelling
174 S Strömställare,utskjut Switch, projecting
175 S Strömställare hyttlyft upp Switch, cab hoist up
176 S Strömställare hyttlyft ner Switch, cab hoist down
177 S Strömställare hyttskjutning Switch, cab movement
178 S Strömställare nollställning Switch, reset
179 S Strömställare Aut/man växling Switch Aut/man gearshifting
180 S Strömställare fyrhjulsdrift Switch, 4-WD
190 S Strömställare klimatanläggning Switch, air conditioner
191 S Strömställare recirkulation Switch, re-circulation
192 S Strömställare vattenavskiljare
195 S Strömställare joy-stick X Switch, joy-stick X
196 S Strömställare joy-stick X+Y Switch, joy-stick X+Y
197 S Strömställare längs/tvärskörning Switch, length/sideways driwing
198 S Strömställare flytläge skevning Switch, equalizing fifth wheel
199 S Strömställare option Switch, option
200 S Brytkontakt lampa park broms Contact, breaking,warning lamp,parking brake
201 S Brytkontakt lampa färdbroms Contact, breaking, warning lamp, brake
202 S Brytkontakt lampa oljetryck motor Contact, breaking, warning lamp, oil pressure engine
204 S Brytkontakt tryck ackumulator Contact, breaking, pressure accumulatortank
205 S Brytkontakt innerbelysning Contact, breaking, interior lighting
206 S Brytkontakt handskfack belysning Contact, breaking, glove
207 S Slutkontakt diff spärr Contact, making, diff. interlock
208 S Slutkontakt lampa temperatur spolkrets Contact, making, warning lamp temperature brake
bromsar
214 S Slutkontakt överväxel Contact, making, over drive
215 S Slutkontakt temp motor Contact, making, temperature engine
216 S Slutkontakt bromsljus Contact, making, brake lights
217 S Slutkontakt backljus Contact, making, reversing light
218 S Slutkontakt AT-regulator Contact, making, AT-control
219 S Slutkontakt lampa luftfilter Contact, making, indicating light air filter
220 S Brytkontakt drivning Contact, breaking, drive cut off
221 S Slutkontakt temp växellåda Contact, making, temperature gear box
222 S Slutkontakt lampa temp moment - Contact, making, warning lamp temperature torque
förstärkare amplifier.
223 S Släpkontakt signal Contact, brush, horn
224 S Slutkontakt insprutningspump Contact, making, injection pump
225 S Brytkontakt säkerhetsbälte Contact, breaking, seat belt
228 S Slutkontakt hyttlåsning Contact, making, cab locking
229 S Slutkontakt stolslåsning Contact, making, seat locking
230 S Brytkontakt stol Contact, breaking, seat
231 S Slutkontakt fotkontroll stolvändning Contact, making, seat rotation, foot switch
232 S Brytkontakt lampa luftanslutning släp Contact, breaking, warning lamp air connection
233 S Slutkontakt lampa låsning vändskiva Contact, warning, interlocking of turntable

235 S Slutkontakt sidoskjutning stol Contact, making, side shifting of seat
236 S Slutkontakt vattennivå Contact, water level
239 S Brytkontakt termisk Contact, breaking, thermic
240 S Slutkontakt termisk Contact, making, thermic
241 S Brytkontakt lampa luftmatning släp Contact, breaking, warning lamp air supply to trailer
242 S Slutkontakt lampa oljetryck v-låda Contact, making, warning lamp, oil pressure gear box
243 S Brytkontakt tryck kylmedia AC Contact, breaking, coolant pressure (air condition)
244 S Slutkontakt hydraulik aktiverad Contact, making, hydraulics
245 S Slutkontakt hydraultryck styrning Contact, making, hydraulic pressure control
246 S Slutkontakt tryck kylmedia Contact, pressure refrigerant
250 S Manöverbrytare Operating Switch
251 S Slutkontakt vändbar förarstol Contact, making, VBFS
260 S Slutkontakt lyft steg 1 Contact, making, hoist step 1
261 S Slutkontakt lyft steg 2 Contact, making, hoist step 2
262 S Slutkontakt tilt Contact, making, tilting
263 S Slutkontakt gaffelspridning Contact, making, fork positioning
264 S Slutkontakt sidoföring Contact, making, sideshift
265 S Slutkontakt stativ in/ut Contact, making, lifting mast in-out
266 S Brytkontakt hyttdörr Contact, breaking cab door
267 S Slutkontakt bromstryck Contact, making, brake pressure
268 S Slutkontakt kompressor Contact, making, Compressor
269 S Slutkontakt sax inne Contact, making extender in
270 S Slutkontakt överlastskydd Contact, making, overload protection
271 S Slutkontakt, filter växellåda Contact, making, filter gearbox
299 S Slut/brytkontakt option Contact, making/braking option
300 K Relä hel/halvljus Relay, main/dipped beam
301 K Relä dimljus Relay, fog light
302 K Relä fjärrljus Relay, distance light
303 K Relä lastljus Relay, mast light
304 K Relä arbetsljus Relay, working light
305 K Relä backljus Relay, reversing light
306 K Relä helljus Relay, main beam
307 K Relä halvljus Relay, dipped beam
308 K Relä bromsljus Relay, brake light
309 K Relä parkeringsbroms Relay, parking light
310 K Relä körvisare vä Relay, direction indicator left
311 K Relä körvisare hö Relay, direction indicator right
312 K Relä startelement Relay,element preheater
313 K Relä vändbar förarstol Relay, rotating driver´s seat (VBFS)
314 K Relä parkeringsbroms Relay, parking brake
315 K Relä tändningslås Relay, ignition key
316 K Relä torkare Relay, wiper
317 K Relä strålkastartorkare Relay, roading lights wiper
318 K Relä AT-regulator Relay, AT-regulator
319 K Relä varningsblinkers Relay, hazard blinkers
320 K Relä elektrisk stopp Relay, electical stop
321 K Relä intervalltorkare Relay, intermittent wiper
322 K Relä kylvätskenivå Relay, coolant level
323 K Relä blinkers Relay, blinkers
324 K Relä rangespärr Relay, range interlock
325 K Relä blinkande bromsljus (back) Relay, flashing brake lights (reversing)
326 K Relä blinkande bromsljus (runt) Relay, flashing hazard brake lights
327 K Relä växel neutral Relay, gear neutral
328 K Relä växelskifte Relay, gear shift
329 K Relä växel hög/låg Relay, high/low gear
330 K Relä startspärr Relay, start interlock
331 K Relä drivning fram Relay, forward driving
332 K Relä drivning bak Relay, reversing driving
333 K Tidrelä förvärmning Time relay, automatically preheating
334 K Relä frikoppling/drivbrytning Relay, free wheel/drive disconnection
335 K Relä växelventil 1:a (diesel, gas) Relay, gear change valve 1-gear (diesel,LPG)

336 K Relä växelventil 2:a (diesel, gas) Relay, gear change valve 2-gear (diesel,LPG)
337 K Relä drivriktning motor Relay, motor drive direction
338 K Relä kylfläkt drivmotor Relay, cooling fan drive motor
339 K Relä kylfläkt elskåp Relay, cooling fan electrical box
340 K Tidrelä fördröjt tillslag Time relay, start delay
341 K Tidrelä fördröjt frånslag Time relay, stop delay
342 K Relä drivning 2/4 hjul Relay, switching 2/4 WD
343 K Relä dimbakljus Relay, fog light rear
344 K Relä momentförstärkare Relay, torque amplifier
345 K Relä låsning vändskiva Relay, interlocking of turntable
346 K Relä frikoppling stollåsning Relay, releasing of seat interlocking
347 K Relä stolvändning/ljussignal Relay, multifunction, seat rotation/light signal
348 K Relä fläktmotor värmare Relay, fan heating
349 K Relä fartreglage Relay, speed control
350 K Relä pumpkontaktor/pumpkontroll Relay, pump contactor/pump control
351 K Relä hyttlyft upp Relay, cab hoist up
352 K Relä hyttlyft ner Relay, cab hoist down
353 K Relä säkerhetsslinga Relay, safety loop
354 K Relä styrsystem Relay, signal control system
355 K Relä sensorstyrning Relay, sensor control
356 K Skiftrelä längskörning/tvärskörning Shift relay, length/sideways driving
357 K Relä roterande varningsljus Relay, hazard beacon
358 K Relä komressor luft Relay, compressor air
359 K Relä Hydrauloljekylare Relay hydraulic oil cooler
360 K Relä startsolenoid Relay, starting solenoid
361 K Relä kompressor AC Relay, compressor air conditione
362 K Relä vattenventil AC Relay, water valve air conditioner
363 K Relä kondensor AC Relay, condenser air conditione
364 K Relä stolsbrytare Relay seat switch
365 K Relä fönsterhiss upp Relay, electrical screen elevator up
366 K Relä fönsterhiss ner Relay, electrical screen elevator down
367 K Relä styrning Relay, steerin
368 K Relä lågt bromstryck Relay, low brake pressure
369 K Relä centralsmörjning Relay, central lubrication
370 K Relä centralsmörjning, aggregat Relay, central lubrication, attatchment
371 K Relä lyfthöjd Relay, liftheight
372 K Relä blinkande varn.ljus, höjdbegränsn. Relay, flashing beacon, lifting height limiter
373 K Relä bakljus Relay light
375 K Huvudkontaktor reglersystem Main contactor, operating control
376 K Kontaktor fram reglersystem Contactor, forward operating control
377 K Kontaktor bak reglersystem Contactor, reversing operating control
378 K Kontaktor by-pass Contactor, ¿by-pass¿ operating control/ Field
reglersystem/Fältförsvagning weakening
379 K Kontaktor pumpmotor Contactor, pump motor
380 K Kontaktor Contactor
381 K Kontaktor återladdning Contactor, recharging
382 K Relä, förbikoppling säkerhetssystem Relay, by-pass safety system
383 K Relä, Stolsvärme Relay, heated seat
384 K Relä vattenseparator Relay, waterseparator
385 K Relä bränslepump insprutning Relay, fuel injection pump
386 K Relä, hög motortemperatur. Relay, high motor temperature
387 K Relä alternativ gaspedal Relay alternative throttle pedal
388 K Relä, Extra färdriktningsväljare Relay, Extra direction selector
389 K Relä, Pausvärme Relay, Paus heat
399 K Relä option Relay, option
400 E G-lampa vä fram Light bulb, roading light left hand front
400 E G-lampa hö fram Light bulb, roading light right hand rear
401 E G-lampa vä bak Light bulb, roading light left hand front
401 E G-lampa hö bak Light bulb, roading light right hand rear
402 E G-lampa fjärrljus Light bulb, distance light
403 E G-lampa lastljus Light bulb, mast light
404 E G-lampa arbetsljus Light bulb, working light

405 E G-lampa backljus Light bulb, rear light
406 E G-lampa cont belysning vänster Container light left-hand
406 E G-lampa cont belysning höger Container light right-hand
408 E G-lampa park ljus vä fram Light bulb, parking light, left-hand forward
408 E G-lampa park ljus hö fram Light bulb, parking light, right-hand forward
410 H G-lampa broms ljus vä fram Light bulb, brake light, left-hand forward
410 H G-lampa broms ljus hö fram Light bulb, brake light, right-hand forward
411 H G-lampa broms ljus vä bak Light bulb, brake light, left-hand rear
411 H G-lampa broms ljus hö bak Light bulb, brake light, right-hand rear
412 H G-lampa bak ljus vä bak Light bulb, rear light, left-hand rear
412 H G-lampa bak ljus hö bak Light bulb, rear light right-hand rear
413 H G-lampa bak ljus vä fram (VBFS) Light bulb, rear light, left-hand forward (VBFS)
413 H G-lampa bak ljus hö fram (VBFS) Light bulb, rear light,right-hand forward (VBFS)
416 H G-lampa sidomarkering vä fram Light bulb, side position light, left-hand forward
416 H G-lampa sidomarkering vä bak Light bulb, side position light, left-hand rear
417 H G-lampa sidomarkering hö fram Light bulb, side position light, right -hand forward
417 H G-lampa sidomarkering hö bak Light bulb, side position light, right-hand rear
420 H G-lampa positionsljus vänster Light bulb, position light, left-hand
421 H G-lampa positionsljus höger Light bulb, position light, right-hand
422 H G-lampa körvisare vä fram Light bulb, direction indicator left-hand forward
423 H G-lampa körvisare hö fram Light bulb, direction indicator right-hand forwrd
426 H G-lampa körvisare vä bak Light bulb, direction indicator left-hand rear
427 H G-lampa körvisare hö bak Light bulb, direction indicator right-hand rear
428 H G-lampa roterande varningsljus Light bulb, flashing beacon lamp
429 E G-lampa cigarettändare belysning Light bulb, cigarett lighter illumination
431 E G-lampa instrument belysning Light bulb, instrument illumination
432 E G-lampa handsfack belysning Light bulb, glove pocket light
433 E G-lampa instegs belysning Light bulb, step-in lighting
434 E G-lampa innerbelysning Light bulb, interior lighting
435 E G-lampa låsbelysning Light bulb, reading lighting
436 E G-lampa identifikationsljus Light bulb, identification light
437 E G-lampa identifikationsljus/takskylt Light bulb, identification light/roof sign
438 E G-lampa motorrumsbelysning Light bulb, engine compartment light
439 E Nummerskyltsbelysning Light license plate
440 E G-lampa värmereglage belysning Light bulb, heating control light
445 H G-lampa körvisare vä (extra) Light bulb, extra direction indicator left
446 H G-lampa körvisare hö (extra) Light bulb, extra direction indicator right
451 H G-lampa dimbakljus vänster Light bulb, fog light rear left
452 H G-lampa dimbakljus höger Light bulb, fog light rear right
453 H G-lampa bromsljus/körvisare vänster Light bulb, brake light/dir. indicator left-hand
453 H G-lampa bromsljus/körvisare höger Light bulb, brake light/dir. indicator right-hand
454 H G-lampa bromsljus blackout vänster Light bulb, brake light blackout left-hand
454 H G-lampa bromsljus blackout höger Light bulb, brake light blackout right-hand
456 E G-lampa backljus blackout IR vänster Light bulb, rear light blackout IR left-hand
456 E G-lampa backljus blackout IR höger Light bulb, rear light blackout IR right-hand
457 H G-lampa positionsljus blackout vänster Light bulb, position light blackout left-hand
457 H G-lampa positionsljus blackout höger Light bulb, position light blackout right-hand
458 E G-lampa fram blackout vänster Light bulb, roading light blackout left-hand
458 E G-lampa fram blackout höger Light bulb, roading light blackout right-hand
459 E G-lampa fram blackout IR vänster Light bulb, roading light blackout IR left-hand
459 E G-lampa fram blackout IR höger Light bulb, roading light blackout IR right-hand
460 E G-lampa arb.belysning hytt blackout IR Light bulb, working light cab blackout IR left
vä
460 E G-lampa arb.belysning hytt blackout IR Light bulb, working light cab blackout IR right
hö
461 E G-lampa arb.bel. bom 20' blackout IR Light bulb, working light boom20' b.out IR left
vä
461 E G-lampa arb.bel. bom 20' blackout IR Light bulb, working light boom20' b.out IR right
hö
462 E G-lampa arb.bel. bom 40' blackout IR Light bulb, working light boom40' b.out IR left
vä

462 E G-lampa arb.bel. bom 40' blackout IR Light bulb, working light boom40' b.out IR right
hö
463 H G-lampa bak ljus vänster bak, blackout Light bulb, rear light left-hand rear, blackout
463 H G-lampa bak ljus höger bak, blackout Light bulb, rear light right-hand rear, blackout
464 E G-lampa cont belysning IR vänster Light bulb,Container light IR left-hand
464 E G-lampa cont belysning IR höger Light bulb,Container light IR right-hand
465 H G-lampa röd saxagregat ute Light-bulb, red extender exended
466 H G-lampa orange vertikalhålning på Light bulb, orange vertical hold on
467 H G-lampa grön klämtryck OK Light bulb, green clamp pressure OK
468 G-Lampa Röd Maxlast Light bulb,Red Overload
500 H Kont lampa körvisare Indicating lamp, direction indicator
501 H Kont lampa körvisare (extra) Indicating lamp, direction indicator extra
503 H Varn lampa oljetryck motor Warning lamp, oil pressure engine
504 H Kont lampa helljus Indicating lamp, main beam
505 H Varn lampa laddning Warning lamp, loading
506 H Varn lampa laddning (extra) Warning lamp, loading extra
507 H Varn lampa färdbroms Warning lamp, brake
508 H Varn lampa parkerings broms Warning lamp, parking brake
509 H Varn lampa nivå kylvatten Warning lamp, coolant level
510 H Kont lampa diff spärr Indicating lamp, diff. interlock
512 H Varn lampa temp momentförst Warning lamp, temperature converter
514 H Kont lampa överväxel Indicating lamp, overdrive clutch
519 H Kont lampa halvljus Indicating lamp, dipped lights
524 H Kont lampa luftfilter Indicating lamp, air filter
525 H Kont lampa UNIKAT Indicating lamp, UNIKAT
528 H Kont lampa förvärmning Indicating lamp, preheating
530 H Kont lampa framhjuls styrning Indicating lamp, forward wheel steering
531 H Kont lampa 4-hjuls styrning Indicating lamp, 4-wheel steering
532 H Kont lampa crab styrning Indicating lamp, crab steering
533 H Kont lampa hyd.pump Indicating lamp, emergency hyd. pump
547 H Varn lampa centralvarning Warning lamp, central warning
549 H Varn lampa oljetryck v-låda Warning lamp, oil pressure gear box
550 H Varn lampa hyttlåsning Warning lamp, cab lock
551 H Varn lampa temp v-låda Warning lamp, temperature gear box
552 H Varn lampa bromstryck Warning lamp, brake pressure
554 H Varn lampa temp spolkrets bromsar Warning lamp, temp. cooling system brakes
555 H Varn lampa temp kylvatten mot Warning lamp, temperature coolant engine
556 H Varn lampa låsning vändskiva Warning lamp, interlocking of turntable
560 H Varn lampa temp drivmotor el Warning lamp, temperature, drive motor
561 H Varn lampa temp pumpmotor el Warning lamp, temperature, pump motor
562 H Varn lampa öppen twistlock Warning lamp, unlocked twist lock
563 H Varn lampa låst twistlock Warning lamp, locked twist lock
564 H Varn lampa anliggning Warning lamp, alignement
565 H Varn lampa temp motor el Warning lamp ,temperature motor
569 H Kont lampa elvärme Indicating lamp, electric heater
569 H Kont lampa elvärme Indicating lamp, electric heater
570 H Varn lampa överkoppling Warning lamp, by-pass safety system
säkerhetssystem
571 H Kont lampa bränslenivå Indicating lamp, fuel level
572 H Varningslampa lyfthöjd Warning lamp lifting height
573 H Kontroll lampa motor information Indicator lamp engine information
574 H Kontroll lampa stödben nere Indicator lamp support jacks down
575 H Kontroll lampa stödben ur arb.läge Indicator lamp support jacks out of working pos
576 H Kontroll lampa anliggning främre ben Indicator lamp, alignment front legs
577 H Kontroll lampa anliggning bakre ben Indicator lamp, alignment rear legs
578 H Kontroll lampa klämläge främre ben Indicator lamp, clamp position front legs
579 H Kontroll lampa klämläge bakre ben Indicator lamp, clamp position rear legs
580 H Kontroll lampa främre ben uppe Indicator lamp, front legs upper position
581 H Kontroll lampa främre ben nere Indicator lamp, front legs lower position
582 H Varningslampa överlast Warning lamp overload
583 H Kontroll lampa anliggning ett ben Indicator lamp, alignment one leg
584 H Kontroll lampa anliggning alla ben Indicator lamp, alignment all legs

599 H Kont lampa option Indicating lamp, option
600 Y M-ventil avgasbroms Solenoid valve, exhaust brake
601 Y M-ventil diff spärr Solenoid valve, diff. interlock
602 Y M-ventil broms Solenoid valve, brake
603 Y M-ventil värme Solenoid valve, heater
604 Y M-ventil kraftuttag sida Solenoid valve, power take off, side
605 Y M-ventil kraftuttag bak Solenoid valve, power take off, rear
606 Y M-ventil 2/4 hjulsdrift Solenoid valve, 2/4WD
607 Y M-ventil hög/låg växel Solenoid valve, high/low gear
608 M Pumpaggregat hyttlyft Pump unit, cab hoist
609 M Ställmotor gaspådrag Regulating motor, throttle
610 Y M-ventil hydraulsystem allm Solenoid valve, hydraulics, general
611 Y M-ventil flödesbegränsning Solenoid valve, flow restriction
612 M Ställmotor recirkulation Regulating motor, re-circulation
613 Y M-ventil momentförstärkare Solenoid valve, torque amplifier
614 Y M-ventil rangespärr Solenoid valve, ranging interlock
615 Y M-ventil hjulvridning Solenoid valve, wheel turning
616 Y M-ventil kallstart Solenoid valve, cold start aid
617 Y M-ventil AT-regulator by-pass Solenoid valve, AT-regulator ¿by-pass¿
618 Y M-ventil vatten klimatanläggning Solenoid valve, water air conditioner
620 Y M-ventil vändskiva upp Solenoid valve, fifth wheel up
621 Y M-ventil vändskiva ner Solenoid valve, fifth wheel down
622 Y M-ventil vändskiva fram Solenoid valve, fifth wheel forward
623 Y M-ventil vändskiva bak Solenoid valve, fifth wheel rear
624 Y M-ventil skevning hö Solenoid valve, levelling right hand
625 Y M-ventil skevning vä Solenoid valve, levelling left hand
626 Y M-ventil AT-regulator Solenoid valve, AT-regulator
627 Y M-ventil vakuum Solenoid valve vacuum
628 Y M-ventil bränsleblandning Solenoid valve fuelmixture
630 Y M-ventil v-låda fram Solenoid valve, gear box, forward gear
631 Y M-ventil v-låda back Solenoid valve, gear box, rear gear
632 Y M-ventil v-låda spole 1 Solenoid valve, gear box, 1 gear
635 Y M-ventil klämtryck Solenoid valve, clamping pressure
636 Y M-ventil styrning Solenoid valve, steering
637 Y M-ventil flytläge skevning Solenoid valve, equalizing fifth wheel
638 Y M-ventil stopp insprut pump Solenoid valve, stop injection pump
639 Y M-ventil låsning orbitrol ls Solenoid valve, locking LS orbitrol
640 Y M-ventil gasol Solenoid valve, LPG
641 Y M-ventil förångare (LPG) Solenoid valve, evaporator (LPG)
642 Y M-ventil park broms Solenoid valve, parking brake
643 Y M-ventil låsning stol (VBFS) Solenoid valve, seat locking (VBFS)
644 Y M-ventil låsning vändskiva Solenoid valve, fifth wheel locking
645 Y Magnetkoppling komp AC Magnetic clutch, compressor AC
646 Y M-ventil stolsvändning Solenoid valve, seat rotation
647 Y M-ventil stolstilt Solenoid valve, seat tilt
648 Y M-ventil luftfjädring Solenoid valve, pneumatic springing
649 B Termostat klimatannläggning Thermostat, air condition
650 M Torkarmotor fram
651 M Vindrutespolarmotor Washer motor
652 M Strålkastarmotor Light motor
653 M Strålkastarspolarmotor Light washer motor
654 M Startmotor Starter motor
655 M Kylfläkt drivmotor (EC) Cooling fan, main motor (EC)
656 M Kylfläkt elskåp (EC) Cooling fan, electrical box (EC)
657 M Fläktmotor värme Heating fan
658 G Generator (extra) Alternator extra
659 G Generator utan laddregulator Alternator without loading regulator

660 G Generator med laddregulator Alternator with loading regulator
661 M Fönsterhissmotor Screenelevator motor
662 G Laddregulator Loading regulator
663 M Doseringspump klimatanläggning Dosage pump, air condition
664 M Cirk pump klimatanläggning Circulating pump, air condition
665 V Diod Diode
666 M Fläktmotor cirkulation Circulation fan
667 M Cirkulationspump värmesystem Circulation pump heating system
668 M Kylfläkt hydraulolja Cooling fan, hydraulic oil
669 E Värmare kupe/ motor diesel Heater compartment/engine diesel
670 M Kompressor Compressor
671 M Doseringspump diesel Dosage pump diesel
672 M Spjäll motor, ECC Draught valve motor, ECC
673 Y Vatten ventil motor, ECC Water valve motor, ECC
674 M Kylfläkt bromsolja Cooling fan, brake fluid
675 M Motor, Stolsvändning Motor, Seat rotation
676 Y M-ventil Broms stolsvändning Solenoid valve Brake seat turning
677 M Motor Låsning stolsvridning Motor Locking revolving seat
685 A Reglerenhet termostat AC Control unit, termostat AC
690 B Fartreglage (EC) Speed control (EC)
693 M Pump centralsmörjning Pump, central lubrication
694 M Styrmotor Steering motor
695 M Drivmotor (EC) Drive motor (EC)
696 M Pumpaggregate nödstyrning Pump, emergency steering
697 B Elbroms Electric brake
698 M Pumpmotor (EC) Pump motor (EC)
699 Y M-ventil option Solenoid valve, option
700 P Hastighetsmätare Speedometer
701 P Mätare oljetemp v-låda Gear box oil temperature gauge
702 P Klocka Clock
703 P Varvtalsmätare Engine rev meter
704 P Tryckluftsmätare Air pressure gauge
705 P Mätare oljetryck v-låda Gear box oil pressure gauge
706 P Termometer temp kylvätska motor Temperature gauge, engine coolant
707 P Bränslemätare Fuel gauge
708 P Timräknare Hour meter
709 P Kapacitetsmätare batteri Capacity gauge, battery
710 P Tidur motor/kupevärmare Timer, engine- and cab heater
711 P Räknare, impuls Counter, impulse
712 P Mätare oljetryck motor Motor oil pressure gauge
714 P Mätare, temp. Hydraulolja Hydraulic fluidtemperature, guage
715 P Extra instrument allm Extra instrument, general
720 S Givare vändbar förarstol Transmitter, revolving driver´s seat (VBFS)
740 D FleetManager kontrollenhet FleetManager control unit
741 U FleetManager batterifilter FleetManager battery filter
742 D FleetManager kortläsare FleetManager card device
743 D FleetManager accelerations givare FleetManager acceleration sensor
744 D Galvaniskt isolerad CAN brygga Galvanic insulated CAN bridge
751 B Givare varvtal turbin Transmitter, speed turbin
752 B Givare varvtal inre växellåda Transmitter, speed internal gear chain
753 B Varvtalsgivare motor Transmitter, engine revolution
754 B Givare lufttryck Transmitter, air pressure
755 B Givare hydraulfilter indikering Transmitter, hydraulics filter indication
756 B Temperatur kylvätska motor Transmitter, engine coolant temperature
757 B Bränslenivågivare Transmitter, fuel level
758 B Varvtalsgivare v-låda Transmitter, gear box revolution
759 B Nivåindikator kylvätska Transmitter, coolant level
760 B Givare rev-spärr/aut-vxl trans Transmitter, reversing interlock / automatic gear
change system (on gearbox output shaft)
761 B Givare rev-spärr/aut-vxl motor Transmitter, reversing interlock / automatic gear
changing system (engine speed)
762 B Givare temp,spolkrets bromsar Transmitter, brake flushing circuit

763 B Givare nivå hydraulolja Transmitter, hydraulic fluid level
764 B Givare servotryck växellåda Transmitter, gear box servo pressure
765 B Givare oljetryck v-låda Transmitter, oil pressure gear box
766 B Givare oljetemp. v-låda Transmitter, oil temperature gear box
767 B Givare oljetryck motor Transmitter, oil pressure engine
768 B Givare oljetryck hydraulik Transmitter, hydraulic pressure
769 B Givare ändläge Transmitter, end position
770 B Givare rattutslag Transmitter, steering wheel angle
771 B Givare vinkel Transmitter, angle
772 B Givare temp bromsolja Transmitter, temperature brake fluid
773 B Givare närvaro Transmitter, presence
774 B Givare utomhustemp Transmitter, ambient temperature
775 B Givare temp klimatanläggning Transmitter, temperature air condition
776 B Givare temp hydraulolja Transmitter, hydraulic temperature
777 B Givare läge Transmitter, position
778 B Givare drivbrytning Transmitter, drive break
779 A Reglersystem återladdning (EC) Control system, recharging (EC)
780 D Reglersystem drivmotor Control system traction motor
781 D Reglersystem pumpmotor Control system pump motor
782 A Logik interface 2 drivmotorer Logic (interface) two main motors (EC)
783 A Logik interface gaspådrag Logic (interface) throttle
784 A Logik interface bromsregl Logic (interface) brake control
785 A Logik interface styrsystem Logic (interface) control system
786 A Servoförstärkare styrsystem Servo amplifier steering system
789 B Givare allmän Transmitter, common
790 D Elektronisk kontrollenhet ECU, hytt Electronic Control Unit ECU, cab
791 D Elektronisk kontrollenhet aggregat Electronic Control Unit, attachment
792 D Elektronisk kontrollenhet styrning Electronic Control Unit, steering system
793 D Elektronisk kontrollenhet växellåda Electronic Control Unit, gearbox
794 D Elektronisk kontrollenhet motor Electronic Control Unit, engine
795 P Display Display
796 D Elektronisk kontrollenhet, lasthantering Electronic Control Unit, Loadhandling
797 D Elektronisk kontrollenhet, ram Electronic Control Unit, frame
798 D Elektronisk kontrollenhet, stolvändning Electronic Control Unit, seat rotation
799 A Logik allm (option) Logic, general (option)
800 S Startelement Start element
802 E Eluppvärmd backspegel Electrical heated observation mirror
803 E Eluppvärmd stol Electrical heated seat
804 E Cigarettändare Cigarett lighter
805 E Elvärme hytt Electrical heating cab
806 A Aggregat klimatanläggning Aggregate, air conditioner
807 R Potentiometer Potentiometer
808 E Eluppvärmd lufttorkare Electrical heater air dryer
810 A Kondensor AC, fläkt Condensor AC, fan
815 S Manöverspak Control lever
820 R Motstånd Resistor
821 C KONDENSATOR CAPACITOR
822 Z Signalfilter Signal filter
823 U Signalomvandlare höger Signal amplifier, right
824 U Signalomvandlare vänster Signal amplifier, left
825 R Reglage spakstyrning Controls, (steering with control levers).
826 Y Ventil spakstyrning Valve, (steering with control levers).
827 A Växellåda Gearbox
828 R Shuntmotstånd Shunt-resitor
830 L Tändspole Ignition coil
835 E Tändstift Ignition plug
840 S Strömfördelare Distributor
850 H Signalhorn Horn
853 H Summer Buzzer
888 E Lufttork, kompressor Air Dryer, Compressor
900 A Radio/bandspelare Radio/tape recorder
901 U Spänningsomvandlare Voltage converter

902 B Högtalare Loud speaker
903 W Antenn radio Aerial, radio
905 A Kommunikationsradio Communication radio
906 W Antenn kommunikationsradio Aerial, communication radio
907 A Monitor Monitor
908 A Kamera Camera
909 A Skrivare Printer
910 U Spänningsomvandlare 80V/24V Voltage converter 80 V / 24 V
911 A Dataterminal Dataterminal
912 A Alkolås Interlock device
940 A Logik batterivakt Logic switch , battery watch
941 U Laddningsutjämnare Even charger
950 A Logik transistortändning Logic transistor ignition
955 A Logik övervarvningsskydd (LPG) Logic overspeed protection (LPG)
960 A Logik rev-spärr/aut-vxl Logic unit, reversing interlock/automatic gear
changing
961 A Motor/kupevärmare Engine- and cab heater
962 E Logik slitageind kol elmotor Logic indication of wear, brush electrical motor
965 H Backvarnare Reversing alarm
1001 S Strömställare, TW Switch, TW
1002 S Strömställare, lossa TW Switch, unlocking of TW
1003 S Strömställare, låsa TW Switch, locking of TW
1004 S Strömställare, stopp vid 30'-35' Switch, stop at 30 -35¿
1005 S Strömställare, förbikoppling av Switch, overriding of the safety system
säkerhetssystem
1006 S Strömställare, fällning främre ben Switch, front legs down
1007 S Strömställare, fällning bakre ben Switch, rear legs down
1008 S Strömställare, klämma/lossa ben Switch, clamping/-releasing legs
1009 S Strömställare, Motor information Switch, Engine information
1010 S Srömställare, tilt av hytt Switch, tilt of cab
1011 S Strömställare IR ljus Switch IR light
1012 S Strömställare utskjut 20¿-40¿ Switch, Extension 20¿-40¿
1013 S Strömställare stödben Switch, Support jacks
1014 S Strömställare förbikoppling Switch, over ride rotation stop
rotationstopp
1015 S Strömställare förbikoppling höjdbeg/tp- Switch, over ride height limit/tp-limit
beg
1016
1017 S Strömställare diagnostik öka/minska Switch, diagnostics increase/decrease
1018 S Strömställare diagnostik on/off Switch, diagnostics on/off
1019 S Strömställare rastvärme Switch, paus heat
1020 S Strömställare automatisk släpp/kläm Switch automatic release/clamp funktion
funktion
1021 S Strömställare sax Switch extender
1022 S Strömställare vertikalhållning Switch, vertical position
1023 S Strömställare låsning övre arm Switch, lock upper arm
1024 S Strömställare Korta Armen av/på Switch, Short Arm on/off
1025 S Strömställare pappersfunktioner av/på Switch, paper funktions on/off
1026 S Strömställare omkoppling Switch, switch papper/bale clamp
pappers/klämmagregat
1027 S Strömställare lyfthöjdsförval Switch, lift height selection
1028 S Strömställare lyfthöjdsförval öka Switch, lift height selection increase
1029 S Strömställare lyfthöjdsförval minska Switch, lift height selection decrease
1030 S Strömställare läraringång givare Switch, teaching ultrasonic sensor
ultraljud
1031 S Strömställare, Over Height Upp/Ned Switch, Over Height Up/Down
1032 S Brytare backljus Switch reverse light.
1033 S Flytta korta armen Move short arm
1034 S Strömställare förbikoppling startspärr Switch Override Start interlock
1035 S Strömställare Val av klämtryck Switch, Clamp pressure selection
1036 S Strömställare Korta Armen av/på Switch , Short Arm on/off
1037 S Strömställare låsning skevning Switch, lock levelling

1038 S Strömställare Övre armpar/Sidoföring Switch Upper arms/Sideshift
1039 S Strömställare Inching Switch, Inching
1040 S Switch stopp motor Switch, Stop engine
1041 S Strömställare motorrumsbelysning Switch, light engine compartment
1042 S Strömställare höjdjustering stol Switch, Seat height level
1043 S Strömställare längdjustering stol Switch, Seat for/aft adjustment
1044 S Strömställare Tankväljare Switch, Tankselector
1045 S Strömställare Avstängning backalarm Switch, Rev. Alarm on/off
1046 S Strömställare eluppvärmd ruta Switch electrical heated shield
1047 S Henrik testar en brytare!
1048 S Strömställare fjärrstyrning Switch remote control
1049 S Strömställare styrning spegel Switch mirror control
1440 S Huvudströmbrytare
2000 D Elektronisk kontrollenhet, Electronic control unit, propotional valve
proportionalventil
3001 K Relä rotation Relay, rotation
3002 K Relä tilt Relay, tilt
3003 K Relä sidoföring Relay, side shifting
3004 K Relä längdinställning Relay, length adjustment
3005 K Relä twist lock Relay, twist lock
3006 K Relä spridning Relay, spreading
3007 K Relä lyft/sänk Relay, lifting/lowering
3008 K Relä hydraulfunktion extra Relay, extra hydraulic function
3009 K Relä manöverbrytare hydr Relay, operating switch
3010 K Relä bromsljus vxl std/blackout Relay, brake light shift std/blackout
3011 K Relä backljus vxl std/blackout Relay, reversing light shift std/blackout
3012 K Relä arb.bel hytt vxl std/blackout Relay, working light cab, shift std/blackout
3013 K Relä arb.bel. bom 20' vxl std/blackout Relay,working light boom20' shift std/b.out
3014 K Relä arb.bel. bom 40' vxl std/blackout Relay,working light boom40' shift std/b.out
3015 K Relä vxl bromsljus/blinkers vä Relay, shift brake light/direction indicator left
3015 K Relä vxl bromsljus/blinkers hö Relay, shift brake light/direction indicator right
3016 K Relä signalhorn relay, horn
3017 K Relä containerbelysning Relay, Container light
3018 K Relä containerbelysning IR Relay, Container light IR
3305 K Relä VBFS, backljus Relay, rotating driver´s seat, reversing light
3306 K Relä VBFS, helljus Relay, rotating driver´s seat, main beam
3307 K Relä VBFS, halvljus Relay, rotating driver´s seat, dipped beam
3308 K Relä VBFS, bromsljus Relay, rotating driver´s seat, brake light
3310 K Relä VBFS, körvisare vä Relay, rotating driver´s seat, direction indicator left
3311 K Relä VBFS, körvisare hö Relay, rotating driver´s seat, direction indicator right
3330 K Relä, säkerhetsbälte Relay, seat belt
3331 K Relä VBFS, drivning fram Relay, rotating driver´s seat, forward driving
3332 K Relä VBFS, drivning bak Relay, rotating driver´s seat, reversing driving
3349 K Relä VBFS, fartreglage Relay, rotating driver´s seat, speed control
3404 K Relä VBFS, mastljus Relay, rotating driver´s seat, mast light
3405 K Relä,backalarm Relay,reversealarm
3412 K Relä bak ljus Relay, rotating driver´s seat, rear light
3500 A Head up display lasthantering Head up display load handling
3768 K Relä oljetryck hydraulik Relay, hydraulic pressure
3769 K Relä, blockering av hyttilt Relay, blocking of cab tilt
3770 K Relä anliggning Relay, alignment
3771 K Relä Krok Relay, Hook
3772 K Relä laddsignal (D+) Relay, charge signal (D+)
3773 K Relä 12V för minne radio Relay 12V for radio memory
3774 Relä kylfläkt olja Relay, cooling fan oil
3775
3776 K Relä värmare ruta Relay heated window
4370 E Sökljus Search light
5000 H Kont lampa tryck lyfttång Indicating lamp, pressure lift tong
5001 H Varn lampa, Over Height ben uppe Warn. Lamp, Over Height leg upper pos
6001 Y M-ventil blockering höger Solenoid valve, blocking right
6002 Y M-ventil blockering vänster Solenoid valve, blocking left

6003 Y M-ventil inkoppling av hydraulik till Solenoid valve, activation of toplift hydraulics
topplyft
6004 Y M-ventil sänk Solenoid valve, lower
6005 Y M-ventil lyft Solenoid valve, lift
6006 Y M-ventil bom ut Solenoid valve, boom out
6007 Y M-ventil bom in Solenoid valve, boom in
6008 Y M-ventil vridning medsols Solenoid valve, rotation clockwise
6009 Y M-ventil vridning motsols Solenoid valve, rotation counter-clockwise
6010 Y M-ventil tilt ut Solenoid valve, tilt out
6011 Y M-ventil tilt in Solenoid valve, tilt in
6012 Y M-ventil tilt Solenoid valve, tilt
6013 Y M-ventil fällning främre ben Solenoid valve, lowering front legs
6014 Y M-ventil fällning bakre ben Solenoid valve, lowering rear legs
6015 Y M-ventil klämma/lossa ben Solenoid valve, clamping/releasing legs
6016 Y M-ventil Hyttskjutning fram Solenoid valve, cab movement forward
6017 Y M-ventil Hyttskjutning bak Solenoid valve, cab movement reverse
6018 Y M-ventil spridning ut Solenoid valve, spreading out
6019 Y M-ventil spridning in Solenoid valve, spreading in
6020 Y M-ventil sidoföring vänster Solenoid valve, side shift left
6021 Y M-ventil sidoföring höger Solenoid valve, side shift right
6022 Y M-ventil extra hydraulfunktion ut Solenoid valve, extra hydraulic function out
6023 Y M-ventil extra hydraulfunktion in Solenoid valve, extra hydraulic function in
6024 Y M-ventil stativ ut Solenoid valve, mast out
6025 Y M-ventil stativ in Solenoid valve, mast in
6026 Y M-ventil höger framhjul styrning vänster Solenoid valve, right front wheel, steering left
6027 Y M-ventil höger framhjul styrning höger Solenoid valve, right front wheel, steering right
6028 Y M-ventil vänster framhjul styrning Solenoid valve, left front wheel, steering left
vänster
6029 Y M-ventil vänster framhjul styrning höger Solenoid valve, left front wheel, steering right
6030 Y M-ventil höger bakhjul styrning vänster Solenoid valve, right rear wheel, steering left
6031 Y M-ventil höger bakhjul styrning höger Solenoid valve, right rear wheel, steering right
6032 Y M-ventil vänster bakhjul styrning Solenoid valve, left rear wheel, steering left
vänster
6033 Y M-ventil vänster bakhjul styrning höger Solenoid valve, left rear wheel, steering right
6034 Y M-ventil skevning Solenoid valve, levelling
6035 Y M-ventil skevning höger Solenoid valve, levelling right
6036 Y M-ventil skevning vänster Solenoid valve, levelling left
6037 Y M-ventil kylfläkt Solenoid valve, Cooling fan
6038 Y M-ventil frikoppling koppling Solenoid valve, lockup clutch
6039 Y M-ventil öppna twistlock Solenoid valve, unlocked twist lock
6040 Y M-ventil låsa twistlock Solenoid valve, locked twist lock
6041 Y M-ventil nöd, twistlock Solenoid valve, emergency, twistlock
6042 Y M-ventil mellan bom Solenoid valve, middle boom
6043 Y Magnetventil, fällning torn (RTCH) Solenoid valve, boom lowering (RTCH)
6044 Y M-ventil blockering twistlock Solenoid valve, blocking twistlock
6045 Y M-ventil blockering lyft Solenoid valve, blocking lift
6046 Y M-ventil utskjut Solenoid valve, projecting
6047 Y M-ventil, hyttilt upp Solenoid valve, cab tilt up
6048 Y M-ventil, hyttilt ner Solenoid valve, cab tilt down
6049 Y M-ventil, kylkrets broms Solenoid valve, cooling cicuit brake
6050 Y M-ventil blockering utskjut Solenoid valve, blocking projecting
6051 Y M-ventil, regenerering höger Solenoid valve, regeneration right
6052 Y M-ventil, regenerering vänster Solenoid valve, regeneration left
6053 Y M-ventil, körläge Solenoid valve, driving position
6054 Y M-ventil, klämma ihop Solenoid valve, clambing in
6055 Y M-ventil, klämma isär Solenoid valve, clambing out
6056 Y M-ventil, främre knä ut Solenoid valve, front knee out
6057 Y M-ventil, främre knä in Solenoid valve, front knee in
6058 Y M-ventil, bakre knä ut Solenoid valve, rear knee out
6059 Y M-ventil, bakre knä in Solenoid valve, rear knee in
6060 Y M-ventil, främre ben upp Solenoid valve, front legs up
6061 Y M-ventil, bakre ben upp Solenoid valve, rear legs up

6062 Y M-ventil, urkoppling hydraulpump Solenoid valve interruption hydraulic pump
6063 Y M-ventil, stödben upp Solenoid valve, brace up
6064 Y M-ventil, stödben ner Solenoid valve, brace down
6065 Y M-ventil, frikoppling vridbroms Solenoid valve, lockup rotation brake
6066 Y M-ventil, v-låda, drivning Solenoid valve, gearbox, drive
6067 Y M-ventil, v-låda, oljetryck till 1:a/3:e Solenoid valve, gearbox,oilpressure to 1st/3rd gear
växeln
6068 Y M-ventil sax/rotation Solenoid valve externder/rotation
6069 Y M-ventil, v-låda, oljetryck till 2:a/4:e Solenoid valve, gearbox,oilpressure to 2nd/4th gear
växeln
6070 Y M-ventil Over Height upp Solenoid valve, Over Height up
6071 Y M-ventil Over Height ner Solenoid valve, Over Height down
6072 Y M-ventil klämtryck Solenoid valve clamp pressure
6073 Y Propertional ventil, Opti speed Proportional valve, Opti speed
6074 Y M-ventil, v-låda, växelväljare för 2:a/4:e Solenoid valve, gearbox, gearswitch for 2nd/4th gear
växeln
6075 Y M-ventil, v-låda, växelväljare för 1:a/3:e Solenoid valve, gearbox, gearswitch for 1st/3rd gear
växeln
6076 Y M-ventil blockering sänk Solenoid valve, blocking lower
6077 Y M-ventil Inching Solenoid valve, Inching
6078 Y M-ventil,Avstängning Övre klämarm Solenoid valve, upper arm off
6079 Y M-Ventil, Sidoföring/Övre armar Solenoid valve, Sideshift/Upper arms
6080 Y M-ventil, aktivering hyttkörning Solenoid valve, activate sliding cab
6081 Y M-ventil, ackumulatorladdning Solenoid valve, accumulator charge
6082 Y M-ventil tryckbegränsning Solenoid valve, pressure restriction
7200 S Givare, axeltryck höger Sensor, axle pressure right
7201 S Givare, axeltryck vänster Sensor, axle pressure left
7202 S Givare, anliggning vänster fram Sensor, alignment left front
7202 S Givare, anliggning höger fram Sensor, alignment right front
7203 S Givare, anliggning vänster bak Sensor, alignment left rear
7203 S Givare, anliggning höger bak Sensor, alignment right rear
7204 S Givare, öppen vänster twistlock Sensor, unlocked twistlock left
7204 S Givare, öppen höger twistlock Sensor, unlocked twistlock right
7205 S Givare, låst vänster twistlock Sensor, locked twistlock left
7205 S Givare, låst höger twistlock Sensor, locked twistlock right
7206 S Givare, gaffel aggregat Sensor, fork attachment
7207 S Givare, 2WD/4WD Sensor, 2WD/4WD
7208 S Givare, hytt i körläge Sensor, Cab in drive position
7209 S Givare, oljefilter indikering Sensor, Oil filter indication
7210 S Givare, hytt i transportläge Sensor, Cab in transportation position
7211 S Givare, lyfthöjd Sensor, lifting height
7212 S Givare, körläge Sensor, driving position
7213 S Givare, Anliggning främre ben Sensor, Alignment front legs
7214 S Givare, Anliggning bakre ben Sensor, Alignment rear legs
7215 S Givare, kläm främre ben Sensor, Clamp front legs
7216 S Givare, kläm bakre ben Sensor, Clamp rear legs
7217 S Givare, främnre knä Sensor, front knee
7218 S Givare, bakre knä Sensor, rear knee
7219 S Givare, främre ben Sensor, front legs
7220 S Givare, bakre ben Sensor, rear legs
7221 S Givare, styraxel Sensor, steering axle
7222 S Givare, stödben uppe Sensor, brace up
7223 S Givare, stödben nere Sensor, brace down
7224 B Givare, mätläge våg Sensor, measurepoint scale
7225 B Givare, rotationsstopp Sensor, rotation stop
7226 B Givare, tryck lyftcylinder Sensor, pressure lift cylinder
7227 B Givare, tryck klämma Sensor, pressure clamp
7228 B Givare lyfthöjd analog Sensor lift height analogue
7229 B Givare tiltvinkel analog Sensor tilt angle analogue
7230 B Givare ultraljud last position Sensor, ultrasonic load position
7231 B Givare, Over Height, Ben uppe Sensor, Over Height, Leg upper position
7232 B Givare,IR Last position Givare,IR Load position

7233 B Givare lambda sond Sensor lambda sond
7234 B Givare vatten i bränsle Transmitter water in fuel
7235 B Givare temp avgaser Sensor exhaust temperature
7236 B Givare tryck avgaser Sensor exhaust pressure
7651 B Givare oljetryck v-låda 1:a/3e Transmitter oil pressure gearbox 1st/3rd
7652 B Givare oljetryck v-låda 1/3
7751 B Givare temperatur inne Sensor temp indoor
7753 B Sensor temperatur avisning Sensor temperatur deicing
7901 D d
8071 R Potentiometer lyft/sänk Potentiometer lift/lower
8072 R Potentiometer tilt Potentiometer tilt
8073 R Potentiometer sidoföring Potentiometer side shifting
8074 R Potentiometer spridning Potentiometer spreading
8075 R Potentiometer extra Potentiometer extra
8076 R Potentiometer mast in/ut Potentiometer reach in/out
8077 R Potentiometer höger framhjul Potentiometer right front wheel
8078 R Potentiometer vänster framhjul Potentiometer left front wheel
8079 R Potentiometer höger bakhjul Potentiometer right rear wheel
8080 R Potentiometer vänster bakhjul Potentiometer left rear wheel
8081 R Potentiometer tiltvinkel Potentiometer tilt angle
8082 R Potentiometer fläkthastighet, ECC Potentiometer fan speed, ECC
8083 R Potentiometer temperatur, ECC Potentiometer temperature, ECC
8084 R Potentiometer spjäll, ECC Potentiometer draught valve, ECC
8085 R Potentiometer rotation Potentiometer rotation
8086 R Potentiometer sax Potentiometer extender
8087 R Potentiometer klämma Potentiometer clamp
8088 R Potentiometer skevning Potentiometer levelling
8089 R Potentiometer kroklåsning Potentiometer flaps
8090 V Laser, pappersaggretgat Lase, Pulp an Paper
8091
8092 E Eluppvärmd ruta Electrical heated window
8093 W Genomföring, kablage Lead-through, harness
9000 M Motor höj/sänkbar stolspelare Motor rise/lower seat column
9001 D Åkerströms fjärrkontroll Åkerströms Remote Control
9002
9003 H Varningssignal aut. rörelse Warning alarm aut. movement
9888 A test
93774 K Relä hållkrets Relay, Holdcircuit
F:1
F Technical data
Contents F Technical data

Technical data.................................................................................................... F:3
Data .................................................................................................................F:3
Volumes ...........................................................................................................F:4
Specification for lifting capacity and dimensions..............................................F:6
Oils and lubricants, recommendation...............................................................F:8
Tightening torques, recommendations...........................................................F:11
Tightening torque, ORFS connections ...........................................................F:12
Tightening torque, connections for air conditioning .......................................F:13
Unit explanations ...........................................................................................F:14
Conversion SI-units........................................................................................F:15
Conversion table length .................................................................................F:16
Conversion table area....................................................................................F:16
Conversion table volume ...............................................................................F:16
Conversion table weight.................................................................................F:16
Conversion table pressure .............................................................................F:17

F:2

F Technical data – Technical data F:3
F Technical data
Data
The machine's weights and dimensions vary depending on how the
machine is equipped. Detailed information regarding this is given in the
product specification and data sheet for the machine in question.
0 Complete machine Volvo TAD761VE

Guaranteed sound power level in LWA 109 dB(A)
accordance with 2000/14/EC and
2005/88/EC including measurement
uncertainty 1.5 dB.
1 Engine Volvo TAD761VE

Output as per ISO 3046 (rated output) 160 kW between 1300-2200 rpm
Torque ISO 3046 1180 Nm at 1200 rpm
Max. rotation speed 1900 rpm
Number of cylinders 6 cylinders
Alternator, output 3360 W
System voltage, voltage-capacity 24 V (2x12 V / 145 Ah)
2 Transmission ZF 3WG171
No. of gears, forward - reverse 3 – 3
3.3 Power transmission, drive

axle Kessler
Drive axle, type D91
4 Brakes
Service brake system – actuated wheel Wet Disc Brake - drive wheel
Parking brake system – actuated wheel Spring brake - drive wheel
5 Steering
Steering system Hydraulic servo
6 Wheels
Dimensions, front and rear 14.00x24
Tyre pressure, also see pressure plate 1.0 MPa

Tyre type, front and rear Inflated. Spare and replacement tyres must be from a manu-
facturer approved by Cargotec.

F:4 F Technical data – Technical data
9 Cab
Equivalent sound pressure level LpAz 72 dB(A)
in cab according to EN12053 with
measurement uncertainty σR=2.5 dB.
Measurement value with standard
engine.
Whole-body vibrations according 0.4 - 0.7 m/s2
to EN13059 with measurement
uncertainty k=0.3 x measured value.
9.6 Lighting system

Instruments 3 Ba7s
Check lamps 1.2 W2x4.6d
Interior lighting 10 S8.5
Tail lights 5 BA15s
Brake light 21 BA15s
Direction indicators 21 BA15s
Tail lights, brake lights & LED direction indicator - Replaced as a single unit
lamps
Position lamps 5 SV8,5
- Replaced as a single unit
Position lamps LED
Headlights (with high/low beam) 75/70 P43t-38 (H4)
Back-up lights 70 PK22s (H3)
Work light, bulb 70 PK22s (H3)
35 D1S Xenon tube. Cartridge and
Work lights, Xenon ballast are replaced completed.
- Replaced as a single unit
Work light LED
Revolving beacon 70 PK22s (H1)
Volumes
Any deviation from this table must be approved in writing by Cargotec.
1.2 Engine, fuel

system
Fuel tank, volume 280 l
Fuel quality Diesel according to:
EN590,
ASTM D 975 No 1-D,
ASTM D 975 No 2-D.
AdBlue tank, volume 15 l
Quality AdBlue, according to ISO standard 22241.
1.7 Engine, cooling system

Coolant volume 35 l

Coolant, filling point Volvo Penta Coolant VCS, ready-mixed
CAUTION
Risk of engine damage and damage to the cooling system if
different types of coolant are mixed.
When changing and topping up coolant, the same type of
coolant must be used as was used before.
1.8 Engine, lubrication system

Oil type, quality See Oils and lubricants, recommendation, page F:8.
Oil volume, incl. filter 27 l
2.6 Transmission, lubrication

system
Oil type See Oils and lubricants, recommendation, page F:8
Oil volume 28 l
3.3 Power transmission, drive axle

Oil grade See Oils and lubricants, recommendation, page F:8.
Oil volume, differential 30 l
Oil volume, hub reduction 2x4 l

Refrigerant, air conditioning R134a
Refrigerant volume 2200 g (see air conditioning system plate)
Lubricant, air conditioning ZXL100PG
Volume lubricant 0.32 l
Volume washer fluid 2.5 l
Oil grade See Oils and lubricants, recommendation, page F:8.
Oil additive Lubrizol 3%
Volume hydraulic oil tank 270 l

Specification for lifting capacity and

dimensions
a
b
H5
A1
100 100 H4
H3
b T1
H6
V1 V B H2
H8
a
014780
R1 R2 L3 L2 L4 S
L L1 T2
DCF 180-12LB DCF 200-12LB DCF 220-12LB DCF 250-12LB

Lifting capacity
Classed (kg x 103) 18 20 22 25
Centre of gravity 1200
distance (L4 [mm])
Dimensions
Truck length 6070 6320
without forks (L
[mm])
Truck width (W 3050
[mm])
Height, base 3270
machine (H6
[mm])
Seat height (H8 2150
[mm])
Axle distance (L3 4000 4250
[mm])
Distance drive axle 1070
- fork front shank
surface (L2 [mm])
Track (front - rear) 2200 - 2140
(S [mm])
Slewing radius, 5500
outer (R1 [mm])
Slewing radius, 550
inner (R2 [mm])
Ground clearance, 300
min. [mm]
Height during cab 3800
tilting, max. (T1
[mm])
Width during cab 3700
tilting, max. (T2
[mm])

DCF 180-12LB DCF 200-12LB DCF 220-12LB DCF 250-12LB

Minimum track 9170 9470
width for 90°
stacking with forks
(A1 [mm])
Service weight [kg 28.5 29.8 31.2 32.9
x 103]
Axle weight front, 15000 15500
(without load) [kg]
Axle weight front, 43200 46300 49500 53800
(with classed load)
[kg]
Axle weight rear, 13500 14800 16200 17400
(without load) [kg]
Axle weight rear, 3300 3500 3700 4100
(with classed load)
[kg]

Oils and lubricants, recommendation

The service intervals specified by Cargotec in the maintenance manual
only apply if oils are selected in accordance with the table below. The
table indicates recommended viscosity for different oil types, and
grades, depending on the outdoor temperature.
Any deviation from this table must be approved in writing by Cargotec,

and may mean changed service intervals.
ºC -30 -20 -10 0 +10 +20 +30 +40 +50

Oil type, quality ºF -22 -4 +14 +32 +50 +68 +86 +104 +122
1.8 Engine, lubrication system
VDS-3 SAE 15W/40
SAE 5W/30
2.6 Transmission, lubrication

system
SAE 10W, 10W/30, 10W/40
API: CD/CE/CF-4/CF/CG-4/
CH-4/CI-4/SF/SG/SH/SJ/SL SAE 15W/30, 15W/40
ACEA: Categories A, B, E SAE 20W/20, 20W/40

SAE 30
3.3 Power transmission, drive

axle
Hypoid oil, API GL-5 and SAE 80W140
MIL-L-2105B
SAE 80W90
SAE 90
SAE 85W140
Hydraulic oil AV 32
SS 155434 AV 46
Hydraulic oil HVLP 46

DIN 51524 HLP 68
Hydraulic oil ISO - LHV 46

ISO 6743/4 ISO - LHM 68

WARNING
Change interval for engine oil requires that the sulphur
content in the fuel does not exceed 0.5%.
A higher sulphur content in the fuel can damage the
engine!
Only use fuel with a sulphur content that does not
exceed 0.5%.
NOTE
Oil filters shall be changed in connection with oil change.
*) API CH-4 or CI-4 are approved for markets outside the EU/EEA.
ACEA = Association des Constructeurs Européenne d'Automobiles
API = American Petroleum Institute
VDS = Volvo Drain Specification
Lubricating grease
Use a universal grease type EP according to NLGI Grade 2 (EP2) for

all lubrication points except hoisting equipment and slide plates.
For hoisting equipment use a universal grease type EP according to

NLGI Grade 2 (EP2) with 3-5% molybdenum sulphide content.
For slide plates use a lubricant approved by Cargotec. Order from

Cargotec Spare Parts Department. 0.65 kg cartridge for grease gun,
part no. 923110.0360 and 5 kg can part no. 923595.0003.
NOTE
Select lubrication class according to the prevailing climate.
Contact grease
Use contact grease part no. 923836.0552.
Sealant silicone
Use silicone part no. 923107.0308.
Silicone adhesive
Use silicone adhesive part no. 923854.0100.

Coolant
Use ready-mixed recommended coolant. Choose the mixture of

coolant that is adapted for the right temperature.
CAUTION
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, the same type
of coolant must be used as was used before.

Tightening torques, recommendations

The tightening torques in the following table are recommendations
when tightening bolts and nuts.
When torque-tightening using a machine, for example, bolt runner, the
tightening torque should be reduced by approx. 5%.
For soft surfaces (lower hardness than 200 HB), use washer under
both bolt head and nut. As an alternative, flange bolt or flange nut
can be used.
Tighten to the prescribed torque without stopping.
Recommended tightening torque may vary depending on surface
treatment. Certain combinations of nut and bolt require lubrication in
accordance with the table below.
Condi- Screw Nut Lubrication

tion
1 untreated untreated oil
2 bright galvanised untreated or bright galvanised dry or oil
3 hot-galvanised untreated dry or oil
Quality 8.8 10.9 12.9

Condition 1 2 3 1 1
Fine M-thread
M81 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm
M101.25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm
M121.25 96 Nm 85 Nm 108 Nm 135 Nm 162 Nm
M161.5 230 Nm 205 Nm 260 Nm 323 Nm 388 Nm
M181.5 330 Nm 294 Nm 373 Nm 466 Nm 559 Nm
M-thread
M4 3.2 Nm 2.9 Nm 3.6 Nm 4.6 Nm 5.5 Nm
M5 6.4 Nm 5.7 Nm 7.2 Nm 9.1 Nm 11 Nm
M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm
M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm
M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm
M12 91 Nm 81 Nm 103 Nm 128 Nm 154 Nm
M16 220 Nm 198 Nm 250 Nm 313 Nm 375 Nm
M20 430 Nm 386 Nm 490 Nm 620 Nm 732 Nm
M24 750 Nm 668 Nm 848 Nm 1050 Nm 1270 Nm
M30 1480 Nm 1317 Nm 1672 Nm 2080 Nm 2500 Nm
UNC-thread
1/4 12.5 Nm 11.1 Nm 14.1 Nm 17.6 Nm 20 Nm
5/16 25 Nm 22.3 Nm 28.3 Nm 35 Nm 42 Nm
3/8 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm
7/16 70 Nm 62 Nm 79 Nm 100 Nm 118 Nm
1/2 107 Nm 95 Nm 121 Nm 151 Nm 178 Nm
9/16 153 Nm 136 Nm 173 Nm 216 Nm 255 Nm
5/8 210 Nm 187 Nm 237 Nm 298 Nm 353 Nm

Quality 8.8 10.9 12.9

3/4 370 Nm 390 Nm 418 Nm 524 Nm 619 Nm
7/8 594 Nm 528 Nm 671 Nm 839 Nm 990 Nm
1 889 Nm 791 Nm 1005 Nm 1260 Nm 1480 Nm
1 1/8 1260 Nm 1120 Nm 1424 Nm 1780 Nm 2100 Nm
1 1/4 1760 Nm 1565 Nm 1990 Nm 2490 Nm 2940 Nm
1 3/8 2320 Nm 2065 Nm 2620 Nm 3280 Nm 3870 Nm
1 1/2 3060 Nm 2720 Nm 3455 Nm 4320 Nm 5100 Nm
Tightening torque, ORFS connections

Pipe and hose fitting
Pipe diameter Tightening torque

mm inch Nm
6 1/4 23-25
8 5/16
33-38
10 3/8
12 1/2 51-57
14 -
15 - 80-90
16 5/8
18 3/4
120-130
20 -
22 7/8
150-170
25 1"
28 -
30 - 180-200
32 1"1/4
35 -
200-240
38 1"1/2
Wrench size Tightening torque

mm inch Nm
17 11/16 23-25
22 13/16 33-38
24 15/16 51-57
36 1 3/8 120-130
41 1 5/8 150-170

Material fitting
UNF-UN Metric-ISO BSSP

Thread (inch) Tightening torque Thread Tightening torque Thread (inch) Tightening torque (Nm)
(Nm) (mm) (Nm)
7/16-20 21 10x1 20 1/8-28 20
1/2-20 27 12x1.5 35 1/4-19 35
9/16-18 40 14x1.5 45 3/8-19 70
3/4-16 78 16x1.5 55 1/2-14 100
7/8-14 110 18x1.5 68 3/4-14 190
1"1/16-12 180 20x1.5 80 1"-11 300
1"3/16-12 230 22x1.5 98 1"1/4-11 330
1"5/16-12 285 26x1.5 170 1"1/2-11 400
1"5/8-12 320 27x2 180
1"7/8-12 400 33x2 310
42x2 330
48x2 400
Tightening torque, connections for air

conditioning
O-ring couplings cooling hoses
Hose diameter Thread Tightening torque

mm inch inch Nm
6 1/4" 7/16" 7-13 Nm
10 3/8" 5/8" 14-20 Nm
10 3/8" 11/16" 14-20 Nm
12 1/2" 3/4" 14-26 Nm
16 5/8" 7/8" 27-41 Nm
19 3/4" 1 1/16" 34-46 Nm
Pressure switch 3/8" 7-13 Nm
7/16"
The above values should be considered guidelines and may vary

depending on installation.

Unit explanations
Unit Abbreviation
Newton metre Nm
Kgf/m kpm
Kilo pascal kPa
Mega pascal MPa
Kilowatt kW
Kilojoule kJ
British thermal unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometre km

Conversion SI-units
Recalculation Recalculation
SI-unit factor Non-SI factor SI
Torque
Nm x 10.2 = kg·cm x 0.8664 = lb·in
Nm x 0.74 = lbf·ft x 1.36 = Nm
Nm x 0.102 = kg·m x 7.22 = lb·ft
Pressure (Pa = N/m2)
kPa x 4.0 = in.H2O x 0.249 = kPa
kPa x 0.30 = in.Hg x 3.38 = kPa
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp/cm 2 x 14.22 = psi x 0.070 = kp/cm2
N/mm 2 x 145.04 = psi x 0.069 = bar
MPa x 145 = psi x 0.00689 = MPa
Power (W = J/s)
kW x 1.36 = hp (cv) x 0.736 = kW
kW x 1.34 = bhp x 0.746 = kW
kW x 0.948 = Btu/s x 1.055 = kW
W x 0.74 = ft·lb/s x 1.36 = W
Energy (J = Nm)
kJ x 0.948 = Btu x 1.055 = kJ
J x 0.239 = calorie x 4.19 = J
Speed and acceleration
m/s2 x 3.28 = ft/s2 x 0.305 = m/s2
m/s x 3.28 = ft/s x 0.305 = m/s
km/h x 0.62 = mph x 1.61 = km/h
Horsepower/torque
Bhp x 5252 rpm= TQ (lb·ft) TQ x rpm 5252 = bhp
Temperature
ºC = (ºF – 32)/1.8 ºF = (ºC x 1.8) + 32
Flow factor
l/min (dm3 /min) x 0.264 = US gal/min x 3.785 = litre/min

Conversion table length

Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm – 1 mm = 0.001 m
Conversion table area

Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000

yd2 - 0.83613 - 0.008361 9 1 1296.00
in2 6.4516 0.000645 - - 0.006943 0.000771 1
1 ha = 100 a – 1 mile2 = 259 ha = 2.59 km2
Conversion table volume

Unit cm3 = cc m3 l in3 ft3 yd3
cm3 = ml 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
dm3 (l) 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
yd3 764529.8 0.76453 764.53 46656 27 1
1 gal (US) = 3785.41 cm3 = 231 in3 = 0.83267 gal (UK)
Conversion table weight

Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 tonne (metric) = 1.1023 ton (US) = 0.9842 ton (UK)

Conversion table pressure

Unit kp/cm2 bar Pa = N/m2 kPa lbf/in2 lbf/ft2
kp/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa = N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm2 = 735.56 Dry (mmHg) = 0.96784 atm

F:18

G:1
Contents G Terminology and index

Terminology and index .....................................................................................G:3
Terminology..................................................................................................... G:3
Index ............................................................................................................... G:7

G:2

G Terminology and index – Terminology and index G:3

Terminology
Explanations
Term Description
AC Air Conditioning Heating unit with manual control of heating, cooling, dehumidification
and air flow.
Accumulator Reservoir that stores (accumulates) pressure for, i.e. hydraulic functions.
Attachment Part of the machine that grips the load when lifting.
Anti-corrosion agent Prevents oxidation, in simple terms, rustproofing.
Working hydraulics All load handling functions, e.g. lifting/lowering, tilt, side shift, spreading and levelling.
Wheelbase Distance between drive axle and steering axle.
Bar Unit to express pressure.
Battery disconnector Cuts off power supply from battery.
Central lubrication An automatic system for lubricating a number of preselected lubrication points.
Daily inspection Actions that should be performed daily to ensure the machine's functionality.
Decitonne Tenth of a tonne, measure of machine's lift capacity.
Displacement The oil volume that the pump can supply per pump revolution.
Display "Window" showing digital information, i.e. on steering wheel panel in the cab.
Operating time Number of hours machine has been in operation, shown on hour meter in cab.
Drive axle Driving axle that receives the torque from the drive-train.
Drive-train Parts in machine involved in power transmission; engine, torque converter, transmission,
propeller shaft, and drive axle with differential and hub reduction.
ECC Electric Climate Control. Air conditioning with automatic control of heating, cooling,
dehumidification and air flow.
ECU Electronic Control Unit.
EDU Electronic Display Unit.
Electrolyte level Fluid level in battery cells.
Electric servo Load handling hydraulic components receive control signals from electro mechanical
controls.
Expansion tank Tank for coolant.
Fixed displacement Non-adjustable volume (capacity) in a pump.
FlexCab Protective cage with protective heavy-duty frame construction. Enclosed.
FlexGuard Protective cage with protective heavy-duty frame construction. Open.
FMI Fault Message Identifier.
Forks Lifting device that lifts the loads.
Fork mounting Mounting for forks, mounted on the trolley.
Main fuse Located by battery. Breaks the current to all systems in the whole machine.
Hydraulic oil Oil for hydraulic system. See specifications in operator's manual.
Hydraulic oil pump Pump in hydraulic system.
Hydraulic servo Load handling hydraulic components receive control signals from mechanical controls.
Hydraulic system System that uses oil pressure to transfer power to different functions.
Hanging load Lifted load.

G:4 G Terminology and index – Terminology
Term Description
Indicator Manual "sensor", for example, shows that a filter is clogged and needs to be changed.
KCS Kalmar Control System. An electronic control system that monitors and handles certain
machine systems that require KCS, for example, certain engine and transmission
alternatives.
Piston rod The bar that slides into the piston cylinder and is acted on by the hydraulic pressure.
Refrigerant Fluid/gas in air conditioning. Must only be handled by authorised trained personnel.
LC Load centre.
Lift capacity Indicates machine's maximum lift capacity.
Lifting point Attaching point for lift device when lifting an object.
Trolley Lifts the load, located on the mast.
Low-emission engine Engine with low emissions of hazardous substances. Manufactured in accordance
with regulations.
Solenoid valve An electro-magnetically controlled valve. See also proportional valve.
Control valve Valves that can be used to control something, e.g., release pressure and thus lower a
mast or a fork.
Machine model Machine type. Specified, for example: DCF 180-250. See also type designation.
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Torque converter Hydraulic, variable clutch.
Counterweight Weights adapted to the machine's lifting capacity to act as counter-load when lifting.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque
from the drive-train.
Pilot oil pressure A low control pressure to, for example, a valve.
Planetary gear Type of transmission with the gears in constant mesh.
Product alternative One of several alternatives is selected for a machine, e. g. engine alternative.
Progressive steering Quick steering wheel movements give greater steering angle.
Proportional valve An electro-magnetically controlled valve. If a voltage is applied, the valve is activated
in proportion to the voltage amplitude. In simple terms, infinitely variable valve, as
opposed to on/off valve. For example, found on transmission's valve housing.
Frame member Structural members in the frame.
Recirculation Circulation in a closed system.
Serial number Unique machine designation. On the machine plate.
Service position How machine should be safely positioned before service may be started.
Servo A small movement by the user results in a large angle, i.e. servo steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side shift The forks are moved parallel sideways.
Levelling The forks are tilted, for example, if the load stands on uneven ground.
SmartLink Software for handling KCS (Kalmar Control System).
Spirit Delta Enclosed type of cab.
SPN Suspect Parameter Number.
Spreading (positioning) Spreading of forks, i.e. changing the internal distance between the forks.
Mast Carriers of unit and load.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, which is emptied
automatically during operation.
Steering axle Wheel axle with steering.

G Terminology and index – Terminology G:5
Term Description
Buzzer Acoustic alarm to catch the operator's attention.
Option Extra equipment for machine.
Tilt The mast is tilted forwards or backwards.
Top lift Attachment. See attachment
Transmission oil Oil for transmission and torque converter. See specifications in operator's manual.
Securing machine for transport Actions before transporting machine.
Twistlocks Two or four locking pins, one in each corner of the attachment, pushed down into
corresponding holes in the container and twisted to lock the container when lifting.
Type designation Indicates machine type and capacity. See also machine model.
Maintenance Periodic maintenance actions so that machine functions safely and for a long service life.
Variable pump Pump with adjustable flow rate.
Variable displacement Adjustable volume (capacity) of a pump.
Valve slide Moveable part in valve. Determines oil's path.
Wet brakes Brake discs in oil bath.

G:6

G Terminology and index – Index G:7
Index Communication radio . . . . . .

Compartment for A4 papers . . .
.
.
.
.
.
.
. . . . . . . 9:66
. . . . . . . 9:93
Complete machine . . . . . . . . . . . . . . . . . 0:3
Compressor air-suspension seat . . . . . . . . . . . 9:22
A Computer . . . . . . . . . . . . . . . . . . . . . 9:67
About the documentation . . . . . . . . . . . . . A:12 Condenser unit . . . . . . . . . . . . . . . . . . . 9:37
About the Workshop Manual . . . . . . . . . . . . . A:3 Connectors . . . . . . . . . . . . . . . . . . . . 2:21
AC compressor . . . . . . . . . . . . . . . . . . . 9:35 Control breaker . . . . . . . . . . . . . . . . . . . 9:14
Accelerator . . . . . . . . . . . . . . . . . . . . 1:22 Control lever . . . . . . . . . . . . . . . . . . . . 7:3
Accumulator . . . . . . . . . . . . . . . . . 4:9, 10:10 Control outputs . . . . . . . . . . . . . . 8:11, 8:15, 8:19
Accumulator charging valve . . . . . . . . . . 4:21, 4:36 Control system . . . . . . . . . . . . . . . . 8:3, D:52
Accumulator damping . . . . . . . . . . . . . . . . 7:14 Control system, engine . . . . . . . . . . . . . . . 1:38
Accumulator drain valve . . . . . . . . . . . . . . . 10:9 Control system, transmission . . . . . . . . . . . . . 2:18
Actuator motor . . . . . . . . . . . . . . . . . . . 9:46 Control unit ECC . . . . . . . . . . . . . . . . . . 9:42
Adjusting joystick control. . . . . . . . . . . . . . . 8:33 Control unit general (ECU 790) . . . . . . . . . . . 11:29
Air cleaning system . . . . . . . . . . . . . . . . . 1:25 Control unit hydraulics (ECU 796) . . . . . . . . . . 11:33
Air distributor . . . . . . . . . . . . . . . . . . . . 9:42 Control unit steering (ECU 792). . . . . . . . . . . 11:36
Air intake and exhaust outlet . . . . . . . . . . . . . 1:25 Control unit terminal (EDU 795). . . . . . . . . . . 11:28
Air suspension . . . . . . . . . . . . . . . . . . . 9:22 Control units . . . . . . . . . . . . . . . . . . . 11:27
Alternator . . . . . . . . . . . . . . . . . . . . . 11:9 Control valve load handling . . . . . 7:11, 7:36, 7:46, 7:53
Arm rest . . . . . . . . . . . . . . . . . . . . . . 9:26 Control valve steering . . . . . . . . . . . . . . . . 5:23
Automatic engine stop 5 minutes after driver's seat is Controls and instruments . . . . . . . . . . . 1:22,
empty . . . . . . . . . . . . . . . . . . . . . . 1:40 2:13, 4:3, 5:3, 7:3, 9:6, 11:3
Automatic gearing . . . . . . . . . . . . . . 2:25, 8:28 Coolant . . . . . . . . . . . . . . . . . . . . . . 1:33
Axial piston pump with variable displacement . . . . . 10:17 Coolant level sensor . . . . . . . . . . . . . . . . 1:37
Cooling fan . . . . . . . . . . . . . . . . 1:33, 10:31
Cooling system . . . . . . . . . . . . . . . . 1:30, 2:17
Cooling unit . . . . . . . . . . . . . . . . . . . . 9:43
B Counterweight . . . . . . . . . . . . . . . . . . . 9:97
Back rest cushion . . . . . . . . . . . . . . . . . . 9:21
Back-up alarm . . . . . . . . . . . . . . . . . . . 9:63
Back-up lights . . . . . . . . . . . . . . . . . . . 9:57 D
Batteries. . . . . . . . . . . . . . . . . . . . . . 11:7
Battery compartment . . . . . . . . . . . . . . . . 9:98 Defroster nozzles . . . . . . . . . . . . . . . . . . 9:29
Battery disconnector . . . . . . . . . . . . . . . . 11:4 Diagnostics . . . . . . . . . . . . . . . . . . 2:27, 8:6
Battery voltage, connection 30 voltage. . . . . . . . 11:11 Direction indicators . . . . . . . . . . . . . . . . . 9:57
Body structure . . . . . . . . . . . . . . . . . . . 9:95 Directional control valve, turnable driver's seat . . 5:27, 9:26
Brake cylinder . . . . . . . . . . . . . . . . . . . 4:20 Disc pack . . . . . . . . . . . . . . . . . . . . . 4:19
Brake lights . . . . . . . . . . . . . . . . . . . . 9:57 Display and menus . . . . . . . . . . . . . . . . . 2:23
Brake pedal . . . . . . . . . . . . . . . . . . . . 4:3 Distribution block . . . . . . . . . . . . 4:13, 4:36, 9:101
Brake valve . . . . . . . . . . . . . . . . . . . . 4:9 Distribution of electricity . . . . . . . . . . . . . . 11:10
Brakes . . . . . . . . . . . . . . . . . . . . . . 4:3 Door stop . . . . . . . . . . . . . . . . . . . . . 9:81
Break contact (opening switch) declutch . . . . . 2:15, 4:14 Doors . . . . . . . . . . . . . . . . . . . . . . . 9:78
Breather filter hydraulic oil tank . . . . . . . . . . . 10:32 Drive axle . . . . . . . . . . . . . . . . . . . . . 3:6
Bumper . . . . . . . . . . . . . . . . . . . . . . 9:22
E
C ECU 790 . . . . . . . . . . . . . . . . . . . . . 8:8
ECU 792 . . . . . . . . . . . . . . . . . . . . . 8:14
Cab fan . . . . . . . . . . . . . . . . . . . . . . 9:30
ECU 796 . . . . . . . . . . . . . . . . . . . . . 8:17
Cab frame . . . . . . . . . . . . . . . . . . . . . 9:78
Electric protection. . . . . . . . . . . . . . . . . . 11:4
Cab heater. . . . . . . . . . . . . . . . . . . . . 9:43
Electro-hydraulic servo . . . . . . . . . . . . . . . 8:37
Cab interior . . . . . . . . . . . . . . . . . . . . 9:87
Electronic box . . . . . . . . . . . . . . . . . . 11:12
Cab structure and suspension . . . . . . . . . . . . 9:78
Engine . . . . . . . . . . . . . . . . . . . . 1:3, D:8
Cab substructure . . . . . . . . . . . . . . . . . . 9:79
Engine control unit . . . . . . . . . . . . . . . . . 1:38
Cab tilting . . . . . . . . . . . . . . . . . . . . . 9:80
Engine heater . . . . . . . . . . . . . . . . . . . 1:37
Cab tilting cylinder . . . . . . . . . . . . . . . . . 9:82
Engine room lighting . . . . . . . . . . . . . . . . 9:61
Cable harness . . . . . . . . . . . . . . . . . . 11:39
Entertainment and communication . . . . . . . . . . 9:65
Calibrate ETC-Electronic Throttle Control . . . . . . . 8:27
Environment . . . . . . . . . . . . . . . . . . . B:21
Calibrating automatic gearing, description . . . . . . . 8:29
Error codes . . . . . . . . . . . . . . . . . . 8:5, D:3
Calibrating Electro-hydraulic servo . . . . . . . . . . 8:41
ETC-Electronic Throttle Control (electronic throttle) . . . 8:26
Calibrating joystick control . . . . . . . . . . . . . . 8:34
Evaporator . . . . . . . . . . . . . . . . . . . . . 9:40
Calibrating Scale . . . . . . . . . . . . . . . . . . 8:42
Exhaust system . . . . . . . . . . . . . . . . . . 1:25
Calibrating Turnable operator's station . . . . . . . . . 8:44
Expansion valve . . . . . . . . . . . . . . . . . . 9:39
Calibration . . . . . . . . . . . . . . . . . . . . . 2:27
CAN bus . . . . . . . . . . . . . . . . . . . . 11:41
CAN bus, driveline/axle . . . . . . . . . . . . . . 11:44
Central lubrication . . . . . . . . . . . . . . . . 9:100 F
Chain wheels and hose wheels . . . . . . . . . . . . 7:25 Feedback . . . . . . . . . . . . . . . . . . . . A:13
Chains . . . . . . . . . . . . . . . . . . . . . . 7:24 Fine filter . . . . . . . . . . . . . . . . . . . . . 9:42
Common electrics . . . . . . . . . . . . . . 11:3, D:13 Fire extinguisher . . . . . . . . . . . . . . . . . . 9:14
Common hydraulics . . . . . . . . . . . . . . 10:3, D:3 Flashing brake light for reversing . . . . . . . . . . . 9:64
Communication. . . . . . . . . . . . . . . . . . 11:40 Flex plates . . . . . . . . . . . . . . . . . . . . . 2:15

G:8 G Terminology and index – Terminology
Floor covering . . . . . . . . . . . . . . . . . . . 9:92 Lift and lower. . . . . . . . . . . . . . . . . . . . 7:8

Flow divider . . . . . . . . . . . . . . . . . . . . 7:48 Lift cylinder . . . . . . . . . . . . . . . . . . . . 7:14
Footstep . . . . . . . . . . . . . . . . . . . . . . 9:96 Lift forks . . . . . . . . . . . . . . . . . . . . . . 7:59
Foreword . . . . . . . . . . . . . . . . . . . . . A:3 Lifting lugs . . . . . . . . . . . . . . . . . . . . . 9:99
Frame . . . . . . . . . . . . . . . . . . . . . . . 9:94 Lighting system. . . . . . . . . . . . . . . . . . . 9:56
Frame connections . . . . . . . . . . . . . . . . 11:12 Lines . . . . . . . . . . . . . . . . . . . . . . 9:101
Frame, body, cab and accessories . . . . . . . 9:5, D:61 Link arm . . . . . . . . . . . . . . . . . . . . . . 5:20
Fresh air / recirculation valve . . . . . . . . . . . . . 9:29 Load carrier . . . . . . . . . . . . . . . . . . . . 7:59
Fresh air filter . . . . . . . . . . . . . . . . . . . 9:32 Load control valve . . . . . . . . . . . . . . . . . 7:29
Fuel system . . . . . . . . . . . . . . . . . . . . 1:23 Load handling . . . . . . . . . . . . . . . . . . . 7:3
Fuel tank . . . . . . . . . . . . . . . . . . . . . 1:23 Load holding valve (over-centre valve). . . . . . . . . 7:54
Fuses . . . . . . . . . . . . . . . . . . . . . . . 11:5 Lubrication system . . . . . . . . . . . . . . . . . 2:16
G M
Gear and direction of travel selector . . . . . . . . . . 2:13 Make-contact (closing switch) brake lights . . . . . . . 4:17
Gear pump with fixed displacement . . . . . . . . . 10:14 Make-contact (closing switch), cooling fan . . . . . . 10:31
General safety information . . . . . . . . . . . . . . B:3 Manual gear changing . . . . . . . . . . . . . . . . 2:25
Glass/windows/mirrors . . . . . . . . . . . . . . . 9:69 Mast . . . . . . . . . . . . . . . . . . . . 7:16, 7:58
Grease nipples . . . . . . . . . . . . . . . . . . 9:101 Mast wheels . . . . . . . . . . . . . . . . . . . . 7:23
Mechanical seat adjustment . . . . . . . . . . . . . 9:23
Mini-wheel . . . . . . . . . . . . . . . . . . . 5:3, 8:35
H Monitor, reversing camera . . . . . . . . . . . . . . 9:77
Head rest . . . . . . . . . . . . . . . . . . . . . 9:26 Monitoring . . . . . . . . . . . . . . . . . . . 8:4, 8:43
Headlights . . . . . . . . . . . . . . . . . . . . . 9:56 Mud guards . . . . . . . . . . . . . . . . . . . . 9:98
Heat exchanger heat . . . . . . . . . . . . . . . . 9:33 Multi-function lever . . . . . . . . . . . . . . . . . 9:10
Heating coil . . . . . . . . . . . . . . . . . . . . 9:21
Heating, ventilation and air conditioning . . . . . 9:27, D:61
High-pressure filter . . . . . . . . . 4:8, 4:28, 4:36, 10:33 N
Holder for pump lever . . . . . . . . . . . . . . . . 9:93 Normally closed (NC) switch, parking brake . . . . . . 4:33
Hood engine compartment . . . . . . . . . . . . . . 9:95 Nut, washer and clamp . . . . . . . . . . . . . . . 6:18
Horn . . . . . . . . . . . . . . . . . . . . . . . 9:63
Hoses, pipes and valves . . . . . . . . . . . . . . 10:22
Hour meter . . . . . . . . . . . . . . . . . . . . 11:3 O
Hydraulic cylinders . . . . . . . . . . . . . . . . 10:34
Hydraulic oil . . . . . . . . . . . . . . . . 4:36, 10:33 Oil cooler . . . . . . . . . . . . . . . . . . 2:17, 4:36
Hydraulic oil cooler . . . . . . . . . . . . . . . . 10:30 Operation, electrical system . . . . . . . . . . . . 11:39
Hydraulic oil pump . . . . . . . . . . . . . . 4:8, Other . . . . . . . . . . . . . . . . . . . . . . 10:34
4:28, 4:35, 5:16, 7:11, 7:36, 7:46, 7:53, 10:33 Other functions . . . . . . . . . . . . . . . . . . . 7:61
Hydraulic oil tank . . . . . . . . . . . . . . . . . . 4:35
P
I Paint/coatings . . . . . . . . . . . . . . . . . . 9:102
Ignition . . . . . . . . . . . . . . . . . . . . . . 1:22 Parking brake caliper . . . . . . . . . . . . . . . . 4:32
Ignition voltage, connection 15 voltage . . . . . . . 11:12 Parking brake disc . . . . . . . . . . . . . . . . . 4:32
Inching . . . . . . . . . . . . . . . . . . . 2:13, 2:26 Parking brake pads . . . . . . . . . . . . . . . . . 4:32
Initiating automatic gearing (ECU793) . . . . . . . . . 8:28 Parking brake system . . . . . . . . . . . . . . . . 4:27
Initiating Electro-hydraulic servo . . . . . . . . . . . 8:38 Parking brake unit . . . . . . . . . . . . . . . . . 4:30
Initiating ETC-Electronic Throttle Control . . . . . . . . 8:26 Particle and moisture filter . . . . . . . . . . . . . . 9:44
Initiating joystick control . . . . . . . . . . . . . . . 8:30 Passenger seat. . . . . . . . . . . . . . . . . . . 9:23
Initiating Mini-wheel . . . . . . . . . . . . . . . . . 8:35 Pause heater. . . . . . . . . . . . . . . . . . . . 9:43
Initiating Monitoring . . . . . . . . . . . . . . . . . 8:43 Pipes and hoses . . 1:29, 4:20, 4:34, 4:36, 5:27, 7:30,
Instrument and control panels . . . . . . . . . . . . 9:87 7:38, 7:49, 7:58, 10:9, 10:13, 10:21–10:22, 10:33
Insulation . . . . . . . . . . . . . . . . . . . . . 9:92 Power assisted system . . . . . . . . . . . . . . . 5:11
Intercooler . . . . . . . . . . . . . . . . . . . . . 1:26 Power transmission . . . . . . . . . . . . . . . . . 3:3
Interior fittings, plastic . . . . . . . . . . . . . . . . 9:88 Power-assisted brake system . . . . . . . . . . . . 4:7
Interior fittings, textile . . . . . . . . . . . . . . . . 9:91 Preventive maintenance . . . . . . . . . . . . . . . C:1
Interior lighting . . . . . . . . . . . . . . . . . . . 9:60 Priority valve . . . . . . . . . . . . . . . . 5:16, 10:23
Propeller shaft . . . . . . . . . . . . . . . . . . . 3:4
Proportional valve . . . . . . . . . . . . . . . . 10:26
J Protective panel in front of windscreen. . . . . . . . . 9:76
Pump unit . . . . . . . . . . . . . . . . . . . . 9:100
Joystick control . . . . . . . . . . . . . . . . . 5:7, 8:30 Pumps . . . . . . . . . . . . . . . . . . . . . 10:14
K R
Kalmar Smart Link . . . . . . . . . . . . . . . . . 8:45 Radiator and expansion tank . . . . . . . . . . . . . 1:31
Radio with CD . . . . . . . . . . . . . . . . . . . 9:65
Reading instructions . . . . . . . . . . . . . . . . A:4
L Rear view mirror . . . . . . . . . . . . . . . . . . 9:76
Last alarms . . . . . . . . . . . . . . . . . . . . 8:23 Rear window . . . . . . . . . . . . . . . . . . . . 9:76

G Terminology and index – Index G:9
Redundant CAN bus . . . . . . . . . . . . . . . 11:43 Tank . . . . . . . . . . . . . . . . . . . . . . 10:10

Reversible operator\qs seat . . . . . . . . . . . . . 9:24 Tank heater . . . . . . . . . . . . . . . . 4:35, 10:28
Reversing camera . . . . . . . . . . . . . . . . . 9:76 Tanks and accumulators . . . . . . . . . . . . . . 10:10
Reversing lock . . . . . . . . . . . . . . . . . . . 2:24 Technical data . . . . . . . . . . . . . . . . . . . F:3
Revolving beacon. . . . . . . . . . . . . . . 9:58, 9:63 Telephone . . . . . . . . . . . . . . . . . . . . . 9:66
Rim . . . . . . . . . . . . . . . . . . . . . . . . 6:17 Temperature control, cleaning and hydraulic oil . . . . 10:27
Roof and door mouldings . . . . . . . . . . . . . . 9:82 Temperature control, cleaning and oil brake system . . . 4:35
Roof grating . . . . . . . . . . . . . . . . . . . . 9:15 Terminal . . . . . . . . . . . . . . . . . . . . . . 9:67
Roof window . . . . . . . . . . . . . . . . . . . . 9:75 Terminal console . . . . . . . . . . . . . . . . . . 9:93
Rotating driver's seat . . . . . . . . . . . . . . . . 9:25 Terminology . . . . . . . . . . . . . . . . . . . . G:3
Running lights . . . . . . . . . . . . . . . . . . . 9:57 Terminology and index . . . . . . . . . . . . . . . G:3
Thermal bypass valve . . . . . . . . . . . . . . . 10:32
Thermostat . . . . . . . . . . . . . . . . . . . . 9:36
S Tilt . . . . . . . . . . . . . . . . . . . . . . . . 7:50
Tilt cylinder . . . . . . . . . . . . . . . . . . . . 7:55
Safety . . . . . . . . . . . . . . . . . . . . . . . B:3 Tool kit . . . . . . . . . . . . . . . . . . . . . . 9:98
Safety and emergency equipment. . . . . . . . . . . 9:14 Top support roller . . . . . . . . . . . . . . . . . . 7:32
Safety instructions . . . . . . . . . . . . . . . . . B:4 Torque converter/Clutch system . . . . . . . . . . . 2:15
Safety valves. . . . . . . . . . . . . . . . . . . . 10:9 Transmission. . . . . . . . . . . . . . . . . 2:3, D:30
Scale . . . . . . . . . . . . . . . . . . . . 7:61, 8:42 Transmission cable harness . . . . . . . . . . . . . 2:23
Schematics . . . . . . . . . . . . . . . . . . . . D:3 Transmission control unit (ECU 793) . . . . . . . . . 2:19
SCR system . . . . . . . . . . . . . . . . . . . . 1:27 Trolley. . . . . . . . . . . . . . . . . . 7:26, 7:38, 7:49
Screen . . . . . . . . . . . . . . . . . . . . . . 9:67 Turnable operator's station . . . . . . . . . . . . . . 8:43
Seat . . . . . . . . . . . . . . . . . . . . . . . 9:16 Tyres . . . . . . . . . . . . . . . . . . . . . . . 6:16
Seat belt. . . . . . . . . . . . . . . . . . . . . . 9:14 Tyres and rims . . . . . . . . . . . . . . . . . . . 6:15
Seat buzzer . . . . . . . . . . . . . . . . . . . . 9:15
Seat cushion . . . . . . . . . . . . . . . . . . . . 9:20
Sensor for ECC . . . . . . . . . . . . . . . . . . 9:41 V
Sensor fuel level . . . . . . . . . . . . . . . . . . 1:24
Sensor hydraulic oil temperature . . . . . . . . . . 10:30 View inputs . . . . . . . . . . . . . . . 8:9, 8:14, 8:17
Sensor turnable driver's seat . . . . . . . . . . 5:27, 9:26 View outputs . . . . . . . . . . . . . . . 8:10, 8:15, 8:18
Sensor, low brake pressure . . . . . . . . . . . . 10:13 Voltage converter . . . . . . . . . . . . . . . . . . 9:67
Sensor, steering wheel movement . . . . . . . . . . 5:22 Voltage feed . . . . . . . . . . . . . . . . . . . 11:11
Service menus . . . . . . . . . . . . . . . . . . . 2:30
Setup . . . . . . . . . . . . . . . . . . . . . . . 8:26
Shuttle valve . . . . . . . . . . . . . . . . . . . 10:26 W
Shuttle valve dual brake pedals . . . . . . . . . . . . 4:25
Side shift . . . . . . . . . . . . . . . . . . . . . 7:33 Warning and engine power limitation . . . . . . . . . 1:40
Side shift cylinder . . . . . . . . . . . . . . . . . . 7:37 Warning lamp, Hazard. . . . . . . . . . . . . 9:58, 9:63
Side window . . . . . . . . . . . . . . . . . . . . 9:73 Warning parking brake . . . . . . . . . . . . . . . 9:63
Signalling system . . . . . . . . . . . . . . . . . . 9:62 Washer motor and reservoir . . . . . . . . . . . . . 9:49
Software. . . . . . . . . . . . . . . . . . . . . . 8:45 Water valve . . . . . . . . . . . . . . . . . . . . 9:35
Solenoid valve parking brake . . . . . . . . . . . . . 4:29 Wheel brakes . . . . . . . . . . . . . . . . 4:18, 4:36
Speed limitation . . . . . . . . . . . . . . . . . . 8:4 Wheel hub . . . . . . . . . . . . . . . . . . . 5:22, 6:9
Spreading (positioning) . . . . . . . . . . . . . . . 7:39 Wheel spindle . . . . . . . . . . . . . . . . . 5:21, 6:7
Spreading cylinder . . . . . . . . . . . . . . . . . 7:48 Windscreen . . . . . . . . . . . . . . . . . . . . 9:70
Start battery . . . . . . . . . . . . . . . . . . . . 11:7 Wings . . . . . . . . . . . . . . . . . . . . . . . 9:95
Start/stop . . . . . . . . . . . . . . . . . . . . . 1:39 Wiper front . . . . . . . . . . . . . . . . . . . . . 9:49
Starter motor . . . . . . . . . . . . . . . . . . . . 1:39 Wiper motor front . . . . . . . . . . . . . . . . . . 9:50
Steering . . . . . . . . . . . . . . . . . . . . . . 5:3 Wiper motor rear . . . . . . . . . . . . . . . . . . 9:54
Steering axle cradle . . . . . . . . . . . . . . . 5:20, 6:5 Wiper motor roof . . . . . . . . . . . . . . . . . . 9:51
Steering cylinder . . . . . . . . . . . . . . . . . . 5:19 Wiper rear . . . . . . . . . . . . . . . . . . . . . 9:49
Steering valve . . . . . . . . . . . . . . . . . . . 5:16 Wiper roof . . . . . . . . . . . . . . . . . . . . . 9:49
Steering wheel and steering wheel shaft . . . . . . . . 5:3 Wiper/washer system . . . . . . . . . . . . . . . . 9:49
Stopping device . . . . . . . . . . . . . . . . . . 1:40 Working lights, cab . . . . . . . . . . . . . . . . . 9:60
Sun visors . . . . . . . . . . . . . . . . . . . . . 9:93 Working lights, fenders . . . . . . . . . . . . . . . 9:60
Support roller . . . . . . . . . . . . . . . . . . . 7:30 Working lights, mast. . . . . . . . . . . . . . . . . 9:60
Suspension . . . . . . . . . . . . . . . . . . 6:3–6:4 Writing desk . . . . . . . . . . . . . . . . . . . . 9:93
Switch normally closed (NC), low brake pressure . . . . 4:16
T
Tail lights . . . . . . . . . . . . . . . . . . . . . 9:57

last page
Cargotec Sweden AB
Cargotec improves the efficiency of cargo flows by offering solutions for Torggatan 3
the loading and unloading of goods on land and at sea – wherever cargo SE-340 10, Lidhult, Sweden
is on the move. Cargotec’s main daughter brands for cargo handling
Hiab, Kalmar and MacGregor are global market leaders in their fields. tel. +46 372 260 00
Cargotec’s global network offers extensive services that ensure the fax +46 372 263 90
continuous, reliable and sustainable performance of equipment. www.cargotec.com

Workshop Manual - DCF 180-250

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Forklift trucks 18-25 tonnes

9 Frame, body, cab and accessories

G Terminology and index

Workshop Manual DCF 180-250 VDCF06.01GB

VDCF06.01GB Workshop Manual DCF 180-250

Cargotec will not accept any responsibility in the event of a modification

About machine version

Cargotec reserves the right to make changes to specifications and

All duplication by any means, such as copying, printing, etc., is

Workshop Manual DCF 180-250 VDCF06.01GB

Read operator's manual

Read the operator's manual

Read the Maintenance manual

refers to important information in the Maintenance manual.

Read the Maintenance manual

VDCF06.01GB Workshop Manual DCF 180-250

The workshop manual's contents

The workshop manual is divided into the following sections.

Workshop Manual DCF 180-250 VDCF06.01GB

Function group structure

The function groups are intended to be used as search terms in

The maintenance manual and workshop manual contain different

References between sections in the same manual are indicated with

References between Maintenance manual and Workshop manual are

VDCF06.01GB Workshop Manual DCF 180-250

References between different information types

The basic rule of searching for information is to use the function

Function descriptions Hydraulic diagrams

Diagnostics Wiring diagrams

• From Function description to Component description, to enable

Workshop Manual DCF 180-250 VDCF06.01GB

Product alternatives and optional equipment

Special equipment is not described in the manual. If uncertain as

Equivalent information for different product alternatives is described

Optional equipment refers to options that can be added to standard

Information on auxiliary equipment is described in separate segments

VDCF06.01GB Workshop Manual DCF 180-250

The machine card indicates of which drawings the machine consists.

If the information on the machine card is not of any assistance, contact

Workshop Manual DCF 180-250 VDCF06.01GB

The function descriptions describe the function in a logical flow from

The function descriptions use symbols to illustrate components such

Example of function description

VDCF06.01GB Workshop Manual DCF 180-250

Symbol explanation function descriptions

Workshop Manual DCF 180-250 VDCF06.01GB

About the documentation

Always indicate publication number when ordering.

For publication number, see machine card.

VDCF06.01GB Workshop Manual DCF 180-250

Your feedback is important to be able to improve the information.

To: Cargotec Sweden AB

Date: .................................... - .................. - ..................

Section / page number: ................................................................................................................................

Workshop Manual DCF 180-250 VDCF06.01GB

VDCF06.01GB Workshop Manual DCF 180-250

Workshop Manual DCF 180-250 VDCF06.01GB

VDCF06.01GB Workshop Manual DCF 180-250

In this publication Cargotec has documented and warned for situations

A near accident is a warning!

Workshop Manual DCF 180-250 VDCF06.01GB

Service position is used for service, maintenance and other situations

Service position entails:

• Forks and trolley in totally lowered position.