VDRG09 01GB

Reachstackers 42-45 tonnes
Publ. no VDRG09. 01GB

Workshop Manual in original WORKSHOP MANUAL
DRG420–450 ECOefficient
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Workshop Manual
2 Transmission
DRG420–450 ECOefficient
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:5
References between different information types ......................................... A:6
Product alternatives and optional equipment............................................... A:7
Machine card................................................................................................ A:7
Function descriptions ................................................................................... A:9
About the documentation ................................................................................ A:11
The documentation's parts......................................................................... A:11
Ordering documentation ............................................................................ A:11
Feedback.................................................................................................... A:11
Workshop Manual DRG420–450 ECOefficient VDRG09.01GB

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 de-
sign 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 warn-
ings 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 regula-
tion 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 re-
fers 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 re-
fers to important information in the Maintenance manual.
001128
Read the Maintenance manual
VDRG09.01GB Workshop Manual DRG420–450 ECOefficient

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 en-
gine, transmission and drive axle. Where possible, the workshop man-
ual provides reference to supplier documentation instead of printing the
same information twice. Methods for preventive maintenance and cer-
tain checks are found in the maintenance manual, no references are
given 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 in-
structions as well as survey for feedback of views and any inaccuracies.
B Safety Keep in mind for your safety.
C Preventive maintenance Reference to maintenance manual: Preventive maintenance.
0 Complete machine
1 Engine
2 Transmission
3 Driveline/Axle
4 Brakes Technical description, comprehensive function descriptions and a description of the
function of components included in the machine, divided into function groups.
5 Steering The components used for each respective function are described under each sub-
6 Suspension function. Consequently, common components are described in several 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 on-
8 Control system ly has a description what is unique for the new function.
Work instructions for corrective maintenance (replacement of components).
9 Frame, body, cab and
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 ma-
chine 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 ma-
chines, 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 sec-
tions according to the type of content, e.g. description or replacement.
The maintenance manual and the workshop manual contain different
information. The maintenance manual only contains the information
needed for preventive maintenance. The workshop manual contains
more in-depth information and repair instructions.
References are indicated by either section and group numbers, e.g.
"see section 4 Brakes, group 4.3.9 Wheel brakes" or with the section
and page number, e.g. "see Fuel level sensor, description page 4:24"
where 4:24 denotes section 4 Brakes, page 24.
References between Maintenance manual and Workshop manual are
only given in exceptional cases. If more information about a function
group is required then the primary recommendation is to search under
the same function group in the other manual. For more in-depth infor-
mation on where different types of information are located and what
references are made, see References between different information
types, page A:6.
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. Cer-
tain 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 compo-
nent in question. As a complement to this, there are references in ac-
cordance with the below.
Function descriptions Hydraulic diagrams

(Technical description) (Section E)
Component descriptions
Error codes
(Technical description, normally in Workshop
(Section D)
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 Diagnos-

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

The information in the manual is divided into modules. If a product alter-
native or optional equipment is fitted, handling may differ from that indi-
cated 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 deter-
mine which information is relevant. See Machine card, page A:7.
Product alternative
Product alternative describes options that are fitted instead of a specific
piece of standard equipment (e.g. engine options).
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 alterna-
tive, e.g. "(Product alternative Climate control system ECC)". In addi-
tion, the alternative that is an option is marked with the symbol for
optional equipment.
Optional equipment
000264
Optional equipment refers to options that can be added to standard

equipment for more or increased functions.
Symbol for optional equipment
Information on auxiliary equipment is described in separate segments
together with the standard equipment as the basis. The optional equip-
ment description covers how the equipment option affects the standard
function and what additional components are involved.
Machine card
NOTE
If the machine has been modified after delivery, information on the
machine card may be incomplete or incorrect.
IMPORTANT
Modifications made to the machine must be reported to
Cargotec so that the machine card can be updated. A
new updated machine card is sent when the customer
requests this.

The machine card indicates which drawings the machine is manufac-

tured after. In many cases these can be associated with options and
product alternatives. For more information about handling of product al-
ternatives and optional equipment, see Product alternatives and option-
al equipment, page A:7. 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 sys-
tem in the manual.
For more information about how the machine card is used for ordering
spare parts, see the spare parts catalogue's foreword.
If the information on the machine card is inadequate, contact Cargotec.
NOTE
All documents that accompany the machine are non-registered docu-
ments 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 in-
put signal to desired output signal. Most functions require that preset
conditions are fulfilled for the function to be activated. In these cases,
the conditions are listed above the illustration.
The function descriptions use symbols to illustrate components such as
valves, sensors, etc.
7:14 7 Lasthantering – Lyft och sänk
Lyft och sänk, funktionsbeskrivning

Förutsättning Börvärde Hänvisning
Manöverbrytare Frikopplad Manöverbrytarspänning (15E), funktionsbeskriv-
ning, sida 11:19
Twistlocks Låst eller olåst, inte mellanläge Twistlocks, beskrivning, sida 7:103
Överbelastningssystem Bom upp: passivt Överbelastningsystem, funktionsbeskrivning,
Bom ned: passivt eller förbikoppling aktiverad sida 8:7
Förbikoppling, beskrivning, sida 8:8
Anliggning Bom ned: ingen anliggning Twistlocks, funktionsbeskrivning, sida 7:98 1
Höjdbegränsning Förbikopplad eller bomhöjd lägre än Höjdbegränsning, beskrivning, sida 8:10
höjdbegränsningen.
1
D1
2
2, 4
D7902 D7950
D7971 D7911
3, 5, 16, 21 27
D26
4
12 UDS D7940
D20 >°
D25 3
D7930 6 D5 6 17 22 25 26
D16
15 PSS PSL
D21
Pa
PP
A1 VA
C-M 19, 24
12 7
P C-
11 LS P D
B1 T
C+
C+M Pa
4
14 20
18, 23
LSP1 A H
LSP2
8, 813
LSPR EF CF 11
LSP3 LSHY C13 P
LSP3X P T T P LSO
LSM
12
10 C9 5
C9 C10
016338
9 9 10
9 Pos Förklaring Signalbeskrivning Hänvisning

6
1 Manöverspak (S8150-Y) sänder Sänk: U = 0,5–2,0 V Manöverspak, beskrivning, sida 7:7
spänningsignal proportionell mot Nolläge: U = 2,0–3,0 V D1: Diagnosmeny, se 7.1 Controls
spakrörelsen till Reglerenhet KPU and Instr 5/XX DIAGNOSE, sida 8:42
(D7902). Lyft: U = 3,0–4,5 V
0,5 V är högsta sänkhastighet
och 4,5 V är högsta
lyfthastighet. Lägre spänning
8 än 0,5 V och högre spänning 7
än 4,5 V används för att
upptäcka fel i kablage och
reglage.
2 Reglerenhet KPU (D7902) sänder Kontrolleras av styr- och 11.5.3.2 Reglerenhet KPU (D7902),
begäran om Bom upp eller Bom ned med övervakningssystemet, fel sida 11:28
hastighets information på CAN-bussen. visas med felkod.
017426
VDRG01.01SE Verkstadsmanual DRG 420–450
Example of function description

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

Symbol explanation function descriptions

The following symbols are used in function descriptions. The symbols
1 2 are based on standard symbols for wiring and hydraulic diagrams.
3 4 1. Electric control signal
2. Electric force
3. Hydraulic control signal
5 6
4. Hydraulic force
5. Hydraulic oil pump with fixed displacement
6. Hydraulic oil pump with variable displacement
7 8 M 7. Hydraulic motor
8. Electric motor
9 10 9. Accumulator
10. Valve block
11. Filter
12. Radiator
11 12
13. Non-return valve
14. Shuttle valve
13 14 15. Restriction
16. Adjustable restriction
15 16 17. Spring brake cylinder
18. Hydraulic cylinder
17 18 19. Disc brake
20. Thermal bypass valve
°C 21. Inductive position sensor
19 20
22. Electrically controlled solenoid valve
23. Temperature sensor
21 22 24. Temperature-controlled switch
25. Pressure-controlled switch
23 °C 24 °C 26. Pressure sensor
27. Bulb
25 Pa 26 Pa
28. Horn or buzzer
29. Control and monitoring system, two control units with CAN bus
27 28 30. Relay
31. Double-acting hydraulic cylinder
D7901
29 30
D7971
017427
31

A Foreword – About the documentation A:11
About the documentation

The documentation's parts
The documentation for the machine consists of the following parts:
Operator's manual
The operator's manual is delivered with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
supplied for the machine as a separate documentation kit.
Supplementary documentation
There is supplementary documentation that can be ordered for the
machine.
• Workshop manual.
• Supplier documentation for engine, transmission, and drive axle.
Ordering documentation
Documentation is ordered from your Cargotec dealer.
Always indicate publication number when ordering.
For publication number, see machine card.
Feedback
Cargotec's ambition is that you who work with maintenance of Kalmar
machines shall have access to correct information.
Your feedback is important to be able to improve the information.
If you have any comments, please send them or fax them to the ad-
dress below. Thanks for your help!
Cargotec Sweden AB
Technical Documentation
Movägen 1
SE-341 32 Ljungby
SWEDEN

A:12

B:1
B Safety
Contents B Safety
Safety ....................................................................................................................B:3
General safety information................................................................................ B:3
Safety concerns everyone!........................................................................... B:3
A near accident is a warning! ....................................................................... B:3
Safety instructions............................................................................................. B:4
General......................................................................................................... B:4
Service position ............................................................................................ B:5
Hydraulic and brake systems, depressurising ............................................. B:5
Oils ............................................................................................................... B:8
Fuel system .................................................................................................. B:9
DEF (Diesel Exhaust Fluid)........................................................................ B:10
Clothing, etc. .............................................................................................. B:11
Several mechanics on the same machine ................................................. B:11
Working under the machine ....................................................................... B:12
Lifting heavy components .......................................................................... B:12
Vibration ..................................................................................................... B:13
Noise .......................................................................................................... B:13
Dissolvent................................................................................................... B:13
Fire and explosion risk ............................................................................... B:14
Fluid or gas under pressure ....................................................................... B:16
Coolant ....................................................................................................... B:17
Refrigerant.................................................................................................. B:17
Air pollution................................................................................................. B:18
Tensioned springs ...................................................................................... B:19
Electrical system and electric motors......................................................... B:19
Rotating components and tools ................................................................. B:19
Tyres and rims ............................................................................................ B:20
Lifting equipment ........................................................................................ B:20
Welding....................................................................................................... B:21
Spare parts................................................................................................. B:22
Non-ionised radiation ................................................................................. B:23
Environment .................................................................................................... B:24
General....................................................................................................... B:24

B:2

B Safety – Safety B:3
B Safety
General safety information
Safety concerns everyone!
The safety information concerns everyone who works with the ma-
chine! Persons who do not follow the safety instructions given in this
manual must make absolutely sure that the work is performed without
risks of personal injury and without 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 serv-
ice or repair of, the machine during normal circumstances.
For this reason it is important that all who work with the machine, or re-
pair or service the machine, read and follow the information in the Op-
erator's manual, Maintenance manual and Workshop manual.
A near accident is a warning!

A near accident is an unanticipated event where no person is injured,
nor is there any damage to the machine or property. However, near ac-
cidents 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 start-
ing to work with the machine:
• Service position, page B:5
• Hydraulic and brake systems, depressurising, page B:5
• Oils, page B:8
• Fuel system, page B:9
• DEF (Diesel Exhaust Fluid), page B:10
• Clothing, etc., page B:11
• Several mechanics on the same machine, page B:11
• Working under the machine, page B:12
• Lifting heavy components, page B:12
• Vibration, page B:13
• Noise, page B:13
• Dissolvent, page B:13
• Fire and explosion risk, page B:14
• Fluid or gas under pressure, page B:16
• Coolant, page B:17
• Refrigerant, page B:17
• Air pollution, page B:18
• Tensioned springs, page B:19
• Electrical system and electric motors, page B:19
• Rotating components and tools, page B:19
• Tyres and rims, page B:20
• Lifting equipment, page B:20
• Welding, page B:21
• Spare parts, page B:22
• Non-ionised radiation, page B:23

B Safety – Safety instructions B:5
Service position
General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
Service position is the starting point in most instructions. Certain work
requires that service position is not used.
Service position entails:
• The machine is parked, i.e. parking brake applied.
• Boom fully retracted and lowered to horizontal position.
• Engine switched off, start key in position 0.
• System voltage disconnected (with the battery disconnector in po-
sition 0). For all work on the machine, apart from the steps where
ignition voltage is required for the procedure, the battery discon-
016252
nector must always be set in position 0 and the key removed from
the disconnector.
Machine with fully retracted and lowered boom • Where required, the cab is moved forward or the engine covers are
removed.
On machines with mechanical cab sliding:
DANGER
The cab is very heavy and the machine must not be
moved without first securing the cab.
Extreme danger! Risk of crushing!
Always make sure that the cab locks on both sides are
locked in their rear position before operating, and that
the locks are secured with the lock pins.
• If the engine shall be started for work indoors then exhaust-venting

equipment must be connected to the exhaust pipe.
Hydraulic and brake systems, depressurising

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

1. Machine in service position, see Service position, page B:5.
2. Depressurise the hydraulic system.
Turn the start key to position I and activate extension out, a loud
hissing noise is heard if there is pressure in the hydraulic system.
Activate lift, extension and side shift several times.
3. Turn the start key to position 0 and remove it from the ignition key
lock.
4. Disconnect the system voltage, turn the battery disconnector to po-
sition 0.
016256

5. Depressurise the attachment.

Open relief valve top lift.
022267
Relief valve for top lift, the figure above shows an

open valve.
6. Depressurise the brake system by opening the drain valve on the
accumulator charging valve.
NOTE
Keep the drain valve open as long as work is in progress.
016821

After work is finished

7. Close the drain valve on the accumulator charging valve
NOTE
Check that the accumulator drain valve is fully closed and tighten
the lock ring.
016822
8. Close the relief valve for top lift.

023125
Relief valve for top lift, the figure above shows a

closed valve.

Oils
The following safety instructions must be followed for work when han-
dling oils.
WARNING
Hot and pressurised oil.
Always depressurise hydraulic and brake systems be-
fore starting to work on the systems. The hydraulic and
brake systems are pressurised and the oil may cause
personal injuries.
Avoid skin contact with the oil, use protective gloves.
Hot oil can cause burn injuries, rashes and irritation!
The oil can act corrosive to eyes and skin, and mucous
membranes in the throat.
CAUTION
Always clean the area around components and connec-
tions before they are loosened, and plug the connec-
tions. 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 recep-
tacles 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
dling 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 en-
gine or exhaust system is warm since fuel can spill on
hot surfaces and may ignite. Allow the engine and ex-
haust system to cool down before working on the fuel
system.
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 pres-
sure. 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 protec-
tion 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 connec-
tions before they are loosened, and plug the connec-
tions. Dirt in the fuel causes malfunctions and engine
stops in undesirable situations as well as increased
wear, resulting in subsequent material damage.
Always take action to avoid spills. In locations where
drainage containers cannot be used, use a pump or
hose for safe handling.
Always check that plugs are sealed tightly before recep-
tacles 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.

DEF (Diesel Exhaust Fluid)

dling DEF.
WARNING
DEF spilled on hot components is quickly evaporated.
DEF may irritate in the event of skin and eye contact
and if inhaled.
Health hazard!
Turn your head away. Vaporised DEF can act corrosive
to eyes and mucous membranes in the throat. If inhaled,
breathe fresh air and seek medical advice if necessary.
Handle with care and avoid contact with skin and eyes,
wear protective gloves and protective safety glasses. In
the event of skin contact and spillage on clothing, rinse
the skin with large amounts of water and change conta-
minated clothing and gloves. In the event of contact
with the eyes, rinse thoroughly with water for several
minutes and seek medical advice if necessary.
CAUTION
Switch off the engine and wait at least five minutes be-
fore working on the DEF system.
Risk of unnecessary large spillage.
When the engine is switched off, the DEF system
pumps the DEF in the pipes back to the DEF tank. Let
this process finish before starting work in order to re-
duce the amount of spillage.
CAUTION
DEF is very corrosive and creeping.
DEF is extremely aggressive towards wiring.
Wiring that has come into contact with DEF must be
replaced.
IMPORTANT
Do not spillDEF on the ground and in watercourses.
Spillage on the ground must be absorbed with sand or
other absorbent non-combustible material.
Risks
DEF is very corrosive and creeping, spillage that is not cleaned up can
cause damage to wiring, equipment and tools. In the event of spillage
there is a risk that DEF will cause oxidation which is impossible to re-
move. Cleaning with compressed air and water is not enough as DEF
oxidises the metal itself.

Safety precautions
• Prior to working with the DEF system, switch off the engine and
wait for two minutes so that the DEF system has time to pump
the solution back to the tank. Do not switch off the system voltage
with the battery disconnector before two minutes have elapsed.
• If a connector has been exposed to DEF solution then it must
be replaced immediately so that the DEF solution does not
creep further into the wiring. DEF creeps at a speed of 0.6 m/h
in the wiring.
• Clean the machine immediately in the event of spillage to prevent
damage.
• Clean tools after the service work to prevent damage.
• Protect all electrical connectors properly prior to working on the
DEF system's tank and pipes.
• Always protect the DEF system's hoses, pump unit, metering valve
and tank when these are disconnected in order to prevent spillage
and to protect the system against contaminants. Use a plastic bag
and straps.
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 mov-
ing parts.
Long hair should be adequately gathered since it can easily get caught
in moving parts. Exercise caution when working with welding or an
naked flame since hair easily catches on fire.
Several mechanics on the same machine
WARNING
If several mechanics are working on the same vehicle,
extra care must be taken so that accidental movements
do not injure any other person. Communicate so that
everyone knows where everyone is, and what they are
doing.
Risks
Operations controlled from the operator's station, e.g. all movement of
lifting equipment, may cause severe personal injury.
Safety precautions
• Make sure that the machine's lifting equipment is completely low-
ered or secured in some other way.
• Move the battery disconnector to position zero and remove the key.
• Be aware of the risks when several persons are working around
the vehicle.
• Make your co-workers aware of what you are working with.
• Do not work with the drive wheels on both sides of the truck at the
same time if the drive wheels on both sides are raised.

Working under the machine

Working under cab
On machines with liftable cab, the cab must be secured in the raised
position with the intended locks.
Working under the frame
A machine must not be moved when there is anyone working under-
neath it.
A raised vehicle may not, for any reason, be supported or raised in
parts that belong to the wheel suspension or steering. Do not support
under mudguards or tanks either. Always support under the frame or
drive axle.
A Risks
Serious personal injury may occur if a machine is moved when there is
001977
someone working underneath it.
Locks on lift mast for securing the liftable cab in the Mechanical or hydraulic tools and lifting devices may fall over or acci-
raised position. dentally lower due to malfunctions or incorrect use.
Safety precautions
• Clearly mark with warning symbols, such as on the cab steps or on
the steering wheel, that work is being carried out under the
machine.
• Use axle stands that withstand the load and stand securely.
• Lifting tools should be inspected and type approved for use.
Lifting heavy components
WARNING
Careless handling of heavy components may lead to
serious personal injury and material damage.
Use type approved lifting tools or other 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 pro-
gress, 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 opera-
tions. Wear a hard hat if there is a risk of head injury.
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 consid-
ered 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-ab-
sorbing 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: Petrole-
um spirits, petrol, thinner, alcohols, diesel, xylene, toluene, etc. Many
dissolvents are flammable.
Risks
Products with dissolvents give off fumes that may cause dizziness,
headache and nausea. They may also irritate mucous membranes in
the throat and bronchi.
If dissolvent comes into direct contact with the skin it can dry and crack.
Increased risk of skin allergies. Dissolvents may also cause injury if
they penetrate through the skin and are absorbed by the blood.
If the body is continuously exposed to dissolvents, there may be dam-
age to the central nervous system. This manifests itself in sleeping
problems, depression, nervousness, poor memory and general tired-
ness. 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 re-
duces the risk of injury.
• Avoid skin contact.
• Use protective gloves that are resistant to dissolvents (e.g. nitrile
rubber gloves)
• Make sure that the protective clothing is resistant to the dissolvents
that shall be used.
Fire and explosion risk
DANGER
In the event of fire the operator's safety must not be
compromised.
If given the opportunity, take the following action at the
slightest sign of fire:
1. Stop the machine and turn the ignition key to stop
position.
2. Leave the cab.
3. Switch off the system voltage with the battery
disconnector.
4. Alert the rescue services.
5. Try to extinguish the fire.
If this is not possible, leave the machine and the risk
area.
DANGER
Smoke can be extremely toxic.
Smoke subdues, suffocates and can kill people! Smoke
can cause damage to lungs and respiratory organs
even in small quantities.
Avoid breathing fumes, do not stand in the smoke. Use
breathing apparatus for fire fighting and work with
burnt material.
DANGER
Tyres that have caught fire are difficult to extinguish
and can cause fires with explosive development.
Extreme danger!
Always seek safety if tyres catch fire.
Examples of fire and explosion prone substances are oils, petrol, diesel,
organic solvents (paint, plastics, detergents), rust preventive agents,
welding gas, gas for heating (acetylene), high concentrations of dust
particles consisting of combustible materials. Rubber tyres that have
caught fire are difficult to extinguish and can cause fires with explosive
development.

Risks
Examples of the cause of ignition are welding, cutting with gas flame,
tobacco smoking, sparks when grinding with grinding machines, con-
tact between hot engine parts and flammable materials, heat genera-
tion in rags soaked with oil or paint 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 cig-
arette embers may cause an explosion. Vaporised fuel has a very
powerful explosive effect.
Special cases
Diesel with added petrol has a lower flashpoint. Risk of explosion even
at room temperature. The explosion risk for heated diesel is higher than
for petrol.
When changing the oil in the engine, hydraulic system and transmis-
sion, keep in mind that the oil may be hot and cause burn injuries. The
engine's coolant may also be hot.
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 po-
rous 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 is used,
as they increase the risk of sparks.
There is a lot of electronic equipment on today's machines. When weld-
ing, 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 equip-
ment or cause an explosion or fire.
Never weld on painted surfaces (remove paint, by blasting at least 10
cm around the welding or cutting point). Use gloves, breathing protec-
tion and protective glasses. Also, welding work 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 ma-
chines that have been exposed to intense heat or fire.

Safety precautions
DANGER
Residue from fuel, oils, grease or other flammable mate-
rials on the engine the exhaust system 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, mani-
folds or turbochargers. If leakage of oil, fuel or coolant
is detected, the reason should be investigated and the
fault corrected before starting the engine. Be careful to
avoid spills when replacing the filter and filling oil.
For machines with exhaust gas after-treatment unit:
Remove combustible materials from the parts of the ex-
haust gas after-treatment unit fitted in the engine com-
partment or on the outside of the machine. This is
particularly important for machines with stage V en-
gines prior to parked regeneration since the exhaust
gas temperature is higher than normal.
• Make it a habit to make a visual inspection of the engine, engine

compartment and exhaust after-treatment unit 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, coolant or
DEF leakage, loose bolts, worn or poorly tensioned drive belts,
loose connections, damaged hoses and electrical cables. The in-
spection 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 explo-
sive substances.
• Make sure that ventilation is adequate or there is an air extraction
unit when handling flammable substances.
• Always have a fire extinguisher close at hand.
Fluid or gas under pressure

Lines with high pressure may be damaged during work and fluid or gas
may jet out.
There may be high pressure in a line even if the pump has stopped.
Therefore, gas or fluid may leak out when the connection for the hose
is loosened.
A gas container that is subjected to external forces may explode, e.g. if
it falls against a hard surface. Gas may jet out from damaged valves.
WARNING
The accumulator is pressurized with gas.
The gas charge pressure is not drained when the accu-
mulator drain valve is opened. Risk of personal injury!
Exercise care when working with the accumulator.

Risks
Risk of damage/injury in connection with work on:
• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Tyre changing.
• Air conditioning.
• Cooling system.
Safety precautions
• Use protective goggles and protective gloves.
• Never work in a pressurised system.
• Never adjust a pressure relief valve to a higher pressure than the
manufacturer's recommendations.
• A hydraulic hose that swells, e.g. at a connection, shows evidence
that it is about to rupture. Replace it as soon as possible! Check
the connections thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• A discarded pressure accumulator must first be depressurised and
then punctured before it is discarded (to avoid risk of explosion).
Carefully, drill a hole with 3 mm diameter after depressurising.
• Never use your hands to check for any leaks. A fine jet from a hy-
draulic 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-cor-
rosion compound and anti-freeze fluid, for example, ethylene glycol.
Only ever use ready-mixed coolant approved by the engine supplier.
Never mix different coolants.
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.
Glycol is highly toxic and deadly to ingest.
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 pres-
sure 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 legisla-
tion 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 sys-
tem), generates gases that are very dangerous to inhale.
Safety precautions
• Use special instructions and equipment for refrigerant according to
the manual when working on the air conditioning system. Special
certification and authorisation must often be held by the person
who may do the work. (Observe national legislation and local
regulations!)
• Use protective gloves and protective safety glasses if there is a risk
of leaks.
• Make sure, for example, that heat-producing sources or objects
are not close by (cigarette glow, welding flame).
Air pollution
Air pollutants are the impurities in the air around us and are regarded
as hazardous to health. Certain impurities are more prevalent in certain
environments.
The following health-hazardous air pollution is particularly prominent in
workshops:
• Carbon monoxide (fumes) is contained in exhaust gases. Odour-
less 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 heat-
ing plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.
• Isocyanates can be found in certain paints, filler, adhesives and
foam plastics.
Risks
Sulphur mist is corrosive and injures the respiratory passages. (Gener-
ated when heating certain plastics and paints, as well as when charging
lead-acid batteries.)
Isocyanates can be released in the form of steam, dust (or present in
aerosol) when cutting, grinding or welding. May give mucous mem-
brane irritation with asthma-like symptoms as well as impaired lung
function. Even brief exposure to high concentrations can give problems
with permanent oversensitivity.
Safety precautions
• Make sure of adequate ventilation with fresh air when welding, bat-
tery 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. Con-
nect 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 re-
leased in an uncontrolled manner.
Safety precautions
• Use protective safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manuals when performing
maintenance and replacing parts and components.
• Always use the tools recommended.
Electrical system and electric motors

Safety precautions
Always switch off the battery disconnector when working on the electri-
cal system and electric motors.
Always block the machine's wheels, make sure that the parking brake
is activated and that the travel direction selector/gear is in neutral posi-
tion 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 in-
to the machine.
Angle grinders and other rotating tools can give off sparks, etc.

Safety precautions
• If you use gloves when working with a drill, you must avoid using
them in a way that they risk becoming trapped in moving parts.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or trouser legs.
• Do not use trousers with loosely hanging pockets.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair net or similar.
• Remove large or loose hanging jewellery from hands, arms and
neck.
• Use a protective screen or protective safety glasses and hearing
protection if there is a risk of ejected matter, e.g. angle grinder.
Tyres and rims
DANGER
Tyres should be regarded as pressure reservoirs. If
handled incorrectly, they constitute fatal danger.
Parts could be thrown out with explosive force and
cause severe injuries.
Never repair damaged tyres, wheel rims or lock rings.
Tyre changes must be performed by authorised
personnel.
Risks
Dismantling of wheels: Tyres, rims and lock rings may be ejected.
Inflating tyres: Tyres, rims or lock rings may be ejected.
Safety precautions
• Always deflate the tyre before starting to work on the wheel.
• Check that tyres, rims and lock rings are not damaged. Never re-
pair damaged wheel rims or lock rings.
• The tyres must be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
• Use protective screen and protective safety glasses.
Lifting equipment
When working on the machine in general, and with the machine's lifting
equipment in particular, the greatest caution must be exercised with re-
spect to securing the mast, boom, and attachment.
Therefore, always make a habit of having the boom fully lowered and
completely retracted when working on the machine.
Risks
If the machine's lifting equipment is not lowered or secured, there is a
risk of crushing.
Risk of crushing is particularly great when depressurising the hydraulic
system, see Hydraulic and brake systems, depressurising, page B:5.
Safety precautions
• If possible, do not start to work before the boom is completely low-
ered and fully retracted.

Welding
DANGER
Contact Cargotec Support before welding on the
machine.
CAUTION
There is a lot of electronic equipment on today's ma-
chines. During all welding work on the machine, con-
nections to control units must be disconnected, the
power switched off with the battery disconnector and
connections to battery terminals disconnected.
Powerful welding currents may otherwise short-circuit
the electronics, destroy expensive equipment or cause
an explosion or fire.

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

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

B:24 B Safety – Environment
Environment
General
The ever-increasing industrialisation of our world is having a significant
impact on our global environment. Nature, animals and people are sub-
jected 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 fluids, 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 "green-
house 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 (envi-
ronmentally polluted or health-hazardous area) before work is started.
Also, there are special local rules in force for such handling and when
servicing such a machine.
Declarations
The machine does not contain asbestos.
The machine contains lead in batteries and in electric cabling.
If the machine is equipped with air conditioning, use refrigerant type
R134a.

C:1
C Preventivem aintenance
C Preventive maintenance
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 sec-
tion A Foreword.

C:2

0:1
0 Complete machine
Contents 0 Complete machine

Complete machine............................................................................................... 0:3
Troubleshooting, general work instructions ................................................. 0:3
Troubleshooting without an error code, example......................................... 0:4
Troubleshooting with an error code, example.............................................. 0:4
Troubleshooting cable harnesses ................................................................ 0:6
Troubleshooting hydraulic hoses ................................................................. 0:7

0:2

0 Complete machine – Complete machine 0:3
0 Complete machine
Troubleshooting, general work
instructions
When troubleshooting, it is important that the work is structured and
logical. The purpose of the troubleshooting described in the workshop
manual is to exclude components as the source of a fault so that the
real source can be identified. A suggested structured work method is
described below.
When troubleshooting, it is important to understand how the machine
functions. Certain faults can be identified directly using the function de-
scriptions. Sections 0–12 contain descriptions of the various functions
of the machine.
Troubleshooting procedure
1. Check that there is battery voltage available.
• Battery disconnector, must be in position 1.
• Battery voltage, should be 24–28 V with the engine running.
• Fuses, check that they are intact.
2. Check that all oil and fluid levels are normal.
• Fuel
• DEF (applies to engine options Volvo TAD873VE and Volvo
TAD883VE)
• 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 0:4.
The error code lists contain recommended actions for every error
code. Error code lists are available in section D Error codes.
5. If there is no error code or the problem persists, read the function
description for the function affected in section 0–12. See Trouble-
shooting without an error code, example, page 0:4.
The function description contains information on which compo-
nents are involved in the function and how these components work
together. In some cases, there is information on what conditions
are required in order for it to be possible to activate the function.
Measurement points are marked with flags in the function descrip-
tion (C for measuring outlet, D for diagnostic menu).
Use the diagnostic menus to read signal and sensor values as well
as to activate individual components in order to identify potential
sources of error. For a more detailed description, 8.4 Diagnostics,
page 8:27.

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

example
1. Choose suitable section 0–12 to locate the function and subfunc-
tion that have caused the symptom.
2. Read the function description for the function in question to get an
overall understanding of which components are affected and how
these interact.
3. Use the function description and check the signals for the function
affected in order to locate where in the function chain that the sig-
nal or reaction is incorrect.
Measurement points are marked with flags in function descriptions
(C for measuring outlet, D for diagnostic menu). The diagnostic
menus can be used to read individual signal and sensor values. In
some cases, it is also possible to activate individual components.
For a more detailed description of the diagnostic menus, see 8.4
Diagnostics, page 8:27.
4. The fault is probably between the two units where the signal is in-
correct. 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 sys-
tem. Many error codes are connected to electrical malfunctions but
there are also error codes that interpret associations between one or
several signals that indicate a non-electrical malfunction. It is important
not to draw conclusions too hastily based on an error code.
1. Note the error code information on the display, e.g. 2/ B7570- /
3. Also note when the error code was set, since this can help to
understand whether there were any external circumstances or an
operator action that caused the error code.
2. Use the error code lists and search information about the error
code, see "Example of error code information in error code list"
below.
The error code lists are available in section D Error codes.
For detailed instructions for reading out error code, see section D
Error codes.
3. Follow the instructions in the field "Action".
4. Use diagnostic menus and circuit diagrams to determine if the in-
put signal to the control unit is correct; see section 8 Control sys-
tem, group 8.4 Diagnostics as well as section E Schematics.
5. Use the function group to find more information if needed.
In section 0–12 there is function description, the function's in-
cluded components and their position as well as, in certain cases,
work instructions for how components are checked, cleaned or
adjusted.

6. If possible, eliminate component faults by testing the component

individually.
Electric components can sometimes be checked with resistance
measurements using a multimeter.
Hydraulic components are usually controlled by measuring the
pressure (which is described under the function group). Some-
times valves can be activated mechanically in order to determine if
the malfunction is electric or hydraulic.
7. If the component's measurement values are correct, continue by
troubleshooting electric cables and hydraulic hoses.
For electric cables, see Troubleshooting cable harnesses, page
0:6.
For hydraulic hoses, see Troubleshooting hydraulic hoses, page
0:7.
8. If the wiring is not defective, then connect the cable to the control
unit.
NOTE
The system voltage must be switched off with the battery
disconnector!
9. Disconnect the cable harness from the component in question.

10. Switch on the system voltage with the battery disconnector.
11. Turn the ignition key lock to position I.
12. Check that voltage reaches the component.
Table Example of error code information in error code list
Connec-
tions
Lo- and Diag-
Typ- No- cati- Descrip- compo- nostic Refer-
e SPN FMI de on tion Limitation Action nents menu ence
B 7570 3 2 Sensor fuel Incorrect dis- Check the cable B7570 1.2 Fuel Sensor,
level (B7570), play of fuel harness between D7971/ System 1/ fuel level,
high signal volume the control unit C2:24 XX DIAG- descrip-
voltage. (empty or and the sensor NOSE, tion, page
full). using the diag- page 8:30 1:6
nostic menu.
Check the
sensor.

0:6 0 Complete machine – Complete machine
Troubleshooting cable harnesses

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

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

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

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

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

0:8

1:1
1 Engine
Contents 1 Engine
1 Engine ................................................................................................................... 1:3
1.1 Controls and instruments .................................................................................. 1:1
1.1.1 Ignition .......................................................................................................... 1:1
1.1.2 Speed pedal ................................................................................................. 1:2
1.1.10 Start button................................................................................................... 1:4
1.2 Fuel system....................................................................................................... 1:5
1.2.1 Fuel tank....................................................................................................... 1:5
1.2.2 Sensor fuel level........................................................................................... 1:6
1.2.12 DEF tank....................................................................................................... 1:6
1.6 Air intake and exhaust outlet............................................................................. 1:7
1.6.1 Air cleaning system ...................................................................................... 1:7
1.6.3 Exhaust system ............................................................................................ 1:8
1.6.4 Intercooler .................................................................................................. 1:15
1.6.8 After-treatment system............................................................................... 1:15
1.6.9 Pipes and hoses......................................................................................... 1:22
1.6.10 Cooling fans intercooler ............................................................................. 1:23
1.7 Cooling system................................................................................................ 1:24
1.7.4 Radiator and expansion tank ..................................................................... 1:26
1.7.5 Cooling fan ................................................................................................. 1:27
1.7.8 Coolant level sensor................................................................................... 1:27
1.7.10 Engine heater ............................................................................................. 1:28
1.9 Control system, engine ................................................................................... 1:29
1.9.1 Engine control unit...................................................................................... 1:29
1.11 Start/stop......................................................................................................... 1:30
1.11.1 Starter motor .............................................................................................. 1:30
1.11.2 Stopping device.......................................................................................... 1:30
1.11.3 Automatic stop of the engine a specific time after leaving the operator's
station ......................................................................................................... 1:30
1.11.4 Automatic stop function.............................................................................. 1:31
1.11.5 Automatic start and stop function............................................................... 1:31

1:2

1 Engine – Engine 1:3
1 Engine
Engine, general
Engine options
The engine provides power for propulsion and working hydraulics.
The engines are low-emission engines and meet emission require-
ments from the U.S. (California) and Europe. The new engines offer a
significant improvement, not only of exhaust emissions, but also on the
power and torque curves.
The machine is equipped with one of the following engine options:
• Volvo TAD853VE Stage IIIA/Tier 3
• Volvo TAD873VE Stage IV/Tier 4f
• Volvo TAD883VE Stage V
Component supplier documentation

The workshop manual only describes components and work descrip-
tions that concern installation in the machine. For descriptions and in-
structions for the engine's components and systems, refer to 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.
Engine option Volvo TAD853VE,

TAD873VE, TAD883VE, function
description
Condition Reference value Reference
Engine heater Disconnected. The engine heater function may Engine heater, description (electric engine heat-
be equipped with an engine start inhibitor. er), page 1:28
Transmission In neutral position Transmission, function description, page 2:3

1:4 1 Engine – Engine
1 7 12
D1 D7 D12
6, 18, 21, 25
D7950
2, 8, 13
D7902
D7901 D7971
20, 24, 26, 31
23, 29 3, 5, 9, 14, 17, 27, 30

D7930 D7940
D19
D22 D28
M SENSORS Pa H2O
023288
22 28 4 15 16 19
10 11
Pos Explanation Signal description Reference

1 The ignition key lock (S1500) sends volt- U = 24 V Ignition key lock, description, page 1:1
age signals to Control unit KCU (D7901) D1: Diagnostic menu, see 11.5 Distr of
when the start key is turned to position 1. Electr 1/XX DIAGNOSE, page 8:137
2 Control unit KCU (D7901) activates ignition Checked by control sys- 11.5.3.1 KCU control unit (D7901), page
voltage, which activates all the control tem, error shown with er- 11:27
units. ror code. D1: Diagnostic menu, see 11.5 Distr of
Electr 1/XX DIAGNOSE, page 8:137
3 If necessary, the intake air to the engine is U = 24 V 11.5.3.6 Control unit, engine (D7940), page
preheated. Control unit engine (D7940) 11:38
controls the preheating requirement and
feeds voltage to the preheating element
via a preheating relay.
4 The preheating element warms the engine Checked by control sys- 11.5.3.6 Control unit, engine (D7940), page
intake air. tem, error shown with er- 11:38
ror code.
5 When preheating is activated, Control unit Checked by control sys- 11.5.3.4 Control unit KFU (D7971), page
engine (D7940) sends information on CAN tem, error shown with er- 11:34
bus drive-train to Control unit KFU (D7971), ror code.
which in turn sends the information further
on the CAN bus.
6 When preheating is activated, Control unit Checked by control sys- 11.5.3.3 Control unit, KID (D7950), page
KID (D7950) shows Event menu tem, error shown with er- 11:32
preheating. ror code.
7 Start button (S1051) sends voltage signals U = 24 V Start button description, page 1:4
to Control unit KPU (D7902) when the start D7: Diagnostic menu, see 1.11 Start & Stop
button is activated. 2/XX DIAGNOSE, page 8:37
8 Control unit KPU (D7902) sends messages Checked by control sys- 11.5.3.2 KPU control unit (D7902), page
a start signal on the CAN bus, via Control tem, error shown with er- 11:30
unit KFU (D7971), to Control unit engine ror code.
(D7940).
9 Control unit engine (D7940) supplies volt- U = 24 V 11.5.3.4 Control unit KFU (D7971), page
age to the starter motor (M6540). 11:34.
10 The starter motor (M6540) cranks the - Starter motor, description, page 1:30
engine.


11 The engine's sensor sends signals to Con- Checked by control sys- 11.5.3.6 Control unit, engine (D7940), page
trol unit, engine (D7940) that controls the tem, error shown with er- 11:38
injectors so the engine starts. ror code.
12 The speed pedal (R6900) sends a voltage U = 0.5-4.5 V Speed pedal, description, page 1:2
signal to Control unit KPU (D7902) propor- Lower voltage than 0.5 V D12: Diagnostic menu, see 1.1 Controls &
tional to pedal actuation. and higher voltage than Instr 1/XX DIAGNOSE, page 8:29
4.5 V is used to detect
faults in cable harnesses
and controls.
13 Control unit KPU (D7902) sends a mes- Checked by control sys- 11.5.3.2 KPU control unit (D7902), page
sage with a speed request on the CAN bus, tem, error shown with er- 11:30
via Control unit KFU (D7971), to Control ror code.
unit transmission (D7930).
Control unit transmission (D7930) calcu-
lates the rotation speed that the engine
needs and sends a message with the en-
gine speed request to Control unit engine
(D7940) via the drive-train's CAN-bus.
14 Control unit, engine (D7940) increases the Checked by control sys- 11.5.3.6 Control unit, engine (D7940), page
engine speed. tem, error shown with er- 11:38
ror code.
15 Temperature and pressure sensor intake - Air cleaning system, description, page 1:7
sends information on temperature and air
pressure to Control unit, engine (D7940).
16 Sensor coolant level sends a voltage sig- Stage V: Sensor coolant level, description, page 1:27
nal to Control unit, engine (D7940) on the U = 24 V (OK level in ex-
coolant level in the expansion tank. pansion tank)
Stage IIIA and Stage IV:
U = 24 V (low level in ex-
pansion tank)
17 Control unit, engine (D7940) sends engine Checked by control sys- 11.5.3.6 Control unit, engine (D7940), page
data and warning messages on the CAN tem, error shown with er- 11:38
bus. ror code. Diagnostic menus engine: 8.4.1 Engine,
page 8:29
18 Control unit KID (D7950) shows engine da- Checked by control sys- 11.5.3.3 Control unit, KID (D7950), page
ta on the display. tem, error shown with er- 11:32.
ror code.
19 Sensor, fuel level (B7570), sends a voltage U = 0.5-4.5 V Sensor, fuel level, description, page 1:6
signal proportional to the fuel level in the Lower voltage than 0.5 V D19: Diagnostic menu, see 1.2 Fuel System
tank to the Control unit KFU (D7971). and higher voltage than 1/XX DIAGNOSE, page 8:30
4.5 V is used to detect
faults in cable harnesses
and controls.
20 Control unit KFU (D7971) sends fuel level Checked by control sys- 11.5.3.4 Control unit KFU (D7971), page
on the CAN bus. tem, error shown with er- 11:34
ror code.
21 Control unit KID (D7950) shows the fuel - 11.5.3.3 Control unit, KID (D7950), page
level in the operating menu for the engine. 11:32
Event menu for low fuel level is shown in
the display if the fuel level is below 10% for
more than 10 seconds.
22 Speed limitation Checked by control sys- Transmission, function description, page 2:3
Sensor, speed, output shaft transmission tem, error shown with er- D22: Diagnostic menu, see 2.8 Control Sys-
(B7580) sends pulses with a frequency ror code. tem 13/XX DIAGNOSE, page 8:42
proportional to the rotation speed of the
output shaft to Control unit, transmission
(D7930).
23 The transmission control unit (D7930) Checked by control sys- 11.5.3.7 Control unit, transmission (D7930),
transmits speed on CAN bus. tem, error shown with er- page 11:39
ror code.


24 Control unit KFU (D7971) recalculates the Checked by control sys- 11.5.3.4 Control unit KFU (D7971), page
rotation speed of the output shaft to ma- tem, error shown with er- 11:34
chine speed and sends the speed on the ror code.
CAN bus.
25 The KID control unit (D7950) shows the Checked by control sys- 11.5.3.3 Control unit, KID (D7950), page
machine's speed. tem, error shown with er- 11:32
ror code.
26 If the limit for the machine's speed limit is Checked by control sys- 11.5.3.4 Control unit KFU (D7971), page
exceeded, Control unit KFU (D7971) sends tem, error shown with er- 11:34
maximum permitted output rotation speed ror code.
on the CAN bus to Control unit transmis-
sion (D7930).
27 Control unit transmission (D7930) calcu- Checked by control sys- 11.5.3.6 Control unit, engine (D7940), page
lates the output rotation speed that the en- tem, error shown with er- 11:38
gine needs and sends a message with the ror code.
engine speed request to Control unit en-
gine (D7940) via the drive-train's CAN-bus.
Control unit, engine (D7940) reduces en-
gine speed until it is correct.
28 Sensor oil temperature transmission Checked by Control unit, 11.5.3.7 Control unit, transmission (D7930),
(B7660) sends a voltage signal proportion- transmission, error page 11:39
al to the oil temperature to Control unit shown with error code. D28: Diagnostic menu, see 1.7 Cooling sys-
transmission (D7930). tem 8/XX DIAGNOSE, page 8:33
29 Control unit transmission (D7930) trans- Checked by control sys- 11.5.3.7 Control unit, transmission (D7930),
mits the temperature on the CAN bus. tem, error shown with er- page 11:39
ror code.
30 Control unit engine (D7940) transmits the Checked by control sys- 11.5.3.6 Control unit, engine (D7940), page
temperature on the CAN bus. tem, error shown with er- 11:38
ror code.
31 Cooling - Fan control cooling fan, function description,
Control unit KFU (D7971) activates cooling. page 1:24
Applies to machines with Volvo TAD873VE - 1.6.8 After-treatment system, page 1:15
and Volvo TAD883VE:
After-treatment system

Engine, component location

1 2 3 4 5
11
10
9
8
017994
Engine right-hand side (in the machine's direction of travel)
1. Filling coolant 7. Radiator, transmission oil
2. Filter crankcase ventilation 8. Condenser air conditioning unit
3. Preheating element 9. Coolant radiator
4. Fuel filter 10. Intercooler
5. Oil filter 11. Cooling fan intercooler left and right (M6590-LE and
6. Control unit, engine (D7940) M6590-RI)
1 2 3 4 5 6
017995
10 9 8 7
Engine left-hand side (in the machine's direction of travel)
1. Engine oil filling point 6. Expansion tank
2. Oil level dipstick 7. Alternator
3. Connection cab heating 8. AC compressor
4. Sensor, coolant level (B7590) 9. Starter motor
5. Sight glass, coolant level 10. Relay, starter motor

Exhaust system, see Exhaust system, description, page 1:8.
Components on the machine, component

location
1 2 3 4
12
6
11
023136
10 9
1. Control unit, transmission (D7930) 7. Ignition key lock (S1500)
2. Diagnostic socket engine 8. Start button (S1501)
3. Control unit, after-treatment system (ACM) (only engine op- 9. Control unit, KID (D7950)
tions Volvo TAD873VE and Volvo TAD883VE) 10. Accelerator pedal (R6900)
4. Sensor fuel level (B7570) 11. KPU control unit (D7902)
5. Fuel tank 12. KCU control unit (D7901)
6. Control unit KFU (D7971)

Engine and transmission, separation

Separation
2. Mark up and disconnect the requisite hoses and cables before
separating engine and transmission.
NOTE
Drain and collect liquids before detaching hoses.
3. Connect lifting equipment to the engine or the transmission.
018521
4. Use a jack to secure the transmission. If the transmission shall be

lifted out, secure the rear part of the engine in an equivalent way.
5. Take up the slack in the hoisting equipment.
NOTE
Do not lift the engine or transmission.
6. For machines with Volvo TAD853VE and TAD873VE:

Remove the cable duct.
022235

7. Remove the attaching bolts (12 pcs) between the engine and the
transmission.
A
022236
8. Loosen the engine or transmission mounts and separate the en-
gine and transmission. The brackets can be detached either from
the mountings in the frame or from the mounting in the engine/
transmission.
022237
For engine replacement

9. Loosen and lift off the adapter ring.
A
B
C D
023614
A. Adapter ring
B. Screw (8 pcs) and washer (8 pcs)
C. Bolt (4 pcs)
D. Bracket

10. Transfer the vibration damper (position B) from the old transmis-
sion to the new engine.
B
11. Fit screws (position A) and tighten them to a torque of 69 Nm.
Secure the screws with Loctite.
A
023593
A. Bolt (8 pcs)
B. Vibration damper, part that is installed on the
engine
12. Fit the adapter ring and brackets.
13. Fit the screws and washers (position B) and tighten them to a tor-
A que of 49 Nm, oiled screw.
B 14. Fit screws (position C) and tighten them to a torque of 50 Nm.
Secure the screws with Loctite.
C D
023614
A. Adapter ring
B. Screw (8 pcs) and washer (8 pcs)
C. Bolt (4 pcs)
D. Bracket

For transmission replacement

15. Detach the vibration damper from the old transmission as follows:
a) Loosen and remove the centre screw (1 pc) and the part that
locks the vibration damper to the transmission.
023616
b) Loosen the screws (5 pcs) sufficiently to allow the removal of

the vibration damper from the transmission.
023617
c) Detach the vibration damper from the transmission.

023615

16. Fit the vibration damper to the new transmission as follows:

a) Fit the vibration damper.
023615
b) Fit the part that locks the vibration damper to the transmission.
023594
c) Fit the centre screw (1 pc) and tighten it to a torque of 120 Nm.
Secure the screw with Loctite.
d) Tighten the screws (5 pcs) to a tightening torque of 210 Nm in
accordance with the marking in the figure.
3
1
5
4
2
023618
Assembly
17. Clean the mating surfaces on the engine and transmission. Check
the oscillation damper's parts. Damaged or worn parts must be
replaced.
18. Install the engine or transmission mounts. This step only applies
when the brackets have been removed from the engine/
transmission.
For tightening torque, see Table Table Tightening torque, engine
and transmission brackets, page 1:15.

19. Insert two studs into the flywheel housing as a guide when the en-
gine is installed.
20. Connect lifting equipment and lift the engine into place in the vicin-
ity of the transmission. Proceed in the equivalent way if the trans-
mission is lifted out.
014940
21. Remove the cover plug over the hole for access with the turning
tool.
It may be necessary to turn the engine round so that the two-part
oscillation damper's splines align with each other.
Use Volvo special tool 999 3590.
022238
Hole for turning tool

22. Carefully connect the engine to the transmission.
Check that the oscillation damper's splines align with each other.
Turn the engine if necessary with the special tool.
022237
23. Remove the stud bolts. Fit the attaching bolts (12 pcs) between
the engine and the transmission. Tighten to a torque of 49 Nm
(oiled screw).
A
022236

24. For machines with Volvo TAD853VE and TAD873VE:

Fit the cable duct.
022235
25. Refit the cover plug behind the flywheel on the right-hand side of
the engine.
022238
022239
A B C D
26. Tighten and secure the engine or the transmission in the frame.
Table Tightening torque, engine and transmission brackets
Screw location Tightening torque, oiled

screw
A. Bracket in engine 205 Nm
B. Engine bracket in vibration 330 Nm
insulator
C. Bracket in transmission 402 Nm
D. Transmission bracket in frame 330 Nm
27. Detach the lifting equipment from the engine or the transmission.
28. Remove the jack under the transmission or the engine.

29. Connect the requisite hoses and cables for the engine and trans-
mission. Check and fill fluids as required.
30. Bleed air from the engine's fuel system before starting.

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

1.1.1 Ignition
Ignition key lock, description
The ignition key lock (S1500) is fitted on the steering wheel panel, see
0 Cab overview, page 9:5. The ignition key lock controls the switching on
and off of the ignition voltage, see Ignition voltage (15), function de-
I scription, page 11:18.
012815
Ignition key lock, replacement

2. Remove the cover.
1 2
015784
1. Cover
2. Ignition

1:2 1 Engine – Speed pedal
3. Remove the screw.

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

Speed pedal, description
The speed pedal acts on a sensor via a linkage in the pedal assembly,
see Cab overview, page 9:5. Sensor, speed pedal (R6900) sends two
voltage signals (for increased safety) proportional to pedal position to
Control unit KPU (D7902).
The signals can be checked with the diagnostic menu, see 1.1 Controls
& Instr 1/XX DIAGNOSE, page 8:29.
016898
Speed control potentiometer, replacement

2. Remove the screws and lift off the cover.
1 2 1
015856
1. Screws
2. Cover

1 Engine – Speed pedal 1:3
3. Remove the split pin and pin.
2
1
018657
1. Split pin
2. Pin
4. Turn the link arm and potentiometer so that the stop screw is
accessible.
5. Loosen the stop screw on the link arm and remove it.
018658
Stop screw
6. Remove the screws which secure the potentiometer.
7. Cut the cable ties and split the contact.
8. Replace the accelerator's potentiometer.
9. Fit in reverse order. Use new split pins.
10. Adjust the pedal assembly, see Pedal assembly, adjusting, page
4:7.
018659

1:4 1 Engine – Start button
1.1.10 Start button

Start button description
The start button (S1051) is fitted on the steering wheel panel, see Cab
overview, page 9:5. The start button controls start and stop of the en-
gine. The signal can be checked with the diagnostic menu, see 1.11
Start & Stop 2/XX DIAGNOSE, page 8:37.
016899

1 Engine – Fuel system 1:5
1.2 Fuel system

Fuel system, description
The fuel system stores and cleans the fuel and supplies the engine with
fuel.
The fuel tank is located on the left-hand side of the machine and is
equipped with a sensor for the fuel level. The amount of fuel in the tank
is shown in an operating menu on the display in the cab. Fuel prefilter
with water separator and fuel filter are fitted on the engine.
The water separator is equipped with electrical indication, an error code
is generated when the water separator must be drained of water.
WARNING
The engine's fuel system operates at very high pres-
sure. The pressure is so high that the jet can injure the
skin, resulting in severe injuries.
Use protective gloves and protective safety glasses,
avoid skin contact with fuel. If a component is being
loosened then hold a rag over the connection as protec-
tion 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 is located on the left-hand side of the machine.
C
D
023107
A. Cover lid for cleaning

B. Fuel filling
C. Sensor fuel level (B7570)
D. Drain plug, under tank

1:6 1 Engine – Sensor fuel level
1.2.2 Sensor fuel level

Sensor, fuel level, description
The fuel level sensor is inserted in the fuel tank from above.
C
The fuel level sensor (B7570) sends a voltage signal proportional to the
fuel level in the tank to the KFU control unit (D7971). An event menu is
B shown in the display if the fuel level is below 10 % for more than 10
seconds.
A The signal from the sensor can be checked with the diagnostic menu
1.2 Fuel System 1/XX DIAGNOSE, page 8:30.
D
023107

B. Fuel filling
Fuel level sensor, replacement

C
2. Disconnect the cable harness from the sensor. Note the cable's
clamping.
B 3. Clean the area on the tank around the level sensor.
4. Unscrew the level sensor.
A The sensor is threaded into the tank.
5. Screw in a new level sensor.
6. Connect the cable harness to the sensor and attach the cable in
the same way as before.
D
023107

B. Fuel filling
1.2.12 DEF tank

DEF tank, description
See After-treatment system for Volvo TAD873VE, description, page
1:15.
See After-treatment system for Volvo TAD883VE, description, page
1:18.

1 Engine – Air intake and exhaust outlet 1:7
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, negative
1 2 3 4 5 pressure indicator for indication of filter change, pipes and hoses.
There are two filters in the air cleaner that purify the air and a separator
with dust container 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. Par-
ticles are collected in the filter material when the air filters clean the air
to the engine. Over time, a great deal of particle matter is collected and
the filter does not let through sufficient air for efficient combustion, the
filter must then be changed. The filter indicator measures the negative
pressure on the engine side of the filter. When the filter is clogged the
negative pressure is higher and the indicator indicates that it is time to
replace the filter.
001357
Air cleaning system, overview As an option the machine can be equipped with a raised air intake with
1. Intake hose pre-cleaner. It consists of an extension of the inlet to the air filter and a
pre-cleaner that sorts out larger particles by creating vortices in the air
2. Negative pressure indicator for indication of filter
change intake. The pre-cleaner does not contain any parts that need to be re-
placed. During operation in dirty environments this means that less
3. Air cleaner
dusty air is sucked into the air cleaner, and in this way the service life of
4. Intake the air filters is extended.
5. Separator with dust container

1:8 1 Engine – Exhaust system
1.6.3 Exhaust system

Exhaust system, description
Volvo TAD853VE
The exhaust system is mounted in the frame. Heat protection is fitted
between the engine and exhaust system to protect cables, etc. A flexi-
ble exhaust hose takes up the movement of the engine. Heat protection
is fitted between engine and exhaust system to protect wiring, etc. On
the outside of the machine, heat protection is fitted over the exhaust
system.
4
WARNING
Hot exhaust system!
Risk of burn injuries!
Never touch hot components, e.g. turbo or exhaust
pipe!
2
1
022761
Volvo TAD853VE
1. Silencer
2. Exhaust pipe
3. Heat protection
4. End pipe

1 Engine – Exhaust system 1:9
Volvo TAD873VE
The exhaust system is mounted in the frame. The exhaust system's
pipes and exhaust after-treatment unit, which consist of SCR catalytic
converter, are partially isolated with enclosed insulation. A flexible ex-
haust hose takes up the movement of the engine. On the outside of the
machine, there is heat protection fitted over the exhaust system.
5
WARNING
Hot exhaust system!
Never touch hot components, e.g. turbo, exhaust pipe
or exhaust after-treatment unit with catalytic
converters!
For the after-treatment system's function and components, see After-

4
treatment system for Volvo TAD873VE, component location, page 1:17.
3
2
1
022762
Volvo TAD873VE
1. Exhaust pipe
2. Silencer with catalytic converter
3. Flexible hose
4. Heat protection
5. End pipe

Volvo TAD883VE
The exhaust system is installed inside and outside the chassis. The ex-
haust system's pipes and the exhaust after-treatment units, which con-
sist of DOC catalytic converter, DPF particulate filter, mixer chamber,
and SCR catalytic converter, are partially isolated with enclosed insula-
tion. A gastight flexible exhaust hose takes up the movement of the en-
gine. On the outside of the machine, there is heat protection fitted over
the exhaust system.
6
WARNING
Hot exhaust system!
Never touch hot components, e.g. turbo, exhaust pipe
or exhaust after-treatment unit with particulate filter and
catalytic converters!
5 For the after-treatment system's function and components, see After-

treatment system for Volvo TAD883VE, component location, page 1:21.
3
2
1
022466
Volvo TAD883VE
1. Exhaust pipe
2. Flexible hose
3. Exhaust after-treatment unit with DOC catalytic
converter, DPF particulate filter, and mixer
chamber
4. Exhaust gas after-treatment unit with SCR cata-
lytic converter
5. Heat protection
6. End pipe

Exhaust pipe with flexible exhaust hose (fitted

between engine and exhaust gas after-treatment unit),
replace
2. Investigate the cause for why the existing flexible hose has failed.
3. Remove the existing flexible hose by loosening the V-clamps.
A
4. Loosen the lower exhaust pipe's mounting by loosening the ex-
haust clamps in order to facilitate the installation and adjustment of
a new flexible hose.
5. Check that the connections on the upper and lower exhaust pipes
are not damaged, corroded, etc. Remove any gasket residue and
clean the contact surfaces.
C
E
023603
E
Exhaust pipe with flexible hose
A. Exhaust pipe, upper
B. V-clamps (2 pcs)
C. Flexible hose
D. Exhaust pipe, lower
E. Exhaust clamps (2 pcs) and nut (4 pcs)
6. Install new gaskets on the upper exhaust pipe and on the flexible
hose.
A
023604
A. Gasket

7. Measure the maximum length (A) of the flexible hose.

A
Extend the flexible hose to maximum position. Measure the maxi-
mum length of the flexible hose.
8. Measure the minimum length (B) of the flexible hose.
Compress the flexible hose to minimum position. Measure the min-
imum length of the flexible hose.
9. Measure the medium length (C) of the flexible hose.
B Extend the hose to a medium position. Calculate the medium
length of the flexible hose. Medium length = maximum length –
minimum length/2 + minimum length.
C 023605
A. Flexible hose extended to maximum length.

B. Flexible hose retracted to minimum length.
C. Flexible hose extended to medium length.
10. Install the new flexible hose.
a) The flexible hose must not be forced into place during
installation.
b) Ensure that no torsional strain is applied during installation.
11. Check that the centre lines for the connections to the upper and
lower exhaust pipes correspond and that they are parallel. Adjust if
necessary.
12. Check the measurement for the length of the flexible hose on three
sides. Adjust the length of the three sides to ensure that they are
as equal as possible. Longitudinal tolerance is ±5 mm from the
measured centre length.
If the flexible hose does not fit, the installation of the lower exhaust
pipe may need to be adjusted.
023606
Check the measurement for the length of the flexible

hose on three sides.
13. Check that the flexible hose is as straight as possible. Use an ob-
ject, e.g. a flat iron bar, to assist when checking that the flexible
hose is as straight as possible. Move the flat iron bar along the
flexible hose to ensure that it is straight all the way round. Toler-
ance ±4 mm laterally.
A
023607
A. Flat iron bar

14. Tighten the bracket and exhaust clamps. Ensure that the installa-
tion of the flexible hose is not affected during tightening.
15. Tighten the V-clamps (2 pcs) to a torque of 12±1 Nm.
16. Start the machine and check that there is no exhaust leakage.
023608
B
A. V-clamps (2 pcs)
B. Exhaust clamps (2 pcs) and nut (4 pcs)
Exhaust pipe with flexible exhaust hose (fitted

between exhaust gas after-treatment units), replace
2. Investigate the cause for why the existing flexible hose has failed.
3. Remove the existing exhaust pipe by loosening the V-clamps.
4. Check that the connections to the exhaust gas after-treatment
units are free of damage, corrosion, etc. Clean the contact
surfaces.
023609
B A B
Exhaust pipe with flexible hose
A. Exhaust pipe with flexible hose
B. V-clamps (2 pcs)

5. Measure the maximum length (A) of the flexible hose.

A Extend the flexible hose to maximum position. Measure the maxi-
mum length of the flexible hose.
6. Measure the minimum length (B) of the flexible hose.
Compress the flexible hose to minimum position. Measure the min-
imum length of the flexible hose.
7. Measure the medium length (C) of the flexible hose.
Extend the hose to a medium position. Calculate the medium
B length of the flexible hose. Medium length = maximum length –
minimum length/2 + minimum length.
C 023610
A. Flexible hose extended to maximum length.

B. Flexible hose retracted to minimum length.
C. Flexible hose extended to medium length.
8. Fit the new exhaust pipe including flex hose.
a) The exhaust pipe must not be forced into place during
installation.
b) Ensure that no torsional strain is applied during installation.
9. Check the measurement for the length of the flexible hose on three
sides. Adjust the length of the three sides to ensure that they are
as equal as possible. Longitudinal tolerance is ±5 mm from the
measured centre length.
023611
Check the measurement for the length of the flexible

hose on three sides.
10. Check that the flexible hose is as straight as possible. Use an ob-
ject, e.g. a flat iron bar, to assist when checking that the flexible
hose is as straight as possible. Move the flat iron bar along the
flexible hose to ensure that it is straight all the way round. Toler-
ance ±4 mm laterally.
A
023612
A. Flat iron bar

1 Engine – Intercooler 1:15
11. Tighten the V-clamps (2 pcs) to a torque of 12±1 Nm.

12. Start the machine and check that there is no exhaust leakage.
023613
A A
A. V-clamps (2 pcs)
1.6.4 Intercooler
Intercooler, description
The charge air passes through a radiator that is cooled by the ambient
air.
1 See also Cooling system, description, page 1:24.
5
017979
1. Intercooler
2. Cooling fan intercooler left and right
3. Coolant radiator
4. Condenser air conditioning unit
5. Radiator, transmission oil
1.6.8 After-treatment system

After-treatment system for Volvo TAD873VE,
description
The exhaust gases from the engine are cleaned in an SCR catalytic
converter (Selective Catalytic Reduction). This is so-called catalytic ex-
haust cleaning. It means that the exhaust gases are after-treated
through the addition of DEF which is injected into the exhaust gases
before they pass through the catalytic converter. Together with the cat-
alytic converter, the additive means that the nitrous oxides are con-
verted to nitrogen and water vapour.

1:16 1 Engine – After-treatment system
After-treatment system for Volvo TAD873VE, function

description
D7940 ACM
5, 9, 12
1
10 NOx
11 13
8
7
6
3 2
4
022439
1 NOx sensor - After-treatment system for Volvo TAD873VE,
Sensor, NOx outlet SCR continuously component location, page 1:17
measures the amount of nitrogen oxide in
exhaust gases and sends a voltage signal
to the Control unit, after-treatment system
(ACM).
2 Sensor exhaust gas temperature - After-treatment system for Volvo TAD873VE,
Sensor, exhaust gas temperature sends a component location, page 1:17
voltage signal proportional to the exhaust
temperature to Control unit, after-treatment
system (ACM).
3 Cleaning of exhaust gases - After-treatment system for Volvo TAD873VE,
Exhaust gases from the engine are routed component location, page 1:17
via the exhaust pipe to the after-treatment
system.
4 The exhaust gases enter the mixer cham- - After-treatment system for Volvo TAD873VE,
ber where DEF is metered out. component location, page 1:17
5 Control unit, after-treatment system (ACM), - After-treatment system for Volvo TAD873VE,
supplies voltage to the DEF pump. component location, page 1:17
6 The DEF pump (M6711) pumps DEF from - After-treatment system for Volvo TAD873VE,
the DEF tank to the DEF injector and back component location, page 1:17
to the tank. The pump circulates DEF in
the system, which also cools the DEF in-
jector when the injector does not have sep-
arate coolant cooling.
7 The DEF injector meters out DEF into the - After-treatment system for Volvo TAD873VE,
mixer chamber where it is mixed with the component location, page 1:17
exhaust gases.
The DEF also cools the DEF injector.
8 The exhaust gases mixed with DEF enter - After-treatment system for Volvo TAD873VE,
the SCR catalytic converter where the component location, page 1:17
amount of nitrous oxides (NOx) is reduced.
Together with the catalytic converter, DEF
means that the nitrous oxides are con-
9 If the levels of nitrogen oxides in the ex- - After-treatment system for Volvo TAD873VE,
haust gases become too high, a request component location, page 1:17
for engine speed limitation is sent from
Control unit, after-treatment system (ACM)
on the CAN bus to Control unit, engine
(D7940). Error code and event menu are
shown in the display.

1 Engine – After-treatment system 1:17

10 The exhaust gases are led out via the end - After-treatment system for Volvo TAD873VE,
pipe. component location, page 1:17
11 DEF tank U = 0.5-4.5 V After-treatment system for Volvo TAD873VE,
DEF temperature, level and quality sen- component location, page 1:17
sors send information about DEF quality,
level and temperature in the tank on CAN
bus drive-train to Control unit, after-treat-
ment system (ACM).
12 For cold DEF, Control unit, after-treatment U = 24 V After-treatment system for Volvo TAD873VE,
system (ACM) supplies voltage to Solenoid component location, page 1:17
valve, coolant.
13 Solenoid valve, coolant (Y6098) circulates - After-treatment system for Volvo TAD873VE,
hot coolant, first to the coiled pipe in the component location, page 1:17
DEF tank and then to the DEF pump unit,
in order to warm them up.

component location
6
7 8
5
4
1 9
2 3
10
14 8
11
12
022764
13
1. DEF tank 8. Coolant hoses for heating the DEF tank and DEF pump
2. Tank unit with heating coil and temperature, level and qual- unit.
ity sensor 9. Catalytic converter SCR/silencer
3. DEF hoses 10. Sensor, NOx outlet SCR
4. Sensor exhaust gas temperature 11. End pipe
5. Exhaust pipe from engine 12. Pump unit, DEF
6. Sensor, NOx inlet SCR 13. Solenoid valve, coolant
7. DEF injector 14. Control unit, after-treatment system (ACM)


description
The exhaust gases from the engine are cleaned in three stages in an
after-treatment system. The after-treatment system broadly consists of:
1. DOC catalytic converter (Diesel Oxidation Catalyst). It consists of a
catalytic converter that removes carbon monoxide (CO) and hydro-
carbons (HC), oil and a certain amount of particles, and soot from
the exhaust gases by means of oxidation.
2. Particulate filter DPF (Diesel Particulate Filter) is a filter that re-
moves particles (PM, Particulate Matter) from the exhaust gases.
The fixed particles mainly consist of soot from the combustion, but
also ash to a lesser extent. The exhaust gases flow through a large
number of channels in the filter, and the particles are trapped when
the exhaust gases flow through the walls of the channels. The soot
particles are oxidised away during regeneration by means of raised
exhaust gas temperature together with surplus oxygen in the ex-
haust gases. Regeneration is performed automatically while oper-
ating but if the soot load is too high then a parked regeneration
must be performed. During parked regeneration, extra fuel is in-
jected into the engine, which raises the temperature to the level re-
quired to burn up the soot from the walls of the channels. During
operation, the exhaust gas temperature is kept as high as possible
with the Heat Management System where the exhaust throttle and
hot EGR can be activated by the system.
3. The SCR catalytic converter (Selective Catalytic Reduction) is a
so-called catalytic exhaust cleaning system. It means that the ex-
haust gases are after-treated through the addition of DEF which is
injected into the exhaust gases before they pass through the cata-
lytic converter. Together with the catalytic converter, the additive
means that the nitrous oxides are converted to nitrogen and water
vapour.
For component location, see After-treatment system for Volvo
TAD883VE, component location, page 1:21.
After-treatment system for Volvo TAD883VE, function

description
13 D7940 ACM
16 NOx 1 10, 15, 18
12
11 4 17 19
9
5 Pa
3
8
6 2
7 14
022438
NOx
1


1 NOx sensor - After-treatment system for Volvo TAD883VE,
Sensor, NOx inlet DOC, and Sensor, NOx component location, page 1:21
outlet SCR, continuously measure the
amount of nitrogen oxides in the exhaust
gases and send a voltage signal to Control
unit, after-treatment system (ACM).
2 Sensor exhaust gas temperature - After-treatment system for Volvo TAD883VE,
Sensor, exhaust gas temperature DOC in- component location, page 1:21
let sends a voltage signal proportional to
the exhaust temperature to Control unit,
after-treatment system (ACM).
3 Sensor, exhaust gas temperature DPF in- - After-treatment system for Volvo TAD883VE,
let sends a voltage signal proportional to component location, page 1:21
4 Sensor, exhaust gas temperature DPF out- - After-treatment system for Volvo TAD883VE,
let sends a voltage signal proportional to component location, page 1:21
5 Sensor, exhaust back pressure - After-treatment system for Volvo TAD883VE,
Sensor, exhaust back pressure measures component location, page 1:21
the pressure difference between the partic-
ulate filter's inlet and outlet and sends a
voltage signal to Control unit, after-treat-
ment system (ACM).
6 Cleaning of exhaust gases - After-treatment system for Volvo TAD883VE,
Exhaust gases from the engine are routed component location, page 1:21
via the exhaust pipe to the after-treatment
system.
7 The exhaust gases enter the DOC catalytic - After-treatment system for Volvo TAD883VE,
converter. component location, page 1:21
The DOC catalytic converter removes car-
bon monoxide (CO) and hydrocarbons
(HC), unburned fuel, oil and a certain
amount of particles and soot from the ex-
haust gases by means of oxidation.
8 The exhaust gases enter the DPF particu- - After-treatment system for Volvo TAD883VE,
late filter. The particulate filter reduces the component location, page 1:21
amount of unburned particles (primarily
soot particles) in the exhaust gases.
If the pressure difference between the inlet
and outlet of the particulate filter is too
great, the soot load in the filter is too high.
Then the particulate filter needs to be re-
generated. The pressure difference is
measured using Sensor, exhaust back
pressure.
9 The exhaust gases enter the mixer cham- - After-treatment system for Volvo TAD883VE,
ber where DEF is metered out. component location, page 1:21
10 Control unit, after-treatment system (ACM), - After-treatment system for Volvo TAD883VE,
supplies voltage to the DEF pump. component location, page 1:21
11 The DEF pump pumps DEF back and forth - After-treatment system for Volvo TAD883VE,
from/to the DEF tank and supplies the DEF component location, page 1:21
injector with DEF.
12 The DEF injector meters out DEF into the - After-treatment system for Volvo TAD883VE,
mixer chamber where it is mixed with the component location, page 1:21
exhaust gases.
Coolant from the motor cools the DEF
injector.


13 Exhaust gases are mixed with DEF when it - After-treatment system for Volvo TAD883VE,
is routed via an exhaust pipe to the SCR component location, page 1:21
catalytic converter.
14 The exhaust gases mixed with DEF enter - After-treatment system for Volvo TAD883VE,
the SCR catalytic converter where the component location, page 1:21
amount of nitrous oxides (NOx) is reduced.
Together with the catalytic converter, DEF
means that the nitrous oxides are con-
15 If the levels of nitrogen oxides in the ex- - After-treatment system for Volvo TAD883VE,
haust gases become too high, or the par- component location, page 1:21
ticulate filter needs to be regenerated, a
request for engine speed and torque limita-
tion is sent from Control unit, after-treat-
ment system (ACM) on the CAN bus to
Control unit, engine (D7940). Error code
and event menu are shown in the display.
16 The exhaust gases are led out via the end - After-treatment system for Volvo TAD883VE,
pipe. component location, page 1:21
The end pipe has an integrated water trap
to divert rain and water when washing the
machine.
17 DEF tank U = 0.5-4.5 V After-treatment system for Volvo TAD883VE,
DEF temperature, level and quality sen- component location, page 1:21
sors send information about DEF quality,
level and temperature in the tank on CAN
bus drive-train to Control unit, after-treat-
ment system (ACM).
18 For cold DEF, Control unit, after-treatment U = 24 V After-treatment system for Volvo TAD883VE,
system (ACM) supplies voltage to Solenoid component location, page 1:21
valve, coolant.
19 Solenoid valve, coolant circulates hot cool- - After-treatment system for Volvo TAD883VE,
ant, first to the coiled pipe in the DEF tank component location, page 1:21
and then to the DEF pump unit, in order to
warm them up.


component location
1 2 3
10 11 12
4
1 7
6
5
13
8 14
9
15
16
17
18
022765
21 20 19
1. Coolant hoses for heating the DEF tank and DEF pump 11. Sensor, exhaust back pressure
unit. 12. End pipe
2. Sensor, NOx inlet SCR 13. Sensor, NOx outlet SCR
3. Exhaust pipe from engine 14. Sensor, exhaust gas temperature DPF outlet
4. Filter, tank ventilation 15. DEF mixer chamber
5. Tank unit with heating coil and temperature, level and qual- 16. DEF injector
ity sensor
17. DEF hoses
6. Sensor, exhaust gas temperature DOC
18. Control unit, after-treatment system (ACM)
7. Catalytic converter DOC
19. Solenoid valve, coolant
8. Sensor, exhaust gas temperature DPF inlet
20. Pump unit, DEF
9. Particulate filter DPF
21. DEF tank
10. Catalytic converter SCR

1:22 1 Engine – Pipes and hoses
Service hatch, exhaust after-treatment units, description.

There is a service hatch on the right-hand side of the machine for eas-
ier access to the engine's exhaust after-treatment units.
023655
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 plas-
tic bag.
4. Remove the hose clamps that hold the intake hose between air
cleaner and turbo.
5. Remove the hose clamps holding the charge air hoses.
6. Remove the charge air hoses.
7. Fit in reverse order.
8. Check the connections with regard to leakage.

1 Engine – Cooling fans intercooler 1:23
1.6.10 Cooling fans intercooler

Cooling fans intercooler, description
Cooling fans intercooler left and right (M6590-LE and M6590-RI) are
electric fans which increase the air flow through the intercooler if re-
1 quired. The cooling fans are fitted in the upper part of the cooling unit.
The cooling fans are supplied with voltage by Control unit KFU (D7971)
2 depending on the charge air temperature from Control unit engine
(D7940). At predetermined intervals, Control unit KFU (D7971)
changes the direction of the cooling fans in order to clean dirt from the
3 intercooler.
The signal can be checked with the diagnostic menu, see 1.7 Cooling
4 system 6/XX DIAGNOSE, page 8:32, 1.7 Cooling system 8/XX DIAG-
NOSE, page 8:33 and 1.7 Cooling system 9/XX DIAGNOSE, page
5 8:33.
017979
Cooling unit
1. Intercooler
2. Cooling fan intercooler left and right
3. Coolant radiator

1:24 1 Engine – Cooling system
1.7 Cooling system

Cooling system, description
The engine is water-cooled and the coolant is cooled in the radiator
which is located at the rear of the engine compartment in the frame.
The engine's cooling system is also used in order to heat the cab and
the DEF tank. The engine's cooling system heats and cools the engine
oil with a built-in heat exchanger on the engine.
The engine's cooling fan is controlled electronically and regulates the
air flow through the transmission oil cooler and condenser.
The cooling system in the machine consists of the following main parts:
• Engine cooling system, see supplier documentation engine.
• Radiator coolant, part of the cooling unit.
• Expansion tank, fitted on the cooling unit in the engine
compartment.
• Sensor coolant level (B7590), in the expansion tank connected to
Control unit engine (D7940).
• Cooling fan, located in front of the radiator.
• Magnetic clutch cooling fan.
The cooling fan's speed is controlled actively depending on engine
and transmission temperatures.
• Intercooler, part of cooling unit.
• Cooling fans intercooler right and left, part of the cooling unit
The speed of the cooling fans is controlled actively depending on
the charge air temperature.
Fan control cooling fan, function description

D7902
D5 D7971 D7901
5, 8
D7
D9 D10 D7930 D7940
2 4
6, 7 1 3
M
022468
SENSORS SENSORS
9, 10

1 The transmission sensor sends signals Checked by control system, error 11.5.3.7 Control unit, transmission
to the Transmission control unit (D7930). shown with error code. (D7930), page 11:39.
2 The Transmission control unit (D7930) Checked by control system, error 11.5.3.4 Control unit KFU (D7971),
sends a signal about the transmission oil shown with error code. page 11:34.
temperature to the KFU control unit
(D7971).
3 The engine sensor sends signals about Checked by control system, error 11.5.3.6 Control unit, engine (D7940),
charge air temperature, coolant tempera- shown with error code. page 11:38.
ture and turbo pressure to Control unit,
engine (D7940).
4 The Engine control unit (D7940) sends Checked by control system, error 11.5.3.4 Control unit KFU (D7971),
signals to the KFU control unit (D7971). shown with error code. page 11:34.

1 Engine – Cooling system 1:25

5 Control unit KFU (D7971) controls the U = 0–24 V 11.5.3.4 Control unit KFU (D7971),
Visco hub's built-in solenoid valve page 11:34.
(M6580) from 0–100% of the engine 1.7 Cooling system 8/XX DIAGNOSE,
speed depending on engine and trans- page 8:33
mission temperature.
6 The Visco hub's built-in solenoid valve - Cooling fan, description, page 1:27.
(M6580) controls the rotation speed of
the cooling fan, which increases or de-
creases the air flow passing through the
cooling unit.
7 A built-in speed sensor sends a pulse - Cooling fan, description, page 1:27.
signal with frequency proportional to the Diagnostic menu, see 1.7 Cooling
fan speed to Control unit KFU (D7971). system 5/XX DIAGNOSE, page 8:32
8 Control unit KFU (D7971) controls Cool- Checked by control system, error 11.5.3.4 Control unit KFU (D7971),
ing fan intercooler left (M6590-LE) and shown with error code. page 11:34
Cooling fan intercooler right (M6590-RI) Diagnostic menu, see 1.7 Cooling
from 0–100% depending on charge air system 6/XX DIAGNOSE, page 8:32,
temperature from Control unit engine 1.7 Cooling system 8/XX DIAGNOSE,
(D7940). page 8:33 and 1.7 Cooling system 9/
At a predetermined interval, Control unit XX DIAGNOSE, page 8:33
KFU (D7971) changes the direction of
the cooling fans in order to clean dirt
from the intercooler.
9 Cooling fan intercooler left (M6590-LE) - Intercooler, description, page 1:15
and Cooling fan intercooler right (M6590-
RI) increase the air flow through the
intercooler.
10 Cooling fan intercooler left (M6590-LE) Checked by control system, error Intercooler, description, page 1:15
and Cooling fan intercooler right (M6590- shown with error code. Diagnostic menu, see 1.7 Cooling
RI) send a pulse signal with frequency system 7/XX DIAGNOSE, page 8:33
proportional to the fan speed to Control
unit KFU (D7971).

1:26 1 Engine – Radiator and expansion tank
1.7.4 Radiator and expansion tank

Radiator and expansion tank, description
The radiator for the engine is located in the cooling unit which is located
1 2 3 behind the engine.
There is an expansion tank fitted on the cooling unit which means that
the coolant can cope with temperature changes without disappearing
4 from the engine, and it counteracts air pockets being formed in the
cooling system.
5 The function of the cooling unit is to cool:

• Engine coolant
6 • Transmission oil (cooled in the lower part of the cooling unit), see
Oil cooler, description, page 2:15.
• Charge air (cooled in the upper part of the cooling unit), see Inter-
7 cooler, description, page 1:15.
• Refrigerant for air conditioning (between engine and transmission
9 in the cooling unit or behind the cooling unit), see Condenser unit,
8 description, page 9:41.
See also Cooling system, description, page 1:24.
For more information, see supplier documentation, engine.
018311
Cooling unit
1. Expansion tank
2. Sensor, coolant level (B7590)
3. Sight glass, coolant level
4. Intercooler
5. Coolant radiator
6. Connection, cooling cab
9. Thermostat transmission oil
Radiator, replacement
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.

2. Drain the coolant from the engine, see Maintenance manual.
3. Drain the transmission oil from the transmission, see Maintenance
Manual.
4. Drain the air conditioning of refrigerant, see General instructions
for working on the air conditioning unit, page 9:30.
5. Detach the hoses for intercooler, engine and transmission cooling,
for the radiator's expansion tank and condenser.
6. Remove the screws that secure the cooling unit to the frame.
7. Connect lifting eyes and lifting equipment to the threaded holes in
the top of the cooling unit.
8. Carefully lift the cooling unit out of the frame.

1 Engine – Cooling fan 1:27
10. Refill the air conditioning with refrigerant, see General instructions
for working on the air conditioning unit, page 9:30.
11. Fill with transmission oil, see Maintenance manual.
12. Fill with coolant, see Maintenance manual.
13. Check and top up fluids as necessary.
1.7.5 Cooling fan

Cooling fan, description
The cooling fan is driven by an electrically controlled Visco clutch that
controls the air flow through the cooling unit. The cooling fan is fitted in
front of the cooling unit.
The cooling fan's operating conditions are regulated by Magnetic clutch
cooling fan (M6580). The magnetic clutch is supplied with voltage by
Control unit KFU (D7971) depending on engine and transmission tem-
perature from Control unit engine (D7940). The magnetic clutch also
contains a rotation speed sensor that sends fan speed back to Control
unit KFU (D7971).
The signal can be checked with the diagnostic menu, see 1.7 Cooling
system 4/XX DIAGNOSE, page 8:32, 1.7 Cooling system 5/XX DIAG-
NOSE, page 8:32 and 1.7 Cooling system 11/XX DIAGNOSE, page
8:34.
CAUTION
Due to the Visco clutch containing a fluid that controls
the extent to which the fan is engaged, the Visco clutch
(or fan with Visco clutch mounted) must not be laid
018304
down horizontally but must be handled in upright

position.
Product damage.
1.7.8 Coolant level sensor

Sensor coolant level, description
The cooling system is equipped with an sensor (level switch) that acti-
vates an alarm on the display if the coolant level is too low.
The sensor is located in the expansion tank.
Coolant level sensor (B7590) sends a voltage signal to the Engine con-
trol unit (D7940).
017997

1:28 1 Engine – Engine heater
Sensor coolant level, replacement

2. Drain the coolant from the expansion tank using suction equipment
for fluid or via the drain on the radiator, see Maintenance manual.
3. Disconnect the cable harness from the sensor.
4. Remove the sensor from the expansion tank.
5. Fit the new sensor on the expansion tank.
Cummins: The sensor has a conical thread that has been pre-
treated with thread lock. Do not tighten the sensor too hard.
Volvo: The sensor has a conical thread that must be sealed with a
thread sealing cord, e.g. Loctite 55. Do not over-tighten the sensor.
6. Connect the cable harness to the sensor.
7. Fill the system with coolant, see Maintenance manual.
017997
8. Check that there is no leakage at the sensor's thread.
1.7.10 Engine heater

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

different units together with heater, hydraulic oil tank, oil tank brake sys-
tem and preparation for cab fan. The engine heater heats the engine
and facilitates starting when the machine has been switched off for a
2
long time and is intended for use in cold climates.
3 The engine heater is supplied with high voltage from an external mains
power connector. The mains power connector is fitted on one of the ter-
4 minal boxes above the left-hand footstep. The machine has a start in-
terlock function that prevents the engine being started when a power
cable is connected to the mains power connector. The sensor for the
start interlock function is an optical sensor that can react to objects oth-
er than the connected power cable.
For more information see supplier documentation engine.
018548
Terminal boxes, engine, cab and tank heater CAUTION

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

heats the engine's cooling system and the cab heating, see Diesel-driv-
en engine and cab heater, description, page 9:52

1 Engine – Control system, engine 1:29
1.9 Control system, engine

Control system, engine, description
The engine is controlled by a control system whose central unit is a
control unit.
The system consists of sensors, control unit (D7940) and electric injec-
tors, amongst other things. The sensors provide input signals to the
control unit, which in turn controls the injectors. The fuel quantity is cal-
culated by the control unit based on signals from the sensors on the en-
gine and a CAN message about the desired engine speed.
If serious malfunctions are detected by the control system on the en-
gine, then engine power is limited to protect the engine from further
damage.
When one of the following limits is exceeded, engine performance is
limited:
• coolant temperature above 107 °C
• intake temperature above 85 °C
• oil temperature above 127 °C
• charge air pressure above 285 kPa
• exhaust gas temperature above 550 °C
1.9.1 Engine control unit

Control unit, engine, general
See 11.5.3.6 Control unit, engine (D7940), page 11:38 and supplier
documentation, engine.

1:30 1 Engine – Start/stop
1.11 Start/stop
1.11.1 Starter motor
Starter motor, description
The engine is started and stopped with the start button. The start button
sends signals to Control unit dashboard panel (D7902) which, via Con-
trol unit KFU (D7971), sends messages via CAN bus drive-train to Con-
trol unit, engine (D7940). Starter motor (M6540) is supplied with
voltage directly from the starter batteries. A relay on the starter motor
(solenoid) is activated by Control unit engine (D7940).
On machines with engine and hydraulic oil heater, engine start is
prevented when the electrical cable to the heaters is connected.
As an option, the machine can be equipped with an automatic start
and stop function for the engine, see Automatic start and stop function,
description, page 1:31.
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 means of pushing the start button or switch-
ing off the ignition on the ignition key lock.
There is also a stop button on the engine that can be used in an emer-
gency to stop the engine, e.g. if the engine cannot be stopped by other
means.
The machine can be equipped with one or several types of automatic
function that can switch off the engine:
• Automatic stop of the engine a specific time after leaving the oper-
ator's station, description, page 1:30 (Standard for Stage V
engines)
• Automatic stop function, description, page 1:31
• Automatic start and stop function, description, page 1:31
NOTE
The battery disconnector cannot and must not be used as emer-
gency stop!
1.11.3 Automatic stop of the engine a specific

time after leaving the operator's station
Automatic stop of the engine a specific time after
leaving the operator's station, description
The machine may be equipped with a function that turns the engine off
if the driver leaves the cab for more than a certain time. During pro-
gramming of the control system, the engine is not shut down automati-
cally in order to ensure the voltage feed to the control units.
30 seconds is the normal standard setting, but the time can be changed
from 10–180 seconds by a service technician via the display login.

1 Engine – Automatic stop function 1:31
1.11.4 Automatic stop function

Automatic stop function, description
Standard for Stage V engines.

The machine may be equipped with an automatic stop function. This
means that the engine is stopped when the machine is considered to
be inactive. The control system monitors a number of conditions for au-
to-stopping the engine and when these are fulfilled the engine is stop-
ped after a certain delay (can be set via the menus in the machine).
The following conditions apply:
• The machine has operating temperature.
• Battery state of charge is OK.
• The machine is stationary running at idling speed in neutral
position.
• Load handling functions are inactive.
• Parking brake is activated.
When the engine has been stopped automatically, the engine must be
started in the normal way.
1.11.5 Automatic start and stop function

Automatic start and stop function, description
The machine may be equipped with an automatic start and stop func-
tion. This means that the engine is stopped when the machine is con-
sidered to be inactive and the engine is started automatically when
work is resumed. The control system monitors a number of conditions
for auto-stopping the engine and when these are fulfilled the engine is
stopped after a certain delay.
The following conditions apply:
• The machine has operating temperature.
• Battery state of charge is OK.
• The operator is sitting in the seat.
• The machine is stationary running at idling speed in neutral
position.
• Load handling functions are inactive.
If the parking brake is activated manually (with the control) then the en-
gine is stopped immediately.
When the engine is auto-stopped, the parking brake is activated auto-
matically (without the need to move the control). If the engine is auto-
started by means of depressing the brake pedal, the parking brake is
released.
The machine is equipped with a timer which determines how long the
ignition can be activated after the engine has been auto-stopped. If the
time expires then the ignition is switched off in order to prevent dis-
charging the batteries.

1:32

2:1
2 Transmission
Contents 2 Transmission
2 Transmission........................................................................................................ 2:3
2.1 Controls and instruments .................................................................................2:11
2.1.1 Gear selector and multi-function lever ........................................................2:11
2.2 Torque converter/Clutch system ..................................................................... 2:13
2.3 Mechanical transmission ................................................................................ 2:14
2.6 Lubrication system .......................................................................................... 2:15
2.6.3 Oil cooler .................................................................................................... 2:15
2.7 Cooling system................................................................................................ 2:17
2.7.3 Oil cooler .................................................................................................... 2:17
2.7.4 Cooling fan ................................................................................................. 2:17
2.8 Control system, transmission.......................................................................... 2:18
2.8.1 Transmission control unit ........................................................................... 2:18
2.8.2 Brake pressure sensor ............................................................................... 2:18
2.8.3 Transmission cable harness ...................................................................... 2:18

2:2

2 Transmission – Transmission 2:3
2 Transmission
Transmission, general
The transmission transfers the engine's power to the drive wheels
(drive axle), via the universal drive shaft and power to drive the hydraul-
ic oil pumps for the hydraulic system.
The transmission is fully automatic with hydrostatics. It has 3 forward
ranges and 2 backward ranges. The first operating range is pure hydro-
static drive; the other operating ranges combine hydrostatic drive with
mechanical drive.
The transmission combines mechanical drive and hydrostatic drive.
The hydraulic oil pumps and the oil pump for the transmission are con-
nected to the engine via power take-offs on the transmission's input
shaft.
Hydrostatic drive power and direction are controlled by means of the
hydraulic pressure being modulated using electric valves that are con-
trolled by Control unit transmission (D7930). Gear positions and direc-
tion of travel are selected by means of pressure being modulated to
clutch plates with electric valves that are controlled by Control unit
transmission (D7930). The control unit uses sensors for pressure, tem-
perature and engine speed in order to determine which gear position
should be activated and solenoid valves in order to activate the gear.

structions for the transmission's components and systems, refer to the
Transmission, function description

Parking brake Released Parking brake system, function description, page 4:39
Sensor, operator-in-seat Not activated (operator in seat) Sensor operator in seat, description, page 9:25

2:4 2 Transmission – Transmission
3
2
1, 4 5 7
D1
D3 D5 D7
18
D7950
6, 8
D7902
D25 D9 D7971 D7901

10, 17, 19, 21, 26
<°
11, 13, 16, 20, 27
D7940 D7930
25 9
D15 D23
SENSORS 15
D13 D22
V 12
A
L 24
V
14 E
023370
S 22,23

1 Travel direction selector (S1310) Neutral: US1310:5 = 24 V Travel direction selector and parking brake, de-
sends a voltage signal to the Forward: US1310:2 = 24 V scription, page 2:11
KPU control unit (D7902). Reverse: US1310:3 = 24 V D1: Diagnostic menu, see 2.1 Controls & Instr
1/XX DIAGNOSE, page 8:39
2 Travel direction selector on Neutral: US1310-2:8 = 24 V Control lever (Ego), description, page 7:6
Control lever (S8150) Forward: US1310-2:7 = 24 V D1: Diagnostic menu, see 2.1 Controls & Instr
Gear selector (S1310-2) sends Reverse: US1310-2:10 = 24 V 1/XX DIAGNOSE, page 8:39.
voltage signals to Control unit
KPU (D7901).
3 Travel direction selector on Neutral: US1310-3:6 = 24 V Mini-wheel, description, page 5:5 or Joystick,
joystick control/mini-wheel Forward: US1310-3:5 = 24 V description, page 5:6
Travel direction selector (S1310- Reverse: US1310-3:7 = 24 V D3: Diagnostic menu, see 2.1 Controls & Instr
3) sends voltage signals to Con- 2/XX DIAGNOSE, page 8:40
trol unit KPU (D7901).
4 If the travel direction selector is Parking brake applied: US1310: 4 Travel direction selector and parking brake, de-
in position for activated parking = 24 V scription, page 2:11
brake (S1310) then a voltage Parking brake released: US1310: D1: Diagnostic menu, see 2.1 Controls & Instr
signal is sent to Control unit KPU 4 = 0 V 1/XX DIAGNOSE, page 8:39
(D7902), at which point neutral
position is selected in the
transmission.
5 Switch on steering panel Checked by control system, er- Cab overview, page 9:5
Switches for manual shifting up, ror shown with error code. D5: Diagnostic menu, see 2.1 Controls & Instr
manual shifting down and for au- 4/XX DIAGNOSE, page 8:40
tomatic shifting send voltage sig-
nals to Control unit KPU (D7902).
6 Control unit KPU (D7902) sends Checked by control system, er- 11.5.3.2 KPU control unit (D7902), page 11:30.
the selected shifting program ror shown with error code. 11.5.3.4 Control unit KFU (D7971), page 11:34
(neutral, forward, backward, or D5: Diagnostic menu, see 2.1 Controls & Instr
operating range 1-3) on the CAN 4/XX DIAGNOSE, page 8:40.
bus via Control unit KFU
(D7971), to Control unit trans-
mission (D7930).


7 The speed pedal (B6900) sends U = 0.5-4.5 V Speed pedal, description, page 1:2
a voltage signal to Control unit D7: Diagnostic menu, see 1.1 Controls & Instr
KPU (D7902). 1/XX DIAGNOSE, page 8:29.
8 Control unit KPU (D7902) sends Checked by control system, er- 11.5.3.2 KPU control unit (D7902), page 11:30.
required speed on the CAN bus ror shown with error code. 11.5.3.4 Control unit KFU (D7971), page 11:34.
to Control unit transmission
(D7930) via KFU (D7971).
9 Sensor, steering axle (B7245- U = 0.5-4.5 V Sensor, steering axle, description, page 5:19.
LE) sends a voltage signal to D9: Diagnostic menu, see 5.2 Power Assisted
Control unit KFU (D7971). The 10/XX DIAGNOSE, page 8:48.
sensor measures the angle of
the steering wheels in order to
adapt the transmission's ratio.
10 Control unit KFU (D7971) sends Checked by control system, er- 11.5.3.4 Control unit KFU (D7971), page 11:34.
the angle of the steering wheels ror shown with error code. 11.5.3.4 Control unit KFU (D7971), page 11:34.
on the CAN bus to Control unit
transmission (D7930).
11 Control unit transmission Checked by control system, er- 11.5.3.7 Control unit, transmission (D7930),
(D7930) sends the speed re- ror shown with error code. page 11:39.
quest on the CAN bus to Control
unit engine (D7940) based on
speed pedal position as well as
which of the hydraulic functions
are activated.
12 The transmission's oil pump - Lubrication system, description, page 2:15.
pumps oil when the engine is
running.
13 Control unit transmission Checked by Control unit, trans- 11.5.3.7 Control unit, transmission (D7930),
(D7930) activates servo valves mission, error shown with error page 11:39.
for hydrostatic drive, travel direc- code. D13: Diagnostic menu, see 2.8 Control System
tion and gear position in order to 13/XX DIAGNOSE, page 8:42 and 2.8 Control
obtain desired drive. System 14/XX DIAGNOSE, page 8:42.
14 Servo valves for hydrostatic Checked by Control unit, trans- Transmission, component location, page 2:7
drive, travel direction and gear mission, error shown with error
position activate hydraulic motor code.
and clutches in the transmission
and engine power is transmitted
to the transmission's output
shaft.
15 Sensors for rotation speed, tem- Checked by Control unit, trans- Transmission, component location, page 2:7
perature and pressure in the mission, error shown with error D15: Diagnostic menu, see 2.8 Control System
transmission send voltage sig- code. 13/XX DIAGNOSE, page 8:42, 2.8 Control Sys-
nals to Control unit transmission tem 15/XX DIAGNOSE, page 8:42, 2.8 Control
(D7930). System 16/XX DIAGNOSE, page 8:43 and 2.8
Control System 17/XX DIAGNOSE, page 8:43.
(D7930) sends operational data mission, error shown with error page 11:39.
on the CAN bus to Control unit code.
KFU (D7971).
17 Control unit KFU (D7971) for- Checked by Control unit, trans- 11.5.3.4 Control unit KFU (D7971), page 11:34.
wards operational data to the mission, error shown with error
machine's CAN network. code.
18 Control unit KID (D7950) shows Checked by Control unit, trans- 11.5.3.3 Control unit, KID (D7950), page 11:32.
transmission information in the mission, error shown with error
operating menus. code.


19 If the limit for the machine's Checked by Control unit, trans- 11.5.3.4 Control unit KFU (D7971), page 11:34.
speed limit is exceeded, Control mission, error shown with error
unit KFU (D7971) sends maxi- code.
mum permitted output rotation
speed on the CAN bus to Control
Control unit transmission
(D7930) calculates the output ro-
tation speed that the engine
needs and sends a message
with the engine speed request to
Control unit engine (D7940) via
the drive-train's CAN-bus.
(D7930) controls the drive and mission, error shown with error page 11:39.
engine speed according to the code.
selected shifting program.
21 Control unit KFU (D7971) con- Checked by Control unit, trans- 11.5.3.4 Control unit KFU (D7971), page 11:34.
trols Magnetic clutch cooling fan mission, error shown with error D21: Diagnostic menu, see 1.7 Cooling system
(M6580) from 0–100% of the en- code. 4/XX DIAGNOSE, page 8:32, 1.7 Cooling sys-
gine speed depending on engine tem 10/XX DIAGNOSE, page 8:33 and 1.7
and transmission temperature. Cooling system 11/XX DIAGNOSE, page 8:34
22 Solenoid clutch, cooling fan Checked by Control unit, trans- Cooling fan, description, page 1:27.
(M6580) regulates the drive ratio mission, error shown with error D22: Diagnostic menu, see 1.7 Cooling system
for the cooling fan which in- code. 5/XX DIAGNOSE, page 8:32.
creases the airflow through the
cooling unit.
23 Magnetic clutch cooling fan Checked by Control unit, trans- Cooling fan, description, page 1:27.
(M6580) sends a pulse signal mission, error shown with error D23: Diagnostic menu, see 1.7 Cooling system
with frequency proportional to code. 5/XX DIAGNOSE, page 8:32.
the fan speed to Control unit
KFU (D7971).
24 The oil cooler cools the transmis- - Oil cooler, description, page 2:15
sion oil.
25 Declutch U = 0.5-4.5 V Brake pressure sensor, description, page 4:35.
The brake pressure sensor D25: Diagnostic menu, see 4.3 Power Assisted
(B7681) sends a voltage signal 3/XX DIAGNOSE, page 8:44 or.
corresponding to the brake pres-
sure to the KFU control unit
(D7971).
26 Control unit KFU (D7971) sends Checked by Control unit, trans- 11.5.3.4 Control unit KFU (D7971), page 11:34.
brake pressure information on mission, error shown with error
CAN bus drive-train. code.
(D7930) supplies voltage to mission, error shown with error page 11:39.
Valve block transmission control code.
in order to declutch the drive if
the criteria for declutch are
fulfilled.

Transmission, component location

1
2
17
7
16 6 8
5
4
3
15
14 9
10
13 11
12
18
022261
Right-hand side
1. Hydrostatic pump 10. Servo valve, clutch CR
2. Servo valves, hydrostatic pump 11. Servo valve, clutch C1
3. Valve unit 12. Servo valve, clutch C3
4. Clutch pressure sensor p_C3 13. Speed sensor N3
5. Clutch pressure sensor p_C1 14. Servo accumulator
6. Clutch pressure sensor p_CR 15. Speed sensor N2
7. Clutch pressure sensor p_C2 16. Speed sensor N1
8. Relief valve 17. Breather valve
9. Servo valve, clutch C2 18. Sensor, hydrostatic motor

2 3
4
1
1
11
1
10
14 9
5
8 6
7
12
022262
13
Left-hand side
1. Power take-off 8. Output shaft
2. Outlet oil sample 9. Hydrostatic pressure sensor p_A
3. Oil filling 10. Connection communication
4. Dipstick 11. Hydrostatic pressure sensor p_B
5. Oil temperature sensor, filter 12. Hydrostatic motor
6. Contamination sensor, filter 13. Oil drain
7. Filter 14. Servo valve, hydrostatic motor

Components in the machine, component

location
1 2
3
4
12
6
11
9
10
023388
8
1. Control unit, transmission (D7930) 7. Switch, shifting program
2. Diagnostic socket, transmission 8. Control unit, KID (D7950)
3. Travel direction selector (S1310-3) 9. Travel direction selector (S1310-2)
4. Travel direction selector (S1310) 10. Accelerator pedal (B6900)
5. Control unit KFU (D7971) 11. KPU control unit (D7902)
6. Brake pressure sensor (B7681) 12. KCU control unit (D7901)
Engine and transmission, separation

See Engine and transmission, separation, page 1:9.
Transmission, stall test

Useful for troubleshooting engine and transmission.
1. Change to value 1 in Row 1, Engine stall test. Change the value
with / and store the value with .
2. Release the parking brake without holding the service brake pedal
depressed.
3. Hold the footbrake depressed and engage gear.
4. Depress the speed pedal. The machine now drives against the
brake.

5. Read out the appropriate menus in the display. For an explanation

of the menu, see 2.8 Control System 15/XX DIAGNOSE, page
8:42 and 1.9 Start & Stop 7/XX INITIATE, page 8:176.
A change in the menu is reset when the ignition is switched off.

2 Transmission – Controls and instruments 2:11

2.1.1 Gear selector and multi-function lever
Travel direction selector and parking brake,
description
Travel direction selector and parking brake control both selection of
travel direction and activation of the parking brake.
The travel direction selector and parking brake (S1310) send voltage
signals to Control unit KPU (D7902), which in turn provides information
about the selected gear via the CAN bus to the Control unit KFU
1 (D7971). Control unit KFU (D7971) sends information about selected
gear to Control unit transmission (D7930) on CAN bus drive-train.
The signals can be checked with the diagnostic menu, see 2.1 Controls
& Instr 1/XX DIAGNOSE, page 8:39.
020711
1. Travel direction selector and parking brake
Travel direction selector and parking brake,

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

Allow the gaiter over the travel direction selector and parking brake
to remain in place.
015780
1 2 3
1. Cover
2. Adjuster lever
3. Screw, adjuster lever

2:12 2 Transmission – Gear selector and multi-function lever

6. Remove the screws that hold the travel direction selector and park-
ing brake.
015782
1 2 3
1. Cover
2. Screw
7. Disconnect the contact.
8. Replace the travel direction selector and parking brake.
NOTE
The cable harness must be reassembled in the same way as
previously, to avoid any possible damage.
015783
Travel direction selector, control lever, general

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

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

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

2 Transmission – Torque converter/Clutch system 2:13
2.2 Torque converter/Clutch

system
Torque converter/clutch, description
G
A vibration damper is fitted between the engine and transmission that
F
E
transmits the engine power to the transmission.
D
I
H
023592
A. Engine
B. Vibration damper
C. Bolt (8 pcs)
D. Bolt (5 pcs)
E. Vibration damper
F. Vibration damper
G. Transmission
H. Centre screw (1 pc)
I. Vibration damper

2:14 2 Transmission – Mechanical transmission
2.3 Mechanical transmission

Mechanical transmission, description
mechanical drive.
The transmission combines mechanical drive and hydrostatic drive.
The hydraulic oil pumps and the oil pump for the transmission are con-
nected to the engine via power take-offs on the transmission's input
shaft.
For hydrostatic drive, the input shaft drives the transmission's hydraulic
oil pump, and machine speed is controlled by means of Control unit
transmission (D7930) transmitting to the transmission's hydraulic motor.
For combined drive, the transmission's input shaft is mechanically con-
nected with the output shaft with clutch plates. The mechanical trans-
mission has two gears. Shifting between the two mechanical gear
ratios takes place with incremental control of the clutch plates and the
hydraulic motor.

2 Transmission – Lubrication system 2:15
2.6 Lubrication system

Lubrication system, description
The transmission has a separate hydraulic system that is used for drive,
lubrication, control, and cooling of the transmission. The transmission
oil cooler is located in the cooling unit behind the engine, a thermostat
in the cooler means that the oil comes up to operating temperature
more quickly. In the event of high oil temperature, a warning is activated
in Control unit KID (D7950) and performance is reduced, if the oil tem-
perature continues to increase then error codes are generated and the
transmission is disengaged.
During operation of the engine, the oil pump draws oil from the trans-
mission's oil sump through a strainer, and then pumps it through an oil
filter to a control valve. The control valve provides oil of the correct
pressure to the transmission's valve housing for the activation of the hy-
draulic motor for hydrostatic drive and engagement of the clutch plates.
The return oil from the hydraulic motor is pumped through the transmis-
sion oil cooler and then back to the transmission's oil sump. Some of
the oil lubricates the transmission's bearings and gear wheels, and
cools the clutch plates.
2.6.3 Oil cooler

Oil cooler, description
The transmission oil is cooled in the lower section of the cooling unit.
1 2 3
A thermostat, which only acts on the transmission oil cooling circuit, is
integrated into the radiator. The thermostat closes the bypass channel
in the cooler tank when the oil starts to reach operating temperature.
4 This means that the oil reaches normal operating temperature more
quickly. When the thermostat fully closes, the oil only circulates through
the transmission oil cooler; the oil is no longer directed to the outlet
5 tank.
6 NOTE
The thermostat guides the oil through the cooler when the thermostat
closes the bypass channel in the tank. Therefore, if the thermostat is
7 removed then not all the oil is directed through the cooler since it has
reached operating temperature. If the thermostat is removed, the by-
9 pass channel and cooler are open for circulation; all the oil is then
8 not forced through the cooler and sufficient cooling is not achieved.
For more information, see supplier documentation, transmission.

018311
Cooling unit
1. Expansion tank
2. Sensor, coolant level (B7590)
3. Sight glass, coolant level
4. Intercooler
5. Coolant radiator
6. Connection, cooling cab
9. Thermostat transmission oil

2:16 2 Transmission – Oil cooler
Thermostat transmission oil cooler, replacement
NOTE
Read the safety instructions for oil before working, see section B
Safety.

2. Drain the oil from the transmission, see Maintenance manual.
3. Clean the area around the thermostat on the radiator.
4. Loosen the cover plug and remove the thermostat.
5. Check the O-ring and the spring in the bottom, replace as
necessary.
6. Install the new thermostat and the cover plug.
IMPORTANT
It is very important that the thermostat is turned with
the temperature bulb facing out as shown.
018347
7. Fill with transmission oil, see Maintenance manual.

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

2 Transmission – Cooling system 2:17
2.7 Cooling system

Cooling system, description
The transmission is cooled by the lubrication system see Lubrication
system, description, page 2:15.
2.7.3 Oil cooler

Oil cooler, description, page 2:15.
2.7.4 Cooling fan

The transmission oil cooler is cooled by the engine's cooling fan, see
Cooling fan, description, page 1:27.

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

Transmission control system, description
mechanical drive. The accelerator pedal controls machine speed (as
opposed to other transmission alternatives where the accelerator pedal
controls engine speed).
Control unit transmission (D7930) controls engine speed, depending
on accelerator pedal position as well as the need for hydraulic power
for the load handling functions, in order to achieve the speed requested
by the accelerator pedal position. If the driver releases the accelerator
pedal, the drive-train slows machine speed, and if hydraulic power is
needed for the hydraulics or to brake the machine using the transmis-
sion, the engine speed will continue to be high.
Control unit transmission (D7930) controls the transmission based on
signals from sensors for pressure, temperature and rotation speed.
The control takes place by means of Control unit transmission (D7930)
activating servo valves for control of the hydraulic motor and engage-
ment of the clutch plates.
Transmission, calibration
See Maintenance manual.
2.8.1 Transmission control unit

Control unit transmission, general
See 11.5.3.7 Control unit, transmission (D7930), page 11:39.
2.8.2 Brake pressure sensor

Sensor brake pressure, general
See Brake pressure sensor, description, page 4:35
2.8.3 Transmission cable harness

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

3:1
3 Driveline/Axle
Contents 3 Driveline/Axle
3 Driveline/Axle ....................................................................................................... 3:3
3.2 Propeller shaft ................................................................................................... 3:4
3.3 Drive axle .......................................................................................................... 3:5

3:2

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

3:4 3 Driveline/Axle – Propeller shaft
3.2 Propeller shaft

Propeller shaft, description
The propeller shaft transfers engine power from the transmission to the
drive axle. The propeller shaft has two joints, which means that the en-
gine and drive axle can move in relation to each other.
023596
Propeller shaft, replacement

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

6. Fit the propeller shaft's attaching bolts.
Tightening torque: 183 Nm (oiled bolt). Retighten the attaching
bolts after 50h operating time.

3 Driveline/Axle – Drive axle 3:5
3.3 Drive axle

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

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

2. Depressurise the brake and hydraulic systems, see Hydraulic and
brake systems, depressurising, page B:5.
NOTE
Leave the valves open during replacement.
3. Turn the start key to position 0 and switch off the main power.
4. Insert wedges between the steering axle and the frame.

3:6 3 Driveline/Axle – Drive axle
5. Detach the hydraulic hoses (position 1) and cable harness (posi-

tion 2) from the distribution block.
NOTE
Plug all connections immediately to protect the hydraulic system
from impurities.
1. Hydraulic hoses
2. Cable harness
6. Remove the cover (position 3) on the parking brake.
3
004505
3. Cover, parking brake

7. Undo the lock nut (position 4) and screw out the adjusting screw
(position 5), this releases the pressure from brake spring. Screw
until the brake pads release from the brake disc. Refit the cover on
the parking brake (position 3).
6 8. Detach the hydraulic hose (position 6) from the parking brake.
NOTE
5 Plug all connections immediately to protect the hydraulic system
from impurities.
4
004506
4. Lock nut
5. Adjusting screw
6. Hydraulic hose, parking brake
9. Detach the propeller shaft from the drive axle. Secure the propeller
shaft, otherwise there is a risk that it will be pulled apart.
Securing the propeller shaft

3 Driveline/Axle – Drive axle 3:7
10. Connect lifting equipment to the front lifting points on the machine.
11. Tension the lifting equipment so that the machine's weight is partly
taken up by the lifting equipment.
Lifting machine
12. Remove the bolts that secure the drive axle in the frame.
13. Raise the front part of the machine carefully and ensure that nei-
ther machine nor drive axle start to roll.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away
Attaching bolts drive axle uncontrollably.
14. When the machine has been raised sufficiently, carefully roll the
drive axle away from the machine.
15. Raise and secure the drive axle so that tyres and components can
be safely removed from the drive axle.
DANGER
The drive axle may twist or tip over when handling the
wheels.
Crushing injury!
Before starting to work on a loose drive axle, always se-
cure the drive axle to prevent it from twisting and tip-
ping over forwards, backwards or sideways.
16. Remove the drive wheels from the drive axle, see Maintenance
manual.
17. Raise and secure the new drive axle so that tyres and components
can be safely fitted.
DANGER
The drive axle may twist or tip over when handling the
wheels.
Crushing injury!
Before starting to work on a loose drive axle, always se-
cure the drive axle to prevent it from twisting and tip-
ping over forwards, backwards or sideways.

3:8 3 Driveline/Axle – Drive axle
18. Transfer parts from the old drive axle to the new one.
NOTE
from impurities.
19. Clean contact surfaces on drive axle and frame. Also clean the
contact surface for the bolts on the underside of the drive axle.
20. Remove the nuts for drive axle attachment, blow clean and refit
the nuts.
21. Transfer the guide pins to the new drive axle.
22. Fit the drive wheels on the new drive axle, see Maintenance
manual.
23. Lower the drive axle down in front of the machine. Fit the mount-
ings on the drive axle, aligned with the mountings in the frame.
24. Carefully roll the drive axle into place under the frame.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away
uncontrollably.
25. Carefully lower the machine towards the drive axle. Check that the
guide pins fit the holes in the frame.
26. Install the new bolts that secure the drive axle in the frame. Tighten
the bolts to a torque of 2400 Nm (oiled screw).
27. Rustproof the bolts with suitable paint.
Attaching bolts drive axle

28. Connect the hydraulic hoses (position 1) and cable harness (posi-
tion 2) to the distribution block on the drive axle.
29. Connect the hydraulic hose to the parking brake.
30. Connect the drive shaft to the drive axle, tighten the bolts with a
torque of 156 Nm. (Check-tighten the attaching bolts after 50 oper-
ating hours.)
31. Check the oil level in the drive axle.
32. Close the valves that were opened for draining the pressure in the
hydraulic system.
1. Hydraulic hoses NOTE

2. Cable harness
the lock ring.
33. Start the machine and bleed the brakes, see Wheel brakes, bleed-
ing, page 4:30 and Parking brake, bleeding, page 4:43.
34. Check for leaks.
35. Adjust the parking brake, see Maintenance manual
36. Test-run the machine carefully and check the function of drive axle
and brakes.

4:1
4 Brakes
Contents 4 Brakes
4 Brakes ................................................................................................................... 4:3
4.1.1 Brake pedal .................................................................................................. 4:4
4.1.2 Switch parking brake .................................................................................. 4:13
4.3 Power-assisted brake system......................................................................... 4:14
4.3.1 Oil pump brake system............................................................................... 4:16
4.3.2 Oil filter brake system................................................................................. 4:19
4.3.3 Accumulator charging valve ....................................................................... 4:20
4.3.4 Accumulator ............................................................................................... 4:23
4.3.5 Brake valve................................................................................................. 4:26
4.3.6 Drive axle block .......................................................................................... 4:29
4.3.9 Wheel brakes ............................................................................................. 4:29
4.3.10 Pipes and hoses......................................................................................... 4:31
4.3.11 Accumulator pressure sensor .................................................................... 4:32
4.3.12 Brake pressure sensor ............................................................................... 4:35
4.5 Parking brake system ..................................................................................... 4:39
4.5.3 Solenoid valve parking brake ..................................................................... 4:41
4.5.4 Parking brake unit ...................................................................................... 4:42
4.5.6 Pipes and hoses......................................................................................... 4:43
4.5.10 Sensor parking brake pressure .................................................................. 4:44
4.8 Temperature control, cleaning and oil brake system ...................................... 4:48
4.8.1 Oil tank brake system................................................................................. 4:50
4.8.2 Tank heater................................................................................................. 4:50
4.8.4 Accumulator charging valve ....................................................................... 4:51
4.8.5 Drive axle block .......................................................................................... 4:51
4.8.6 Wheel brakes ............................................................................................. 4:51
4.8.7 Oil cooler .................................................................................................... 4:51
4.8.8 Cooling fan ................................................................................................. 4:52
4.8.9 Thermal bypass valve ................................................................................ 4:53
4.8.10 Sensor, oil temperature brake system ....................................................... 4:54
4.8.11 Breather filter.............................................................................................. 4:55
4.8.13 Pipes and hoses......................................................................................... 4:55
4.8.14 Oil, brake system........................................................................................ 4:55

4:2

4 Brakes – Brakes 4:3
4 Brakes
Brakes, general
Brakes are designed to facilitate stopping the machine. The brakes act
on the drive axle (the steering axle has no brakes).
The brake system is divided into three functions:
• Power-assisted brake system, description, page 4:14
• Parking brake system, description, page 4:39
• Temperature control, cleaning and oil brake system, description,
page 4:48

4:4 4 Brakes – Controls and instruments

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

2. Depressurise the hydraulic system, see Hydraulic and brake sys-
tems, depressurising, page B:5.
NOTE

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

4 Brakes – Brake pedal 4:5
6. Loosen the tab washers and remove the screws that fasten the
pedal assembly to the floor. Lift out the pedal assembly.
016178
Tab washers and screws

7. Remove the circlip.
1 2 3 4 3 5
8. Remove the stop screws.
9. Pull out the brake pedal's axle.
10. Loosen the nut securing the speed pedal axle.
11. Pull out the speed pedal's axle.
12. Loosen the brace to the brake valve.
13. Replace the speed pedal.
023127
1. Axle, brake pedal

2. Circlip
3. Stop screw
4. Nut, shaft, speed pedal
5. Brace, brake valve

4:6 4 Brakes – Brake pedal

Use new split pins. If required, replace the tab washers for the
screws that attach the pedal assembly to the floor.
4:7.
hydraulic system.
NOTE
the lock ring.
016179
Tab washers and screws
Brake pedal potentiometer, replacement

1 2 1
015856
1. Screws
2. Cover
3. Loosen the stop screw on the link arm and remove it.
023128

4. Remove the screws which secure the potentiometer.

5. Cut the cable ties and split the contact.
6. Replace the accelerator's potentiometer.
4:7.
023128
Pedal assembly, adjusting
Checking the pump pressure
1. Operate and warm up the machine so that the oil in the brake sys-
0:00pm tem reaches operating temperature, at least 50 °C.
a Use Operating menu transmission and hydraulics in order to check
the oil temperature.
75°C 50%
b c
50°C 50°C
016372
Operating menu, transmission and hydraulic system

a. Oil temperature transmission
b. Oil temperature hydraulic system
c. Oil temperature brake system
1 2 1
015856
1. Screws
2. Cover

3. Check that the distance (A) between the adjusting device and the
adjusting screw is 5 mm.
Fully depress the adjusted pedal. Check that none of the pedals
reaches the mat.
If the distance between pedal and mat is too great then the dis-
tance between adjusting device and adjusting screw can be re-
duced to at least 3 mm. Check once again that none of the pedals
reaches the mat when they are fully depressed.
WARNING
Incorrectly adjusted pedals may lead to poor function.
Check the settings of the pedals and adjust if necessary.
A
A016567
Adjustment of distance (A)

4. Connect a pressure gauge (0-25 MPa) to the measuring outlet for
brake pressure on the drive axle block.
5. Start the engine and run the engine at idling speed in order to en-
sure that the brake system has working pressure.
016319
Measuring outlet, brake pressure

6. Fully depress the centre pedal and check that the distance be-
tween the bottom of the brake pedal and the floor mat is at least
10 mm.
If necessary, adjust the adjusting screw for bottom position until
the correct measurement is obtained.
DANGER
Inadequate clearance may result in reduced braking
performance.
Extreme danger.
017454
Ensure that the clearance between brake pedal and

Adjusting screw, centre pedal bottom position. floor in fully depressed position is correct.

7. Fully depress the centre pedal and check that the brake pressure
corresponds with the brake pressure on the pressure plate.
If necessary, adjust the push rod until the correct pressure is
obtained.
8. Fully release the centre pedal and check that the brake pressure
falls to 0 MPa.
017457
Adjusting screw, brake pressure.

9. Check that there is a small amount of play in the centre pedal be-
fore the brakes are pressurised.
If necessary, adjust the adjusting screw for top position until there
is some play.
017455
Adjusting screw, centre pedal top position

10.
Check that the speed pedal has the same height as the centre
pedal in released position.
If necessary, adjust the position with the adjuster screw for the
speed pedal's top position.
11. Check that the speed pedal does not travel lower down to the floor
than the fully depressed position of the centre pedal.
If necessary, adjust the position with the adjuster screw for the
speed pedal's bottom position.
017458
1 2
1. Adjuster screw, speed pedal, bottom position.
2. Adjuster screw, speed pedal, top position.

12. Check that there is clearance for the linkage between speed pedal
and potentiometer.
13. Depress the speed pedal and check that the linkage does not bind
or make contact against other parts.
014778
Play, linkage, speed pedal
14. Check that the left-hand brake pedal has the same height as the
centre pedal.
If necessary, adjust the position with the adjusting screw for the
left-hand brake pedal.
15. Fully depress the left-hand brake pedal and check that the brake
pressure corresponds with the brake pressure on the pressure
plate.
16. Fully release the left-hand brake pedal and check that the brake
pressure falls to 0 MPa.
17. Remove the pressure gauge and fit the protective cap on the
measuring outlet.
017456
18. Test drive the machine and check the function of the brakes and
the sensitivity in the pedals.
Adjusting screw, left-hand brake pedal
Brake pedal, calibration
1. Machine parked with engine running at idling speed.

2. To be able to select the function to calibrate, first navigate to the
10:23
CUSTOMER SETTINGS
menu for service and settings with or and confirm with .
0
014981
3. Enter diagnostic code 1111, with or . Confirm each figure with

10:23
.
0 WRITE PIN CODE NOTE

The code determines which service menus should be activated.
0 0
015625

4. Select 4. BRAKES by scrolling with or and confirm with .

*SETTINGS & DIAGNOSTICS*
4.BRAKES
016946
5. Select 4.1 Controls & Instruments by scrolling with or and
* 4.BRAKES * confirm with .
4.1 Controls & Instruments

4.2 ABS
4.3 Power Assisted System
4.4 Non Power Assisted System
4.5 Parking Brake
4.6 Speed Retardation System
4.7 Trailer Brake Connections
4.8 Brake Oil Temp/Clean
018530
6. Select CALIBRATE by scrolling with or and confirm with .

* 4.BRAKES *
DIAGNOSE INITIATE CALIBRATE
4.2 ABS
4.5 Parking Brake
018531
7. Scroll to menu 1 Brake pedal signal A Pedal upper position with

or .
8. Check that the brake pedal is fully released and that the brake
pressure is below 0.1 bar. Save the position with .
9. Scroll to menu 2 Brake pedal signal A Pedal lower position with

or .
10. Fully depress the brake pedal and check that the brake pressure
corresponds with the pressure plate. Save the position with .

11. Go back to CALIBRATE with .

* 4.BRAKES *
4.2 ABS
4.5 Parking Brake
018531
Check
12. Select DIAGNOSE by scrolling with or and confirm with .
* 4.BRAKES *
4.2 ABS
4.5 Parking Brake
018532
13. Check that the value in the row Pedal percent request corresponds
with the actual situation.
14. Go back to DIAGNOSE with .

* 4.BRAKES *
4.2 ABS
4.5 Parking Brake
018532
15. Select INITIATE by scrolling with or and confirm with .

* 4.BRAKES *
4.2 ABS
4.5 Parking Brake
020504

4 Brakes – Switch parking brake 4:13
16. Check that the stored value in the row for Brake pedal start dead-
band is 5%. A lower value for the brake pedal's deadband in re-
leased position may result in the transmission driving against the
brake, while a higher deadband may make the machine run more
jerkily.
4.1.2 Switch parking brake

Switch, parking brake, general
The parking brake is controlled with the gear and multi-function lever,
see Travel direction selector and parking brake, description, page 2:11.

4:14 4 Brakes – Power-assisted brake system
4.3 Power-assisted brake system

Power-assisted brake system, description
The power-assisted brake system consists of oil tank brake system, oil
pump brake system, oil filter brake system, accumulator charging valve,
accumulators, brake valve, pressure sensor, brake cylinder and wheel
brake units.
Oil pump brake system pumps oil (from the tank) that is cleaned in the
oil filter. The accumulator charging valve routes pressure to the accu-
mulators that store the pressure, or routes the oil through the wheel
brake for cooling the brake discs. The brake valve routes pressure from
the accumulators to the brake cylinder. The brake cylinder compresses
the discs in the brake units which brakes the machine. Make-contact
(closing switch) brake light emits a signal so that the brake light is
switched on when the brake cylinder is pressurised.
When the accumulators are charged, the accumulator charging valve
routes oil through the drive axle's brake units and cools the brakes. The
oil passes through the cooler back to the tank. An electric cooling fan
increases the air flow through the cooler when the temperature needs
to be lowered. A thermal bypass valve routes the oil past the cooler if
the oil temperature is low. The temperature sensor controls fan activa-
tion and temperature warning in the display.
Power-assisted brake system, function

description
15
D7950
D7902 5
P
B
T
D11 D7971 D7901
10 9
11 C
Pa
13
D7930 D9
D14
6
4
14 8 8
Pa
ACC
C H
P 3 7 7
2 T
B
1
023371

1 Oil pump brake system pumps oil from P = 20.5±1.0 MPa (when the Oil tank brake system, description, page
oil tank brake system. accumulators are charged) 4:50
Oil pump brake system, description, page
4:16
2 Oil filter brake system cleans the oil. - Oil filter brake system, description, page
4:55
3 The accumulator charging valve directs - Accumulator charging valve, description,
oil to charging of accumulators or page 4:20
through the brake system's cooling
circuit.
4 The accumulators store oil pressure. See the pressure plate, Ac- Accumulator, description, page 4:23
cumulator pressure brake
system, on the left frame
member.
5 The brake valve directs pressure from - Brake valve, description, page 4:26
the accumulators to the distribution block
in proportion to pedal depression.
6 The drive axle block shares the pressure See the pressure plate, Drive axle block, description, page 4:29
to right and left brake cylinder. Brake pressure, on the left
frame member.
7 The brake cylinders compress the discs - Wheel brakes, description, page 4:29
in the wheel brakes.

4 Brakes – Power-assisted brake system 4:15

8 The wheel brakes brake the machine. - Wheel brakes, description, page 4:29
9 The brake pressure sensor (B7681) U = 0.5-4.5 V Brake pressure sensor, description, page
sends a voltage signal corresponding to 4:35
the brake pressure to the KFU control D9: Diagnostic menu, see 4.3 Power As-
unit (D7971). sisted 3/XX DIAGNOSE, page 8:44
10 If the voltage signal from Sensor brake U = 24 V 11.5.3.4 Control unit KFU (D7971), page
pressure (B7681) is equivalent to brake 11:34
pressure above 0.2 MPa: D10: Diagnostic menu, see 9.6 Lighting
Control unit KFU (D7971) activates volt- Sys 5/XX DIAGNOSE, page 8:121
age feed to Brake lights (H4110-LE and
H4110-RI).
11 Brake lights (H4110-LE and H4110-RI) - Brake lights, description, page 9:75
are switched on. D10: Diagnostic menu, see 9.6 Lighting
Sys 5/XX DIAGNOSE, page 8:121
12 Control unit KFU (D7971) sends pedal Checked by control system, 11.5.3.4 Control unit KFU (D7971), page
angle and brake torque (calculated from error shown with error code. 11:34
brake pressure) on CAN bus drive-train
to Control unit transmission (D7930).
At a certain pedal angle and brake tor-
que the transmission changes to neutral.
13 Control unit transmission (D7930) disen- Checked by control system, 11.5.3.7 Control unit, transmission
gages the engine drive. error shown with error code. (D7930), page 11:39
14 The accumulator pressure sensor U = 0.5-4.5 V Accumulator pressure sensor, description,
(B7683) sends a voltage signal equiva- page 4:32
lent to the pressure in the accumulators D14: Diagnostic menu, see 4.3 Power As-
to Control unit KFU (D7971). sisted 3/XX DIAGNOSE, page 8:44
15 If the voltage signal from Sensor, accu- Checked by control system, 11.5.3.4 Control unit KFU (D7971), page
mulator pressure (B7683) is equivalent error shown with error code. 11:34
to pressure below 15 MPa: D14: Diagnostic menu, see 4.3 Power As-
Control unit KFU (D7971) sends a warn- sisted 3/XX DIAGNOSE, page 8:44
ing about low pressure on the CAN bus.
15 KID control unit (D7950) activates the Checked by control system, 11.5.3.3 Control unit, KID (D7950), page
event menu low accumulator pressure. error shown with error code. 11:32
16 Control unit, engine (D7940) limits the Checked by control system, 11.5.3.6 Control unit, engine (D7940),
engine speed error shown with error code. page 11:38
Hydraulic diagram brake system, see Hydraulic diagram brake system,

page E:4.

4:16 4 Brakes – Oil pump brake system
4.3.1 Oil pump brake system

Oil pump brake system, description
The brake system has a gear pump with fixed displacement. Oil pump
5 brake system is fitted in the power take-off directed toward the engine.
2
The pump generates hydraulic power, which is stored in the accumula-
1 tors for brake force to the power-assisted brake and parking brake. It al-
so generates the oil flow used for cleaning and cooling. The switchover
4 between power generation and flow is regulated by the accumulator
charging valve, see Accumulator charging valve, description, page
4:20.
3
Oil pump brake system is driven from the transmission's power take-off.
The pump's rotation speed is directly dependent on engine speed. The
pump flow rate increases with engine speed and varies with the rotation
speed of the input shaft.
022700
1. Hydraulic oil pump 1

4. Hydraulic oil pump cooling and cleaning
5. Oil pump brake system
Oil pump brake system, checking
NOTE
Safety.
Checking the pump pressure

1. Operate and warm up the machine so that the oil in the brake sys-
0:00pm tem reaches operating temperature, at least 50 °C.
a Use Operating menu transmission and hydraulics in order to check
75°C 50% 2. Machine in service position, see Service position, page B:5.
b 3. Open the drain valve on the accumulator charging valve.

c
50°C 50°C
016372


4 Brakes – Oil pump brake system 4:17
4. Connect a pressure gauge (0-25 MPa) to the pump measuring out-

let on the accumulator charging valve.
5. Start the engine and run it at idle.
6. Close the drain valve on the accumulator charging valve and
check the pump pressure during charging.
NOTE
the lock ring.
During charging the pressure should increase to 20.5±1.0 MPa be-

fore the accumulator charging valve switches to cooling. When the
accumulator charging valve switches to cooling, the pressure
drops.
7. Check the pressure during cooling.
During cooling the pressure should be max. 0.10–0.15 MPa at
max. engine rpm.
8. Switch off the engine.
016290
measuring outlet.
Measuring outlet, pump pressure
Checking the accumulator charging
CAUTION
Accumulator charging has two pressure limits that are
dependent on each other. Both the upper pressure and
the lower pressure must be within specified limits.
Reduced brake performance.
The machine must not be taken into service with incor-
rect brake pressure.
10. Open the drain valve on the accumulator charging valve.

11. Connect a pressure gauge (0-25 MPa) to the accumulator measur-
ing outlet on the accumulator charging valve.
13. Close the drain valve on the accumulator charging valve.
NOTE
the lock ring.
14. Check that the pressure increases slowly to 20.5±1.0 MPa.

15. Check that Sensor accumulator pressure shows the correct pres-
sure in the display, see Sensor accumulator pressure, checking,
page 4:32.
16. Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve must switch to charging at 15.5±0.5 MPa.
The pressure level depends on the setting of the boost pressure's
upper limit in step 6.
016291
Measuring outlet, accumulator pressure measuring outlet.

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

NOTE
3. Mark up and detach the hydraulic hoses from the pump.
NOTE
Plug all connections immediately to protect the brake system
from impurities.
022766
4. Remove the attaching bolts, pull the pump out backwards and lift it
away.
5. Transfer the connection adapters to the new pump.
022767
6. Fit the brake pump on the main pump.

Install the pump and check that the pump's splines engage in the
shaft in the main pump.
Fit the pump's attaching bolts.
022767

4 Brakes – Oil filter brake system 4:19
7. Connect the suction hose to the brake pump.
NOTE
Change the O-rings. Check that the O-rings are positioned
correctly.
8. Fill the brake pump with oil through the connection for the pressure
hose.
022768
9. Connect the pressure hose to the brake pump.
NOTE
correctly.
hydraulic system.
NOTE
022769
the lock ring.
11. Switch on the system voltage and start the engine.

12. Check that the hose connections and seal between the transmis-
sion and brake pump are sealed tightly.
Check the feed pressure from the brake pump, see Oil pump brake
system, checking, page 4:16.
13. Check the oil level in the brake system, fill if necessary.
NOTE
If the pump is replaced due to malfunction, change the oil and fil-
ter in the brake system as well.
4.3.2 Oil filter brake system

Oil filter brake system, general
See Oil filter brake system, description, page 4:55.

4:20 4 Brakes – Accumulator charging valve
4.3.3 Accumulator charging valve

Accumulator charging valve, description
The accumulator charging valve distributes the oil from the pump be-
1 2 3 tween pressure storage and cooling of the wheel brakes. The accumu-
lator charging valve is fitted on the beam in front of the transmission in
4 the engine compartment.
14 The accumulator charging valve stores pressure by directing the oil to
5 the accumulators. The wheel brakes are cooled by oil being directed to
the drive axle cooling circuit and then on to the brake system's cooler.
6
The accumulator charging valve prioritises charging of the accumula-
tors above cooling. A restriction of the charging means that a small
quantity of oil also flows to cooling during accumulator charging. At idle
13 7 the flow from the pump is so small that all oil flows to pressure storage.
12
The drain valve (position 5) is used to relieve the pressure in the accu-
11 8 mulators to the tank. The valve opens a connection between the accu-
mulators and the wheel brake's cooling circuit. The oil is drained
10 9 through the wheel brake to the tank.
There is a measuring outlet for measuring the pump pressure (position
11) and accumulator pressure (position 12) on the accumulator charg-
ing valve. The pressures are individual to each machine and the values
are specified on the pressure plate on the left-hand frame member, see
016820
Common hydraulics, description, page 10:3. Also fitted on the accumu-

lator charging valve is Solenoid valve parking brake (Y6420) (position
1. Connection, parking brake caliper (HB) 13), Sensor parking brake (B7682) (position 2) and Sensor accumula-
2. Sensor parking brake (B7682) (LB) tor pressure (B7683) (position 4).
3. Connection, accumulators (ACC) • Solenoid valve parking brake, description, page 4:41
4. Accumulator pressure sensor (B7683) • Accumulator pressure sensor, description, page 4:32
5. Drain valve • Sensor parking brake pressure, description, page 4:44
6. Pressure relief valve
7. Main valve, charging
8. Safety valve
9. Connection, wheel brake (T)
10. Connection from pump (P)
11. Measuring outlet, pump pressure (P)
12. Measuring outlet, accumulator pressure (M)
13. Solenoid valve parking brake (Y6420)
14. Connection, brake valve (B)

4 Brakes – Accumulator charging valve 4:21
Accumulator charging, checking and adjustment
NOTE
Safety.

2. Check the accumulator's charging, see Oil pump brake system,
checking, page 4:16.
3. If necessary, adjust the accumulator charging pressure on the
pressure relief slide.
Undo the lock nut and adjust the pressure by turning the adjusting
screw.
Clockwise: reduce pressure.
Anticlockwise: increase pressure.
4. Open the drain valve on the accumulator charging valve so that
the accumulators are drained and the valve switches to charging.
Close the drain valve and check the max. pressure again.
5. Repeat steps 3 and 4 until the pressure is correct.
6. Close the drain valve on the accumulator charging valve.
NOTE
the lock ring.
016814
Adjusting screw accumulator charging pressure

4:22 4 Brakes – Accumulator charging valve
Accumulator charging valve, replacement
NOTE
Safety.

NOTE
3. Mark up hydraulic hoses and electric cables.

4. Detach the wiring from the accumulator charging valve.
5. Detach and plug all hydraulic hoses from the accumulator charging
valve.
Remove the parking brake valve for easier access.
NOTE
Plug all connections immediately to protect the brake system
from impurities.
6. Remove the accumulator charging valve.

7. Transfer the connection adapters and sensors to the new accumu-
lator charging valve.
8. Fit the new valve.
9. Connect the hoses to the accumulator charging valve in accord-
ance with the marking.
NOTE
016985

correctly.
10. Fit the parking brake valve.

11. Connect the wiring to the accumulator charging valve.
hydraulic system.
NOTE
the lock ring.

Check that the hydraulic connections are sealed tightly.
14. Bleed the brakes, see Wheel brakes, bleeding, page 4:30 and
Parking brake, bleeding, page 4:43.
15. Check the charging and switching function, see Accumulator
charging, checking and adjustment, page 4:21.

4 Brakes – Accumulator 4:23
4.3.4 Accumulator
Accumulator, description
The accumulators store pressure so that there is a pressure reserve in
the event of engine or brake system malfunction. The brake system
has four accumulators connected in parallel. These are fitted at the
front in the engine compartment, above the drive axle.
The accumulators are of the diaphragm type. Each accumulator is
divided into two compartments by a diaphragm. One side of the dia-
phragm is pressurised by nitrogen gas. The other side is pressurised
by the hydraulic oil, which compresses the nitrogen gas.
The accumulator has pressure check connections for checking the gas
pressure on the opposite side of the pressure connection.
016340
Accumulator, checking
NOTE
Safety.

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

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

4:24 4 Brakes – Accumulator
Checking with test equipment

4. Remove the accumulators and test them with the test equipment
designed for the purpose, see Accumulator, replacement, page
4:25.
The accumulators' gas pressure must match with the pressure
plate.
5. Continue with step 17.
Checking in the machine

6. Detach one of the accumulators from the distribution block. Plug
the distribution block connections with plugs that can withstand the
system pressure. Plug the connections on the accumulators to pro-
tect against impurities.
022263
Pressure plate, gas pressure brake accumulators
7. Connect a pressure gauge (0-25 MPa) to the accumulator measur-
ing outlet on the accumulator charging valve.
9. Close the drain valve on the accumulator charging valve and
charge the accumulator until the accumulator charging valve
changes to cooling.
10. Check that the plugs seal properly.
12. Lower the pressure by means of braking carefully several times
while checking the pressure on the pressure gauge.
When the pressure reaches approx. 10 MPa the pressure must
decrease immediately to 0 MPa.
If the pressure drops immediately when the engine is switched off
then the accumulator does not have any precharge pressure. This
indicates internal leakage and the accumulator must be replaced.
If the pressure can be reduced slowly to a pressure below 10 MPa
then the pre-charge pressure is too low and the accumulator must
be replaced or given to authorised personnel for maintenance.
016291
14. Mark up and disconnect the tested accumulator. Plug the connec-
tions. Connect one of the other accumulators to the distribution
block.
15. Repeat steps 8 - 14 until all accumulators have been checked.
Installation and final checking

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

hydraulic system.
NOTE
the lock ring.

4 Brakes – Accumulator 4:25
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 system voltage.
NOTE
4. Detach the accumulator's clamp and remove the bolt.

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

4:26 4 Brakes – Brake valve
7. Fit the new accumulator.
NOTE
Check that the seal is intact, clean and fitted in the correct
position.
8. Secure the accumulator's clamp and tighten the bolt.

hydraulic system.
NOTE
the lock ring.

11. Check that the accumulator's connection is sealed tightly.
12. Check precharging and function, see Accumulator, checking, page
4:23 steps 18-19.
4.3.5 Brake valve

Brake valve, description
The brake valve controls the hydraulic pressure to the brakes and is
pressurised by the accumulator. The brake valve is mounted under the
cab floor, a lever transmits the pedal force from the brake pedal to the
valve.
The foot brake valve is a mechanically activated pressure reducing
valve. With the brake pedal depressed halfway the brake pressure is
around 3 MPa, then pedal resistance increases more steeply. When
the pedal is depressed to the bottom, the brake pressure is up to
15 MPa (depending on machine version). This provides optimum pedal
responsiveness as well as increased safety as the operator can easily
016392
sense if no brake pressure is being built up (no resistance in the pedal).

1 2
1. Brake valve
2. Lever from the brake pedal
Brake valve, checking
NOTE
Safety.
1. Operate and warm up the machine so that the hydraulic oil rea-
0:00pm
ches operating temperature, at least 50 °C.
a
Use Operating menu transmission and hydraulics in order to check
b c
50°C 50°C
016372


4 Brakes – Brake valve 4:27

4. Start the machine and run it at idling speed until the accumulator is
charged and the accumulator charging valve changes to cooling.
016319

5. Press down the pedal completely and read off the pressure. Com-
pare with the value specified on the pressure plate.
7. Depress the pedal fully and keep it pressed down, check the
pressure.
The brake pressure must correspond with the value specified on
the pressure plate and must not decrease from this value for 15
seconds.
022264
Pressure plate, brake pressure

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 Pedal
assembly, adjusting, page 4:7.
If the brake pedal is correctly adjusted and the pressure does not
fall to 0 MPa, the brake valve is not sealed and can cause the
brakes to remain applied and then overheat during operation.
Replace the brake valve if it is not sealed.
015817
measuring outlet.
Adjuster screw brake

4:28 4 Brakes – Brake valve
Brake valve, replacement
NOTE
Safety.

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

5. Remove the brake valve.
6. Transfer the connection adapters to the new brake valve.
7. Fit the new brake valve.
8. Connect the hydraulic hoses to the brake valve in accordance with
the marking.
016391
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.
10. Switch on the system voltage and start the engine. Let the engine
run at idle speed.
11. Check the brake valve; see Brake valve, checking, page 4:26.
12. Check that the brake valve's connections are sealed tightly.
13. Bleed the wheel brakes' brake cylinders, see Wheel brakes, bleed-
ing, page 4:30

4 Brakes – Drive axle block 4:29
4.3.6 Drive axle block

Drive axle block, description
The drive axle block distributes oil flow and brake pressure to the right
1 2 and left-hand wheel brakes. The drive axle block is fitted on a bracket
above the drive axle differential.
3
1
The drive axle block has a measuring outlet for brake pressure and for
9 measuring back pressure in the disc brake's cooling circuit.
3
4 The drive axle block has a bypass valve which leads oil directly from
the cooling circuit intake to the cooling circuit return if the resistance in
8 4 the axle becomes too great. This protects the wheel brake seals, e.g.
when the oil is cold.
7 Sensor brake pressure (B7681) is fitted in the drive axle block, see
6 Brake pressure sensor, description, page 4:35.
5
016397
1. Connection brake cooling, return from wheel

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

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

4:30 4 Brakes – Wheel brakes
1 2 The wheel brakes have two main sections - disc pack and brake cylin-
der. The disc pack performs the braking. The brake cylinder presses
the discs in the disc pack together during braking.
000016
Wheel hub and brake, cross-section

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

4 Brakes – Pipes and hoses 4:31
Wheel brake, replacement

See supplier documentation, drive axle.
4.3.9.1 Disc pack

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

Brake cylinder, description
The brake cylinder is integrated in the wheel brake and consists of a
metal ring (cylinder) with two seal rings. The seals have lateral support
from a bevel on the cylinder and a bevel on the wheel brake housing.
The space between the seal rings is pressurised through a channel in
the wheel brake housing. The pressure moves the metal ring sideways
and compresses the disc pack.
000007
Brake cylinder

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

4:32 4 Brakes – Accumulator pressure sensor
4.3.11 Accumulator pressure sensor

Accumulator pressure sensor, description
Sensor accumulator pressure (B7683) detects the pressure for the ac-
cumulators. The sensor is fitted on the accumulator charging valve on
the lifting beam in front of the transmission in the engine compartment.
The sensor is used to detect pressure drops in the brake system. The
limit level for warning of low brake pressure is selected so that pressure
for at least eight brake applications is available when the warning for
low brake pressure is activated.
Sensor, accumulator pressure (B7683) is supplied with voltage by, and
sends voltage signals proportional to the accumulator pressure to Con-
trol unit KFU (D7971).
The signal can be checked with the diagnostic menu, see 4.3 Power
017451
Assisted 3/XX DIAGNOSE, page 8:44.
Sensor accumulator pressure, checking
NOTE
Safety.
1. Operate and warm up the machine until the oil reaches operating
0:00pm
temperature, at least 50 °C.
a
The temperature can be checked with Operating menu, transmis-
sion and hydraulic system.
b c
50°C 50°C
016372

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

4 Brakes – Accumulator pressure sensor 4:33

accumulator pressure on the accumulator charging valve.
018318
Measuring outlet, accumulator pressure

4. To be able to read the signal from the sensor, first navigate to the
10:23
CUSTOMER SETTINGS
0
014981

10:23
.

0 0
015625

4.BRAKES
016946

4:34 4 Brakes – Accumulator pressure sensor
7. Select 4.3 Power Assisted System by scrolling with or and

* 4.BRAKES *
confirm with .
4.2 ABS
4.5 Parking Brake
016947
* 4.BRAKES *
4.2 ABS
4.5 Parking Brake
016948
9. Select 4.3 Power Assisted 3 by scrolling with or .

For a more detailed description, 4.3 Power Assisted 3/XX DIAG-
NOSE, page 8:44.
10. Start the engine and compare the pressure in the diagnostics
menu with the measured pressure on the pressure gauge.
measuring outlet.

4 Brakes – Brake pressure sensor 4:35
Accumulator pressure sensor, replacement
NOTE
Safety.

NOTE
3. Disconnect the electrical connections and replace the sensor.

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

Brake pressure sensor, description
Sensor brake pressure (B7681) controls activation of the brake light
when the machine is braked. The sensor is fitted on the drive axle block
which is fitted on a bracket above the drive axle differential.
Sensor, brake pressure (B7681) is supplied with voltage by, and sends
voltage signals proportional to the brake pressure to Control unit KFU
(D7971).
The signal can be checked with the diagnostic menu, see 4.3 Power
Assisted 3/XX DIAGNOSE, page 8:44.
016398

4:36 4 Brakes – Brake pressure sensor
Sensor brake pressure, checking
NOTE
Safety.
1. Operate and warm up the machine until the oil in the brake system
0:00pm
reaches operating temperature, at least 50 °C.
a
b c
50°C 50°C
016372

016319

10:23
CUSTOMER SETTINGS
0
014981

4 Brakes – Brake pressure sensor 4:37
10:23 5. Enter diagnostic code 1111, with or . Confirm each figure with
.
0 WRITE PIN CODE

NOTE
0 0
015625
0

4.BRAKES
016946

* 4.BRAKES * confirm with .

4.2 ABS
4.5 Parking Brake
016947

* 4.BRAKES *
4.2 ABS
4.5 Parking Brake
016948
9. Select 4.3 Power Assisted 3 by scrolling with or .

For a more detailed description, 4.3 Power Assisted 3/XX DIAG-
NOSE, page 8:44.
10. Start the engine and brake.
Compare the pressure in the diagnostics menu with the measured
pressure on the pressure gauge.
11. Stop the engine and turn the start key to position I.
measuring outlet.

4:38 4 Brakes – Brake pressure sensor
Brake pressure sensor, replacement
NOTE
Safety.

NOTE

hydraulic system.
NOTE
the lock ring.
6. Start the machine and bleed the brake cylinders for the wheel
brakes, see Wheel brakes, bleeding, page 4:30
016398

4 Brakes – Parking brake system 4:39
4.5 Parking brake system

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

Accumulator pressure Above limit for warning Power-assisted brake system, function description, page 4:14
Service brake Activated Power-assisted brake system, function description, page 4:14
D5
5
6, 12
D7902
D7971
4 D8 7, 11, 13
8 10 D10
Pa
C C
ACC
H
P 3
2 T
B
1
9
016394

1 Oil pump brake system pumps oil from P = 20.5±1 MPa Oil tank brake system, description, page 4:50
oil tank brake system. Oil pump brake system, description, page
4:16
2 Oil filter brake system cleans the oil. - Oil filter brake system, description, page 4:55
3 The accumulator charging valve directs - Accumulator charging valve, description,
oil to charging of accumulators or page 4:20
through the brake system's cooling
circuit.
4 The accumulators store oil pressure. See the pressure plate on Accumulator, description, page 4:23
the left-hand frame beam.
5 The travel direction selector in position U = 24 V Travel direction selector and parking brake,
for activated parking brake (S1310) description, page 2:11
sends a voltage signal to Control unit D5: Diagnostic menu, see 4.5 Park Brake
KPU (D7902). Sys 3/XX DIAGNOSE, page 8:45
The service brake must be actuated to
release the parking brake before the
travel direction selector is moved to the
released parking brake position (S1310).


6 The KPU control unit (D7902) sends re- Checked by control sys- 11.5.3.2 KPU control unit (D7902), page
lease the parking brake on the CAN bus. tem, error shown with er- 11:30
ror code.
7 KFU control unit (D7971) activates the U = 24 V 11.5.3.4 Control unit KFU (D7971), page
parking brake solenoid valve (Y6420). 11:34
D8: Diagnostic menu, see 4.5 Park Brake
8 Solenoid valve parking brake (Y6420) Pump pressure. Solenoid valve parking brake, description,
acts on the valve slide which drains pres- page 4:41
sure in the parking brake's brake caliper
to tank.
9 The brake caliper is drained of pressure 0 MPa Parking brake unit, description, page 4:42
and the spring applies the parking brake.
10 Sensor parking brake pressure (B7682) U = 0.5-4.5 V Sensor parking brake pressure, description,
sends voltage signals equivalent to the page 4:44
pressure for the parking brake caliper to D10: Diagnostic menu, see 4.5 Park Brake
Control unit KFU (D7971). Sys 3/XX DIAGNOSE, page 8:45
The pressure indicates that the parking
brake is released.
11 The KFU control unit (D7971) sends Checked by control sys- 11.5.3.4 Control unit KFU (D7971), page
parking brake applied on the CAN bus. tem, error shown with er- 11:34
ror code.
12 KPU control unit (D7902) activates indi- Checked by control sys- 11.5.3.2 KPU control unit (D7902), page
cator light, parking brake. tem, error shown with er- 11:30
ror code.
13 Control unit KFU (D7971) sends a signal U = 24 V 11.5.3.4 Control unit KFU (D7971), page
over the CAN bus to allow declutch of 11:34
the transmission.

page E:4.

Oil pump brake system, general
See Oil pump brake system, description, page 4:16.

Oil filter brake system, general
See Oil filter brake system, description, page 4:55.

4 Brakes – Solenoid valve parking brake 4:41
4.5.3 Solenoid valve parking brake

Solenoid valve parking brake, description
Solenoid valve parking brake (Y6420) activates the parking brake. The
solenoid valve is fitted on the accumulator charging valve, which is fit-
ted on the lifting beam in front of the transmission in the engine com-
partment, see Accumulator charging valve, description, page 4:20.
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 con-
nection between the parking brake caliper and tank is opened and the
parking brake is applied. This means that the parking brake is applied if
the machine becomes de-energised or if the brake system becomes
depressurised.
The solenoid valve is voltage fed by the KFU control unit (D7971) on
activation.
The signal can be checked with the diagnostic menu, see 4.5 Park
Brake Sys 3/XX DIAGNOSE, page 8:45.
016817
Solenoid valve parking brake, checking
DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to roll
when the parking brake is released.
1. Start the engine and run it at idling speed until the accumulator
charging valve changes to cooling.
2. Let the ignition key lock be in the I position.
3. Release the parking brake with the travel direction selector and
check that the parking brake's brake caliper releases. The brake
caliper should be able to move.
4. Actuate the service brake pedal, apply the parking brake with the
travel direction selector and check that the parking brake's calipers
are applied.

4:42 4 Brakes – Parking brake unit
Solenoid valve parking brake, replacement

2. Depressurise the hydraulic system, see Hydraulic and brake sys-
tems, depressurising, page B:5.
NOTE
3. Detach the electrical connection from the solenoid valve.

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

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

2. Parking brake caliper
3. Brake disc parking brake

4 Brakes – Pipes and hoses 4:43
1 2 3 4 5 The brake caliper has a spring section and a hydraulic section. The
spring section applies the brake while the hydraulic section is used to
release the brake. This means that the parking brake is applied if the
brake system loses pressure. This, in turn, means that the machine is
braked if a serious fault arises. The clearance between brake pads and
brake disc is adjusted by changing the position of an adjustment piston
that runs in the release cylinder. The adjustment is also used in order to
release the parking brake mechanically in the event of emergency
situations.
018554
1. Brake pads
2. Adjustment piston
3. Release cylinder
4. Thrust spring
5. adjusting screw
Parking brake, bleeding
NOTE
Safety.
1. Park the machine with blocks at the steering wheels and the drive
wheels.
2. Position a ring spanner on the bleed nipple on the parking brake
caliper and connect a transparent hose to the bleed nipple.
Route the other end of the hose down into a receptacle.
3. Start the machine and apply the parking brake.
4. Open the bleed nipple on the parking brake caliper and allow oil to
run out of it until the oil is free of air bubbles.
5. Close the bleed nipple.
6. Check the oil level in the brake system, fill if necessary.
018561
Bleed nipple, parking brake


4:44 4 Brakes – Sensor parking brake pressure
4.5.10 Sensor parking brake pressure

Sensor parking brake pressure, description
Sensor parking brake pressure (B7682) detects the pressure to the
parking brake caliper. The sensor is fitted on the accumulator charging
valve on the lifting beam in front of the transmission in the engine
compartment.
Sensor, parking brake pressure (B7682) is supplied with voltage by,
and sends voltage signals proportional to the parking brake pressure to
Control unit KFU (D7971).
The signal can be checked with the diagnostic menu, see 4.5 Park
Brake Sys 3/XX DIAGNOSE, page 8:45.
016816
Sensor parking brake pressure, checking
NOTE
Safety.
1. Operate and warm up the machine until the oil reaches operating
0:00pm
temperature, at least 50 °C.
a
b c
50°C 50°C
016372


4 Brakes – Sensor parking brake pressure 4:45

parking brake pressure on the accumulator charging valve.
016816
Measuring outlet parking brake pressure

10:23
CUSTOMER SETTINGS
0
014981

10:23
.

0 0
015625

4.BRAKES
016946

4:46 4 Brakes – Sensor parking brake pressure
7. Select 4.5 Parking Brake by scrolling with or and confirm with

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

For a more detailed description, 4.5 Park Brake Sys 3/XX DIAG-
NOSE, page 8:45.
10. Start the engine and release the parking brake, compare the pres-
sure in the diagnostics menu with the measured pressure on the
pressure gauge.
measuring outlet.

4 Brakes – Sensor parking brake pressure 4:47
Sensor parking brake pressure, replacement
NOTE
Safety.

NOTE

hydraulic system.
NOTE
the lock ring.
6. Start the machine and bleed the parking brake, see Parking brake,
bleeding, page 4:43.
016816

4:48 4 Brakes – Temperature control, cleaning and oil brake system
4.8 Temperature control, cleaning

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

system, function description
12
D7950
D7902
C
D7971 D7901
9, 10
13 4 5
D7930
Pa
D10
ACC
C H
5
P 3
B
T
2
D8
1 8 7 6
M 11
023372

1 Oil pump brake system pumps oil from P = 20.5±1.0 MPa Oil pump brake system, description, page
oil tank brake system. 4:16
Oil tank brake system, description, page
4:50
2 Oil filter brake system cleans the oil. - Oil filter brake system, description, page
4:55

4 Brakes – Temperature control, cleaning and oil brake system 4:49

3 The accumulator charging valve routes Max. 0.1 MPa Accumulator charging valve, description,
oil to charging of the accumulators or the page 4:20
drive axle block.
4 The drive axle block distributes the oil to - Drive axle block, description, page 4:29
the cooling circuit of both wheel brakes.
The bypass valve in the distribution block
leads oil past the drive axle if the back
pressure through the wheel brake is too
great.
5 The oil cools the wheel brake. - Wheel brakes, description, page 4:29
6 The cooler cools the oil. - Oil cooler, description, page 4:51
7 The thermal bypass valve routes oil past approx. 50 °C Thermal bypass valve, description, page
the cooler if the oil temperature is low. 4:53
8 The temperature sensor (B7720) detects R = 25 kΩ at 20 °C Sensor, oil temperature brake system, de-
the oil temperature and sends a voltage scription, page 4:54
signal proportional to the oil temperature D8: 4.8 Oil Temp/Clean 1/XX DIAGNOSE,
to Control unit KFU (D7971). page 8:46
9 Control unit KFU (D7971) sends oil tem- Checked by control system, 11.5.3.4 Control unit KFU (D7971), page
perature information on the CAN bus. error shown with error code. 11:34
10 When the oil is hot, Control unit KFU Activated fan: U = 24 V 11.5.3.4 Control unit KFU (D7971), page
(D7971) activates voltage feed to Cool- Activates at 65 °C. 11:34
ing fan (M6740). Deactivates at 55 °C. D10: 4.8 Oil Temp/Clean 2/XX DIAG-
NOSE, page 8:46
11 Cooling fan (M6740) starts and in- - Cooling fan, description, page 4:52
creases air flow through the cooler.
12 If the oil temperature increases above Checked by control system, 11.5.3.3 Control unit, KID (D7950), page
85 °C then Control unit KID (D7950) acti- error shown with error code. 11:32
vates a warning for high oil temperature
in the display.
13 If the oil temperature increases above Checked by control system, 11.5.3.4 Control unit KFU (D7971), page
90 °C then Control unit transmission error shown with error code. 11:34
(D7930) limits the speed of the machine
in order to protect the brakes.

page E:4.

4:50 4 Brakes – Oil tank brake system
4.8.1 Oil tank brake system

Oil tank brake system, description
The oil tank brake system stores oil in the brake system and is fitted on
1 2 3 the left-hand side of the machine in front of the fuel tank.
The brake system is separate from other hydraulics and has its own
tank and oil filter. This makes it possible specify the oil in the brake sys-
tem so that additives can be avoided.
Filling oil takes place directly to the tank. There is a drain plug located
at the bottom of the tank. Hatches on top of the tank facilitate internal
cleaning.
The tank is equipped with a filtered breather that allows volume
changes in the tank, due to temperature variations and use. See
Breather filter, description, page 4:55.
The tank has a sight glass for checking oil level.
016324
1. Sight glass
2. Filling oil, brake system
3. Breather filter, brake oil tank
4.8.2 Tank heater

Tank heater, description
The machine can be equipped with electrically-driven tank heater in dif-

1 ferent units together with electrical heater for engine, hydraulic oil tank
and preparation for cab fan. The tank heater heats the oil in the oil tank
and is intended for use in cold climates.
2 The tank heater is supplied with high voltage from an external mains
3 minal boxes above the left-hand footstep. The machine has a start in-
terlock function that prevents the engine being started when a power
4 cable is connected to the mains power connector. The sensor for the
start interlock function is an optical sensor that can react to objects oth-
er than the connected power cable.
Tank heater output is adapted through different connections to different
operating voltages - 110, 230 or 400 V AC. Higher voltage generates
higher heater output. The tank heater is fitted in a cavity in the connec-
tion cover on the lower part of the tank's short side.
5
The tank heater has an adjustable thermostat that keeps the tempera-
ture at a constant level. The thermostat is fitted on the heating element
and is adjusted with a knob on the junction box. The recommended
temperature setting is 20-30 °C.
018549
1. Mains power connector high voltage CAUTION

2. Sensor, start interlock function
3. Terminal box, start interlock, engine and cab The tank heater is connected to high voltage (110 - 400
heater V).
4. Terminal box, heater hydraulic oil tank and oil High voltage.
tank brake system
5. Tank heater, oil tank brake system Installation and reconnection of the tank heater may on-
ly be performed by personnel authorised for work with
high voltage.

4 Brakes – Oil pump brake system 4:51

Oil pump brake system, general
See Oil pump brake system, description, page 4:16.
4.8.4 Accumulator charging valve

Accumulator charging valve, general
See Accumulator charging valve, description, page 4:20.
4.8.5 Drive axle block

Drive axle block, description
See Drive axle block, description, page 4:29.
4.8.6 Wheel brakes

Wheel brake, general
See Wheel brakes, description, page 4:29 and supplier documentation,
drive axle.
4.8.7 Oil cooler

The oil cooler cools the oil in the brake system in order to maintain
brake performance. The oil cooler is fitted inside the side panel on the
left-hand side behind the front wing.
The brake system uses a flow-through cooler with electric cooling fan.
The bake system's oil is cooled when it passes through the cooler.
Openings in the frame panel allow air to pass through the cooler.
The cooling fan is screwed onto the cooler. See Cooling fan, descrip-
tion, page 4:52.
016830

4:52 4 Brakes – Cooling fan
Oil cooler brake system, replacement
NOTE
Safety.

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

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

The cooling fan (M6740) is a suctioning electric fan. The fan draws air
from the outside of the machine through the cooler and increases the
airflow through the oil cooler as required. The cooling fan is mounted
on the inside of the cooler inside the side panel behind the left-hand
drive wheel.
The cooling fan (M6740) is supplied with voltage by Control unit KFU
(D7971). The cooling fan is activated when oil temperature is 65 °C in
the oil tank brake system and the fan is deactivated when oil tempera-
ture is 55 °C.
The signal can be checked with the diagnostic menu, see 4.8 Oil Temp/
Clean 2/XX DIAGNOSE, page 8:46.
016831

4 Brakes – Thermal bypass valve 4:53
4.8.9 Thermal bypass valve

Thermal bypass valve, description
When the oil is cold, the thermal bypass valve directs the oil past the
cooler directly to the tank. The thermal bypass valve is fitted inside the
oil tank adjacent to the hose connections to and from the cooler.
The thermal bypass valve is a temperature-regulated bimetal valve.
The valve is open at low temperatures and completely closed at 50 °C.
016832
Thermal bypass valve, replacement
NOTE
Safety.

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


4:54 4 Brakes – Sensor, oil temperature brake system
4.8.10 Sensor, oil temperature brake system

Sensor, oil temperature brake system, description
Sensor, oil temperature brake system (B7720) detects the temperature
of the oil in the brake system.
The sensor is fitted on the rear short side of the oil tank and therefore
takes into account the accumulated heat in the brake system oil.
Sensor, oil temperature brake system (B7720) is supplied with voltage
by, and sends voltage signals proportional to the temperature to Control
unit KFU (D7971).
The signal can be checked with the diagnostic menu, see 4.8 Oil Temp/
Clean 1/XX DIAGNOSE, page 8:46.
018599
Sensor, oil temperature brake system, replacement
NOTE
Safety.

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

018599

4 Brakes – Breather filter 4:55
4.8.11 Breather filter

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

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

4.8.14 Oil, brake system

Oil brake system, general
See section F Technical data.

4:56

5:1
5 Steering
Contents 5 Steering
5 Steering................................................................................................................. 5:3
5.1.1 Steering wheel.............................................................................................. 5:4
5.1.2 Mini-wheel .................................................................................................... 5:5
5.1.3 Joystick......................................................................................................... 5:6
5.2 Power assisted system ..................................................................................... 5:9
5.2.1 Hydraulic oil pump...................................................................................... 5:13
5.2.3 Steering valve............................................................................................. 5:13
5.2.4 Steering cylinder......................................................................................... 5:16
5.2.5 Steering axle cradle.................................................................................... 5:18
5.2.6 Link arm...................................................................................................... 5:18
5.2.7 Wheel spindle............................................................................................. 5:18
5.2.8 Wheel hub .................................................................................................. 5:18
5.2.9 Sensor, steering axle.................................................................................. 5:19
5.2.12 Sensor, steering wheel angle ..................................................................... 5:19
5.2.13 Pipes and hoses......................................................................................... 5:20
5.2.14 Control valve steering ................................................................................ 5:21
5.2.21 Arm rest in position sensor......................................................................... 5:27
5.2.22 Relief valve for hydraulic oil pump, steering .............................................. 5:28

5:2

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

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

5:4 5 Steering – Controls and instruments

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

2. Remove the steering wheel cover plate.
015788
Steering wheel cover

3. Unscrew the nut counter holding the with an Allen key.
4. Replace the steering wheel.
Tighten the nut to a torque of 25 Nm.
015786
Nut

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

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

Switch direction indicators (S1470) activates the direction indicators
when the machine is steered with the mini-wheel. The switch is sup-
plied with voltage by, and sends voltage signals to Control unit KCU
(D7901).
The signals can be read with the diagnostic menu, see 9.6 Lighting Sys
6 6/XX DIAGNOSE, page 8:122.
Mini-wheel
The control is connected to two rotary potentiometers (R8250-1 and
R8250-2), each potentiometer provides a signal of 0-5 V during one
revolution. The potentiometers are phase shifted in order to determine
the direction of rotation. The rotary potentiometers are supplied with
voltage by, and send voltage signals to Control unit KCU (D7901), pro-
portional to the rotation in order to indicate steering deflection.
The signals can be read with the diagnostic menu, see 5.2 Power As-
sisted 3/XX DIAGNOSE, page 8:47.
015422
The ratio between the mini-wheel's and the wheels' deflection can be
adjusted in 10 different positions, from linear to very progressive. The
1. Switch direction indicators (S1470)
steering angle can also be adjusted according to machine speed. This
2. Mini-wheel (R8250-1 & R8250-2)
is performed with the menu system in the machine, see 8.5.5.2 Initia-
3. Switch, mini-wheel activation (S1130) tion menus, Power assisted system, page 8:179.
4. Switch, travel direction selector (S1310-3)
5. Switch, light signal (S1992) Switch, mini-wheel activation
6. Arm rest Switch activation of mini-wheel (S1130) activates steering with the
mini-wheel. The switch is supplied with voltage by, and sends voltage
signals to Control unit KCU (D7901).
Switch, travel direction selector

Switch, travel direction selector (S1310-3) is used to select the travel
direction (forward or backward) when the mini-wheel is activated. The
switch is supplied with voltage by, and sends voltage signals to Control
unit KCU (D7901).
The signals can be read with the diagnostic menu, see 2.1 Controls &
Instr 2/XX DIAGNOSE, page 8:40.

5:6 5 Steering – Joystick
Switch, light signal

Switch, light signal (S1992) activates flashing of the work lights on the
wings, when the lighting is switched off. The switch also activates the
windscreen and roof wipers. On machines with high and low beam, the
switch changes between high and low beam, when the headlights are
activated .
The switch only works when the mini-wheel is activated. The switch is
supplied with voltage by, and sends voltage signals to Control unit KCU
(D7901).
1/XX DIAGNOSE, page 8:120.
5.1.3 Joystick
Joystick, description
1 2 3
An electric control is used to steer machines equipped with a joystick. A
4 directional control valve actuates the steering cylinder.
The joystick is built into the left-hand armrest.
NOTE
wheel is used.
5 If the left-hand arm rest is folded up then joystick control/mini-wheel
is disengaged.
3 km/h.
016849
Joystick
1. Joystick
Joystick (R8250-1) controls wheel angle. The sliding potentiometer is
2. Switch direction indicators (S1470)
3. Travel direction selector (F / N / R) (D7901), proportional to the movement in order to indicate steering
4. Switch, light signal (S1992) deflection.
5. Switch, joystick activation (S1130)
sisted 2/XX DIAGNOSE, page 8:46, menu 1.
The ratio between the joystick's and the wheels' deflection can be ad-
justed in 10 different positions, from linear to very progressive. The
steering angle can also be adjusted according to machine speed. This
is performed from the menu system in the machine, see 8.5.5.2 Initia-
tion menus, Power assisted system, page 8:179.
Joystick positions (left, centre, right) can be calibrated with the menu
system in the machine, see Lever steering, calibration, page 5:7.
Switch, direction indicators

Switch direction indicators (S1470) activates the direction indicators
when the machine is steered with the mini-wheel. The switch is sup-
plied with voltage by, and sends voltage signals to Control unit KCU
(D7901).
Switch, travel direction selector

Switch, travel direction selector (S1310-3) is used to select the travel
direction (forward or backward) when the mini-wheel is activated. The
switch is supplied with voltage by, and sends voltage signals to Control
unit KCU (D7901).

5 Steering – Joystick 5:7
The signals can be read with the diagnostic menu, see 2.1 Controls &
Instr 2/XX DIAGNOSE, page 8:40.
Switch, light signal

Switch, light signal (S1992) activates flashing of the work lights on the
wings, when the lighting is switched off. The switch also activates the
windscreen and roof wipers. On machines with high and low beam, the
switch changes between high and low beam, when the headlights are
activated .
The switch only works when the mini-wheel is activated. The switch is
(D7901).
Switch, mini-wheel/joystick activation

Switch activation of mini-wheel (S1130) activates steering with the
mini-wheel. The switch is supplied with voltage by, and sends voltage
signals to Control unit KCU (D7901).
Lever steering, calibration

2. Start key in operating position.
10:23
CUSTOMER SETTINGS
0
014981
4. Enter the code for calibration with or . Confirm each figure

10:23
with .
Code is obtained from Cargotec Support.
0 WRITE PIN CODE
NOTE
0 The code determines which service menus should be activated.
0
015625
5. Select 5. STEERING by scrolling with or and confirm with .

5. STEERING
016949

5:8 5 Steering – Joystick

* 5. STEERING *
confirm with .
016950
* 5. STEERING *
016986
8. Navigate to the calibration menu 5.2 POWER ASSISTED, menu 1

with / . See Navigation to a menu, work instruction, page
8:169 for an explanation of navigation.
Row 1 shows the joystick position.
Row 2 shows the saved value for the joystick position.
9. Move the joystick to the desired centre position to set the centre
position for joystick control. Press Save to store this value.
The value on row 1, Comfort steering lever middle position, is
saved on row 2.

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

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

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

Power assisted system, description
The function of the power assisted system is to steer the machine. Ma-
chine steering is servo assisted with pressure from hydraulic oil pump 3.
The steering consists of steering wheel, steering axle, steering valve,
hydraulic oil pump, control valve steering, steering cylinder, link arms,
and wheel spindles.
The steering wheel acts on the steering valve (via the steering column)
which, via pilot pressure to Control valve steering, controls the oil pres-
sure from the hydraulic oil pump to the steering cylinder. The steering
cylinder acts on the wheel spindles. The link arms are located between
steering cylinder and wheel spindles.
Power assisted system, function description

D7901
D7971 D7902 1
3,10
D2
4 2
D7940 D7930
2
6, 8
P
Ps P 5
Ts T
C 11
LS L
T
CL CR R
7
9
022280
1 The steering wheel is turned and acts on - Steering wheel, description, page 5:4
the steering valve\qs input shaft.
2 Sensor, steering wheel angle (B7700-1 U = 24 V Sensor, steering wheel angle, description,
and B7700-2) sends a voltage signal to page 5:19
the KPU control unit (D7902). D2: Diagnostic menu, see 11.5 Distr of Electr
3 Control unit KFU (D7971) sends steering Checked by the control 11.5.3.4 Control unit KFU (D7971), page
wheel rotation on the drive-train's CAN system, error indicated 11:34
bus to Control unit transmission (D7973). with error code.
4 Control unit transmission (D7930) sends Checked by the control 11.5.3.7 Control unit, transmission (D7930),
a rotation speed request on the CAN bus system, error indicated page 11:39.
to Control unit engine (D7940). with error code.
5 The steering valve sends control signals - Steering valve, description, page 5:13
to control valve, steering.
6 Control valve steering sends a load sig- Checked by control sys- Control valve steering, description, page
nal to Hydraulic oil pump 3. tem, error shown with error 5:21
code.
7 Hydraulic oil pump 3 increases the - Axial piston pump with variable displace-
capacity. ment, description, page 10:8
8 The steering control valve leads pressur- - Control valve steering, description, page
ised oil to the steering cylinder. 5:21
9 The steering cylinder turns the wheels. - Steering cylinder, description, page 5:16

5:10 5 Steering – Power assisted system

10 Steering is limited if there is a risk of 11.5.3.4 Control unit KFU (D7971), page
overloading the diesel engine. 11:34
This takes place by limiting the load sig-
nal to Hydraulic oil pump 3.
Control unit KFU (D7971) sends a volt-
age signal to Relief valve for hydraulic oil
pump, steering (Y6360).
11 Relief valve for hydraulic oil pump, steer- Relief valve for hydraulic oil pump, steering,
ing (Y6360), limits the load signal. description, page 5:28
The steering is limited to avoid overload-
ing the diesel engine.
Hydraulic diagram, basic machine, see Hydraulic diagram, basic ma-

chine, page E:6.
Joystick control/mini-wheel, description
Mini-wheel or joystick control is a steering option that makes it possible

to steer the machine with an electric control on the left-hand arm rest of
the driver's seat. The electric control sends signals to the control sys-
tem. The steering cylinder is pressurised by a control valve, which is al-
so controlled by the control system.
Joystick control and mini-wheel work the same way, but with different
design of the steering control.
The ratio between the control's and the wheels' deflection can be ad-
justed in different steps, from linear to very progressive. The steering
angle can also be adjusted according to machine speed. This is per-
formed with the initiation menus, see 8.5.5 Steering, page 8:179.
NOTE
wheel is used.
If the left-hand arm rest is folded up then joystick control/mini-wheel
is disengaged.
3 km/h.
Joystick control/mini-wheel, function description

Joystick control/ Voltage signal from the connection of mini-wheel/joystick Mini-wheel, description, page 5:5 or Joystick,
mini-wheel control switch (S1130). description, page 5:6
activated
Left-hand arm Voltage signal from the arm rest in position sensor Arm rest in position sensor, description, page
rest lowered (D7250). 5:27
Steering wheel The signals from Sensor, steering wheel angle (B7700-1 Sensor, steering wheel angle, description,
stationary and B7700-2) must not detect movement (pulse train page 5:19
over a certain frequency).
Speed Below 3 km/h (at engagement) -

5 Steering – Power assisted system 5:11

Control breaker Disengaged Control breaker voltage, function description,
page 11:20
Sensor, operator- Not activated (operator in seat) Sensor operator in seat, description, page
in-seat 9:25
D3
D5 5 3
2, 4, 6
D7901 D1
D7971 D7902 15
7, 9, 18, 20 17
1
16
8
16
D7940 D7930
10 D16
D9 11, 13
P
Ps P 19
Ts T
C 21
LS L
T
CL CR R
12
14
022281
1 Arm rest in position sensor (B7250) U = 24 V Arm rest in position sensor, description,
sends a voltage signal to the KCU control page 5:27.
unit (D7901). D1: Diagnostic menu, see:
• Joystick control: 5.2 Power Assisted 2/
XX DIAGNOSE, page 8:46
• Mini-wheel: 5.2 Power Assisted 3/XX DI-
AGNOSE, page 8:47
2 Control unit KCU (D7901) permits en- Checked by the control 11.5.3.1 KCU control unit (D7901), page
gagement of mini-wheel or joystick system, error indicated 11:27
control. with error code.
3 Switch, engagement of mini-wheel/joy- U = 24 V Mini-wheel, description, page 5:5
stick control (S1130) sends voltage sig- Joystick, description, page 5:6
nals to Control unit KCU (D7901). D3: Diagnostic menu, see:
• Joystick control: 5.2 Power Assisted 2/
• Mini-wheel: 5.2 Power Assisted 3/XX DI-
AGNOSE, page 8:47
4 Control unit KCU (D7901) sends electric Checked by the control 11.5.3.1 KCU control unit (D7901), page
steering active on the CAN bus. system, error indicated 11:27
with error code.
5 Joystick control US8520-1 = 0.5 - 4.5 V Joystick, description, page 5:6
The potentiometer in the switch joystick D5: Diagnostic menu, see 5.2 Power Assis-
(R8250-1) sends a voltage signal to KCU ted 2/XX DIAGNOSE, page 8:46
control unit (D7901).
Mini-wheel US8520-1 = 0.5 - 4.5 V Mini-wheel, description, page 5:5
The 2-channel potentiometer in the mini- US8520-2 = 0.5 - 4.5 V (only D5: Diagnostic menu, see 5.2 Power Assis-
wheel switch (R8250-1 and R8250-2) mini-wheel) ted 3/XX DIAGNOSE, page 8:47
sends a voltage signal to the KCU control
unit (D7901), which calculates the rota-
tion speed of the joystick.

5:12 5 Steering – Power assisted system

6 Control unit KCU (D7901) sends steering Checked by the control 11.5.3.1 KCU control unit (D7901), page
angle on the CAN bus. system, error indicated 11:27
with error code.
7 Control unit KFU (D7971) sends steering Checked by the control 11.5.3.4 Control unit KFU (D7971), page
wheel rotation on the CAN bus to Control system, error indicated 11:34
unit transmission (D7973). with error code.
8 Control unit transmission (D7930) sends Checked by the control 11.5.3.7 Control unit, transmission (D7930),
a rotation speed request on the CAN bus system, error indicated page 11:39.
to Control unit engine (D7940). with error code.
9 Control unit KFU (D7971) supplies volt- U = 0 V to battery voltage. 11.5.3.4 Control unit KFU (D7971), page
age to Electric steering module (Y6150). Steering takes place as 11:34
When the voltage is 50% of the battery set out below as a per- D7: Diagnostic menu, see 5.2 Power Assis-
voltage the valve is in the neutral posi- centage of the battery ted 5/XX DIAGNOSE, page 8:47
tion. Lower voltage gives steering to the voltage:
right and higher voltage gives steering to 0-15% = error indication
the left. 25% = full steering right
approx. 45% = start steer-
ing right
50% = neutral position
approx. 56% = start steer-
ing left
76% = full steering left
85-100% = error indication
In the event of signal error
or internal fault in the
valve a signal is sent from
the steering valve to Con-
trol unit, steering (D7971)
(24V).
10 Electric steering module (Y6150) pres- - Control valve steering, description, page
surises the steering slide in Control valve, 5:21
steering.
11 Control valve steering sends a load sig- Control valve steering, description, page
nal to Hydraulic oil pump 3. 5:21
12 Hydraulic oil pump 3 pumps oil from the See the pressure plate on Axial piston pump with variable displace-
hydraulic oil tank. the left-hand frame beam. ment, description, page 10:8
13 The steering slide in Control valve steer- - Control valve steering, description, page
ing changes position and pressurises the 5:21
steering cylinder.
14 The steering cylinder turns the wheels. - Steering cylinder, description, page 5:16
15 The steering wheel is turned and acts on - Steering wheel, description, page 5:4
the steering valve\qs input shaft.
16 Sensor, steering wheel angle (B7700-1 U = 24 V Sensor, steering wheel angle, description,
and B7700-2) sends a voltage signal to page 5:19
the KPU control unit (D7902). D14: Diagnostic menu, see 11.5 Distr of
17 The KPU control unit (D7902) sends in- Checked by the control 11.5.3.2 KPU control unit (D7902), page
terrupt steering on the CAN bus. system, error indicated 11:30
with error code.
18 Control unit KFU (D7971) sets Electric U = 12 V (50% of battery 11.5.3.4 Control unit KFU (D7971), page
steering module (Y6150) in neutral voltage) 11:34
position. D5: Diagnostic menu, see 5.2 Power Assis-
ted 5/XX DIAGNOSE, page 8:47
19 The steering valve pressurises Control - Power assisted system, function description,
valve steering in the same way as for page 5:9
normal steering.

5 Steering – Hydraulic oil pump 5:13

20 Steering is limited if there is a risk of 11.5.3.4 Control unit KFU (D7971), page
overloading the diesel engine. 11:34
This takes place by limiting the load sig-
nal to Hydraulic oil pump 3.
Control unit KFU (D7971) sends a volt-
age signal to Relief valve for hydraulic oil
pump, steering (Y6360).
21 Relief valve for hydraulic oil pump, steer- Relief valve for hydraulic oil pump, steering,
ing (Y6360), limits the load signal. description, page 5:28
The steering is limited to avoid overload-
ing the diesel engine.

chine, page E:6.
5.2.1 Hydraulic oil pump

Hydraulic oil pump, general
Steering is supplied with oil from hydraulic oil pump 3, see Axial piston
pump with variable displacement, description, page 10:8.
5.2.3 Steering valve

Steering valve, description
The control system consists of a pilot control valve that gives a signal
with low pressure and low flow (load signal) to the control valve steer-
ing. Control valve steering acts as a pilot-controlled directional control
valve which can be supplemented by an electronic control unit (option
for joystick control/mini-wheel).
1 Control valve steering also has a built-in priority valve that gives priority
2 to oil to the steering function. For control valve steering, see Control
valve steering, description, page 5:21.
5
4
016802
1. Steering valve
2. Load signal steering left (L)
3. Tank return (T)
4. Pressure feed (P)
5. Load signal steering right (R)

5:14 5 Steering – Steering valve
Steering valve, replacement
NOTE
Safety.

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

brake, replacement, page 2:11, steps 2-5.
4. Remove the steering wheel, see Steering wheel, replacement,
page 5:4.
1
015789
1. Covers
5. Remove the screws and cover.
1
2
015791
1. Screw
2. Cover

5 Steering – Steering valve 5:15
1 2 6. Place a receptacle under the steering valve.

Mark up and detach the hydraulic hoses from the steering valve.
NOTE
from impurities.
015792
1. Hydraulic connections
2. Steering valve
7. Remove the steering valve's attaching bolts and remove the steer-
ing valve.
8. Transfer the connections to the new steering valve.
NOTE
correctly.
NOTE
Transfer one connection at a time so that the marking is not
mixed up.
015790
9. Fit the new steering valve, tighten the attaching bolts crosswise
with increasing torque to 10±3 Nm.
Steering valve attaching bolts
CAUTION
Incorrectly assembled steering valve can impair the
function.
Uneven resistance in the steering wheel when driving.
Tighten the steering valve crosswise with increasing
torque in order to avoid tension in the valve.
10. Connect the hydraulic hoses in accordance with the marking.
NOTE
correctly.
11. Fit the covers and steering wheel.

hydraulic system.
NOTE
the lock ring.

5:16 5 Steering – Steering cylinder

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

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

5 Steering – Steering cylinder 5:17
Steering cylinder, replacement
NOTE
Safety.
1. Park the machine with the wheels fully turned so that the steering
cylinder can be lifted out to one side.
NOTE
4. Detach the link arms from the steering cylinder.

A B C
5. Mark up and detach the hydraulic hoses from the steering cylinder.
NOTE
from impurities.
6. Release the mounting for the sensor for the steering axle from the
steering cylinder.
023134
A. Link arm mounting

B. Mounting, sensor, steering axle (B7245–LE)
C. Hydraulic connection
7. Remove the steering cylinder's attaching bolts.
8. Replace the steering cylinder. Lift the steering cylinder aside.
NOTE
The steering cylinder is heavy, use lifting equipment.
9. Support the new steering cylinder so that the holes for the attach-
ing bolts are lined up directly opposite the holes in the steering
axle.
10. Fit and lubricate the steering cylinder attaching bolts. Tighten the
bolts crosswise in steps with increasing torque to 680 Nm (oiled
screw).
11. Fit the link arms to the steering cylinder.
Attaching bolts steering cylinder. 12. Connect the hydraulic hoses to the steering cylinder.
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.

5:18 5 Steering – Steering axle cradle

manual.
Hydraulic cylinders, repairs

See Hydraulic cylinders, repairs, page 10:44.
5.2.5 Steering axle cradle

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

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

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

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

5 Steering – Sensor, steering axle 5:19
5.2.9 Sensor, steering axle

Sensor, steering axle, description
The machine is equipped with one sensor (B7245-LE) as standard.
The sensor measures the angle of the steering wheels in order to adapt
the transmission's ratio. The sensor is located on the steering cylinder,
rear axle.
020621
Sensor, steering axle, checking

5.2.12 Sensor, steering wheel angle

Sensor, steering wheel angle, description
Sensor, steering wheel angle (B7700-1 and B7700-2) detects whether
the steering wheel has been turned and sends a signal to KPU control
unit (D7902). This is used to send a message that the steering is in use.
The sensor is located by the steering axle inside the panels.
For machines equipped with joystick control or mini-wheel, the sensors
are also used to disengage joystick control or mini-wheel.
The sensor is activated by a disc on the steering axle with several
cams. The location of the sensor and the spacing between the cams
means that small movements on the steering wheel can be detected.
Status for supply voltage can be read with the diagnosis menu, see
11.5 Distr of Electr 21/XX DIAGNOSE, page 8:142.
016803
Sensor, steering wheel deflection, checking

Position sensor, checking and adjustment

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

5:20 5 Steering – Pipes and hoses
Sensor, steering wheel angle, replacement

2. Remove the steering wheel and steering column cover, see Steer-
ing wheel, replacement, page 5:4 and Interior plastic components,
replacement, page 9:132.
3. Remove the screws which secure the sensor.
1 4. Unplug the connector from the sensor.
2 5. Replace the sensor.
NOTE
Do not tighten the screws that hold the sensor too tightly. The
sensor could then break.
NOTE
The distance between the sensor and metal plate must not be
more than 1.5 mm.
3
016130
1. Sensor, steering wheel angle

2. Screw, sensor, steering wheel angle
3. Connector, sensor, steering wheel angle


5 Steering – Control valve steering 5:21
5.2.14 Control valve steering

Control valve steering, description
The control valve is a proportional valve controlled by load signals from
the steering valve. This means that both volume and direction of the
1 2
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 spool that controls the pressure and flow for the
existing direction to the steering cylinder.
Valve slide, steering

The valve slide controls the direction and steering angle by controlling
the hydraulic pressure to the steering cylinder.
The valve slide is controlled by servo signals from either the steering
valve or electrical servo valve steering (machines with joystick con-
trol or mini-wheel).
10 9 8 7 6 5 4 3
022756
1. Control valve steering

2. Load signal steering right (R)
3. Pressure feed to steering valve (PS)
4. Load signal steering left (L)
5. Connection steering cylinder (CR)
6. Connection steering cylinder (CL)
7. Tank return from steering valve (TS)
8. Tank return (T)
9. Load signal to hydraulic oil pump 1 (LS).
10. Electric steering module (Y6150)

5:22 5 Steering – Control valve steering
Electric steering module
On machines with joystick control or mini-wheel, Electric steering mod-

ule (Y6150) is fitted on Control valve, steering. The steering module is
an electrically-operated pressure reducing valve that converts electric
current into servo pressure. The servo pressure then controls the
1 spring-centred valve slide, which controls the pressure and flow for the
current direction. The steering module controls the control valve for
steering via signals from the Control unit KFU (D7971).
Servo valve steering

The steering servo valve controls the servo pressure to valve slide
steering, so that it controls the oil pressure for steering right or left.
The steering servo valve is controlled electrically with Solenoid valve
steering (Y6150) which is activated by Control unit KFU (D7971).
022757
Control valve steering, replacement
NOTE
Safety.

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

Disconnect the wiring from the electrical control module.
5. Undo the screws and remove the control valve's mounting plate
from the body.
6. Undo the screws and remove the control valve from the mounting
plate.
7. Fit the new control valve on the attaching plate.
022759

8. Transfer parts to the new control valve.
NOTE
correctly.
NOTE
mixed up.
9. Fit the valve in the machine.
022759
10. Connect the hydraulic hoses to the control valve in according to

the marking.
NOTE
correctly.
11. Only machine with joystick control or mini-wheel

Connect the wiring to the electrical control module.
hydraulic system.
022758
NOTE
the lock ring.

CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the steering carefully and operate at the lowest
possible speed a couple of times to avoid cavitation.
manual.
16. Check the steering pressure, see Steering pressure, checking,
page 5:25.

Electric steering module, replacement
NOTE
Safety.

NOTE
3. Mark and disconnect the wiring from Electric steering module

(Y6150).
1
022757

4. Loosen the screws and remove Electric steering module (Y6150)
from the control valve.
5. Fit a new Electric steering module (Y6150).
6. Connect the cable harness to Electric steering module (Y6150) in
accordance with the marking.
hydraulic system.
NOTE
the lock ring.
022760

9. Check the function, try to steer with the steering wheel and with
the mini-wheel or joystick.
CAUTION
product damage.
10. Test drive the machine and check that the steering is working and
that steering with the steering wheel disengages steering with
mini-wheel or joystick.
manual.
Steering pressure, checking
NOTE
Safety.
0:00pm
ches operating temperature, 50 °C.
a
The oil temperature can be checked with Operating menu, trans-
mission and hydraulics.
b c
50°C 50°C
016372
Operating menu, transmission and hydraulics

a. Transmission oil temperature
b. Hydraulic oil temperature

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

for control pressure.
4. Start the engine and increase engine speed to approx. 1200 rpm.
022754
Measuring outlet control pressure

5. Turn the steering wheel fully and read pump pressure during the
steering wheel movement. Compare this to the steering pressure
on the hydraulics plate.
023141
6. Adjust the hydraulic pressure if necessary. The adjusting screw is

located under a rubber plug on Control valve steering.
7. Switch off the engine and switch off the system voltage.
measuring outlet.
022755
Adjusting screw

5 Steering – Arm rest in position sensor 5:27
5.2.21 Arm rest in position sensor

Arm rest in position sensor, description
Arm rest in position sensor (B7250) is located in the arm rest mounting
in the driver's seat and detects the angle of the arm rest. If the arm rest
is angled upward, the mini-wheel function is deactivated at a specific
angle and must be activated again using the connection of mini steer-
ing wheel switch.
The signal can be read with the diagnostic menu, see:
• 5.2 Power Assisted 2/XX DIAGNOSE, page 8:46
• 5.2 Power Assisted 3/XX DIAGNOSE, page 8:47
016136
Arm rest in position sensor (B7250)
Arm rest in position sensor, replacement

2. Unscrew the steering wheel on the arm rest joint.
3. Cut off the cable ties and split the connector.
016133
1 2 3
1. Steering wheel, arm rest joint
2. Cable ties
3. Connectors
4. Remove the screws and cover plate.
016134
1 2
1. Cover plate
2. Screw

5:28 5 Steering – Relief valve for hydraulic oil pump, steering
5. Remove the screw which secures the sensor.

6. Replace the arm rest in position sensor.
7. Refit in reverse order.
016135
1 2
1. Arm rest in position sensor
2. Screw
5.2.22 Relief valve for hydraulic oil pump,

steering
Relief valve for hydraulic oil pump, steering,
description
There is a relief valve (Y6360) fitted on hydraulic oil pump 3 for steering
that can limit the load signal so that the diesel engine is not overloaded.
023130
Relief valve for hydraulic oil pump, steering (Y6360)

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 ...................................................................................................6:11
6.3 Tyres and rims................................................................................................. 6:20
6.3.1 Tyres........................................................................................................... 6:22
6.3.2 Rim ............................................................................................................. 6:23
6.3.3 Nut, washer and clamp............................................................................... 6:24
6.3.4 Tyre pressure monitoring ........................................................................... 6:25

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 steer-
ing axle's suspension in the frame. The drive axle belongs to the drive-
line/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 attached into the frame with two bushings,
2 3 4 5 one in the front edge and one in the rear edge of the steering axle cra-
dle. Two wheel spindles are fitted in the steering axle cradle on bear-
ing-mounted axles. The wheel spindle is pivoted in order to facilitate
steering. Bearing-mounted wheel hubs are fitted on the wheel spindles
where the wheels are mounted.
Suspension refers to:
6
1 • Steering axle cradle
2 • Wheel spindle
• Wheel hub
023699
9 8 7
For machines with tyre size 18.00-25
1. Wheel hub
2. Counterweight
3. Front suspension
4. Steering axle
6. Rear suspension
7. Link arm
8. Wheel spindle
9. Wheel bolt
, and
3 4 5
6
1
023752
9 8 7
1. Wheel hub
2. Steering axle
3. Front suspension
5. Rear suspension
6. Counterweight
7. Link arm
8. Wheel spindle
9. Wheel bolt

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

Steering axle cradle, description
The steering axle cradle provides the frame in the mounting of the
2 3 4 5 steering wheels. The steering axle cradle is pendulum-mounted in the
body at two points with maintenance-free elements. The wheel spin-
dles, steering cylinder and a counterweight are attached in the steering
axle cradle. The design comprises a minimum of moving parts to mini-
mise service points and simplify maintenance.
6
1
2
023699
9 8 7
1. Wheel hub
2. Counterweight
3. Front suspension
4. Steering axle
6. Rear suspension
7. Link arm
8. Wheel spindle
9. Wheel bolt
, and
3 4 5
6
1
023752
9 8 7
1. Wheel hub
2. Steering axle
3. Front suspension
5. Rear suspension
6. Counterweight
7. Link arm
8. Wheel spindle
9. Wheel bolt

6:6 6 Suspension – Steering axle cradle
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.
1. Clean the steering axle and the surrounding area.

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

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

5 4 2 3 3
2 12. Lift the machine up so that the frame is lifted away from the axle.
1
13. Lift out the steering axle.
CAUTION
022637
The steering axle may start to roll.

Steering axle mounting
Crushing injury!
1. Shaft
2. Spacer Make sure that the steering axle does not roll away
uncontrollably.
3. Washer
4. Washer
14. Adjust the support so that the machine is secured in the new
5. Lock nut position.
15. Lift the steering axle into place under the frame.
16. Remove the support under the frame.
17. Lower the rear of the machine.
18. Fit the pins at the steering axle mountings.

6 Suspension – Wheel spindle 6:7
19. Connect the hydraulic hoses to the steering cylinder.
NOTE
correctly.
20. Remove the lifting equipment from the machine.

21. Fit the counterweights.
NOTE
Make sure that all counterweights are refitted and that they are
fitted in the exact same location as before. The stability of the
machine is affected if the counterweights are changed.
22. Fit the steering wheel and retighten in accordance with the instruc-
tions, see Maintenance Manual.
6.2.2 Wheel spindle

Wheel spindle, description
2 3 4 5 6 1 2 3 4 5 6
7 7
1
8 8
5 5
4
016827
023759

For machines with tyre size 18.00-25 1. Wheel spindle
1. Wheel spindle 2. Spindle bolt
2. Spindle bolt 3. Seal
3. Seal 4. Slide bearing washer
4. Slide bearing washer 5. Cover
5. Cover 6. Spindle bolt bearing
6. Spindle bolt bearing 7. Thrust bearing
7. Thrust bearing 8. Lock screw
8. Lock screw
The wheel spindle is the link between steering axle and wheel hubs
which means that the wheels can be turned.

6:8 6 Suspension – Wheel spindle
Spindle bolt bearing, replacement

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

2
Remove the lock screw and then remove the axle. Move the link
arm aside.
5. Position a lifting strap inside the hub to secure the spindle.
1
6. Remove the covers at the spindle bolt's upper and lower bearing.
7. Remove the grease between the cover and spindle bolt.
004516
3
1. Shaft, link arm
2. Cover (upper)
3. Cover (lower)
8. Remove the spindle bolt's upper and lower lock screw.
Remove the nut and the lock screw.
9. Adjust the lifting equipment to relieve the load on the wheel spindle.
10. Remove the spindle bolt.

Pull the spindle bolt up, using a sliding hammer or similar con-
nected to the threaded hole in the centre of the spindle bolt.
11. Remove the wheel spindle.
Place the wheel spindle on a soft surface.

6 Suspension – Wheel spindle 6:9
1 12. Remove the thrust bearings from the steering axle.

13. Press out the old bearing bushings. Note how the old bearing
bushings are fitted so that the new ones can be positioned the
same way with the space between in the same place.
14. Clean the surfaces inside the steering axle.
15. Press in the new bearing bushings. Make sure that the space is in
the same location as before.
NOTE
The upper bearing bushing must protrude (4.5-4.8 mm) so that it
is level with the thrust bearing's slotted washer.
004517
1. Wear washer, thrust bearings
16. Fit new thrust washers on the steering axle. Only fit three bolts in
the manner illustrated. The fourth bolt cannot be fitted until the
wheel spindle is in place. Only tighten the bolts slightly (5-10 Nm)
so that the thrust bearings are secured in position.
Thoroughly coat the bearing bushings with lubricating grease. For
grade, see section F Technical data.
NOTE
Make sure the nuts are positioned as illustrated.
17. Fit new O-rings on the wheel spindle.

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

6:10 6 Suspension – Wheel spindle
21. Fit the spindle bolt.

Apply lubricating grease onto the spindle bolt and press it into
place.
NOTE
Check that the spindle bolt is turned so that the holes for the lock
screws align with the holes in the wheel spindle. It is important
that the spindle bolt is perfectly seated before the lock screws
are fitted. It is not possible to "tighten" the spindle bolt into place.
22. Fit the lock screws and tighten the lock nut. Tighten to a torque of
250 Nm (oiled screw).
23. Apply lubricating grease in the space between the wheel spindle
and steering axle.
24. Position the O-rings.
25. Fit the remaining bolts to the thrust bearings' wear washers. Fit the
1 bolts in the manner illustrated. Tighten to a torque of 25 Nm (oiled
screw).
004517
1. Wear washer, thrust bearings

6 Suspension – Wheel hub 6:11
2 26. Fit the upper cover and the lower cover.

27. Lubricate the upper and lower bearings of the spindle bolt with lu-
bricating grease.
For a machine with central lubrication, the spindle bolt's upper and
1
lower bearings are lubricated manually before operating the
machine.
28. Turn the wheel spindle back and forth a few times to even out the
grease. Check that resistance is uniform.
29. Connect the link arm to the wheel spindle.
Lubricate the link arm bearings with lubricating grease.
004516
3 tions, see Maintenance Manual.
1. Shaft, link arm 31. Remove the support and lower the steering wheel.
2. Cover (upper) 32. Test-operate the machine and test the steering. Check also that
3. Cover (lower) the machine feels stable when driving straight ahead.
6.2.3 Wheel hub

Wheel hub, description
1 2 3 4 5 6
5 6 7 8
4
3
2
1
016828
023760

For machines with tyre size 18.00-25 1. Hub nut with locking washer
1. Cover washer 2. Outer wheel bearing
2. Castle nut and flat key 3. Hub
3. Washer 4. Inner wheel bearing
4. Hub 5. Seal
5. Outer wheel bearing 6. Support ring
6. Inner wheel bearing The wheel hub holds the wheel in place and allows the wheel to rotate.
7. Shaft seal
8. Spacer

6:12 6 Suspension – Wheel hub
Wheel bearings, replace (machines with tyre size

18.00x25)
Support under the steering axle in a safe way.
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 envi-
ronmentally hazardous waste.
023761
6. Secure the hub with a lifting strap.
7. Remove the bolt, washer and cover washer.

8. Tension the lifting equipment so that the hub is unloaded.
023762

9. Remove the flat key, castle nut and washer.
023763
10. Lift the hub out from the spindle.
Remove the outer bearing's inner race and pull the hub from the
axle.
11. Remove the inner bearing from the wheel spindle.
12. Remove the seal from the hub.

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

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

20. Install the outer bearing and washer.

Pack the bearing with grease and fit the bearing.
Grease the washer and fit it.
21. Remove the lifting equipment.
023764
B
A. Outer bearing
B. Washer
22. Torque the castle nut as follows.
A. Lubricate the thread and the side of the castle nut facing the
bearing with oil (SAE 80W/140).
B. Tighten the castle nut to a torque of 250 Nm (oiled screw).
C. Rotate the hub 10 revolutions.
D. Angle-tighten the castle nut 45°.
E. Rotate the hub 10 revolutions.
A F. Then tighten the castle nut further to be able to lock it with the
flat key in the next recess on the wheel spindle.
B
023765
A. Castle nut
B. Flat key
23. Fit the cover washer, washer and screw.
023762
24. Fill the bearing casing with grease and fit it.
25. Grease the wheel bearing with grease through the lubricant nipple.
Lift the seal ring's lip with a small screwdriver to facilitate the es-
cape of air. Lubricate until grease comes out at the seal.
27. Remove the support and lower the steering wheel.
023761

Wheel bearings, replace (machines with tyre size

18.00x33)
Support under the steering axle in a safe way.
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 envi-
ronmentally hazardous waste.
6. Secure the hub with a lifting strap.
7. Bend up the locking washer's tabs, remove the lock nut and lock-
ing washer.
8. Tension the lifting equipment so that the hub is unloaded.
9. Remove the hub nut.

10. Lift the hub out from the spindle.

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

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

17. Fit the inner bearing's inner race and rollers on the wheel spindle.
Pack the bearing with universal grease "EP2".
18. Fill the empty space in the hub with universal grease "EP2".
19. Fit the hub on the wheel spindle.
20. Install the outer bearing, protecting washer, and bearing nut.
Pack the bearing with grease and fit the bearing.
Fit the washer and hub nut with the smooth surface in towards the
hub.
21. Remove the lifting equipment.

22. Tighten the bearing nut in the following stages.

A. Lubricate the thread and the side of the nut facing the bearing
with oil (SAE 80W/140).
B. Tighten the nut to a torque of 250 Nm (oiled screw).
C. Rotate the hub 10 revolutions.
D. Angle tighten the nut 45°.
E. Rotate the hub 10 revolutions.
F. Angle tighten the nut 45°.
23. Apply grease onto the locking washer and fit it.
24. Fit the lock nut and tighten to at least 250 Nm (oiled screw) and
then further to engage the locking washer in the closest groove.
Lock the bearing nut and lock nut with the locking washer.
25. Fill the bearing casing with grease and fit it.
26. Grease the wheel bearing with grease through the lubricant nipple.
Lift the seal ring's lip with a small screwdriver to facilitate the es-
cape of air. Lubricate until grease comes out at the seal.
28. Remove the support and lower the steering wheel.

6:20 6 Suspension – Tyres and rims
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.
Wheels (tyre + rim) must only be handled pressurised
after inspection and approval, as well as inflated to full
pressure, by certified personnel.
Fully deflate the tyre before removal. Otherwise the con-
ical 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 must always be released via the valve. If this is
not possible - loosen the valve in the 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 drill-
ing a hole in the tyre tread. Use a drill bit with max. Ø 5
mm. Damaged tyres may explode.
Never stand directly in front of the wheel when deflating
or inflating. The conical ring and locking clips can loos-
en and shoot out when the pressure is changed.
Never fit damaged tyres or rims.
It is not permitted to mix rim components between rims.
The parts are adapted during manufacture.
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 Suspension – Tyres and rims 6:21
CAUTION
When removing wheels, the wheel nuts should be left in
place after loosening. If the wheel nuts are removed im-
mediately, 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 operat-
ing hours.
Always follow the tyre manufacturer's or other ap-
proved instructions when changing tyres.
Never use a steel hammer to fit or remove rim compo-
nents. Use a lead, brass or plastic mallet instead.
Keep tyre pressures at the prescribed level. Insufficient
tyre pressure impairs stability and reduces the ma-
chine'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 problem. Rectify faults immediately and
change damaged tyres.
Tyres and rims, description

The tyres are the point of contact between the machine and the ground,
the tyres absorb unevenness and act as suspension.
The drive axle is subjected to major forces during operation, if the roll-
ing circumference of the drive wheels is different then the stress on the
drive axle increases. It is important that the tyres on the drive axle are
the same model, type and make and have equal wear and the correct
air pressure.

6:22 6 Suspension – 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.
002027
Front wheels
, and
002026
Rear wheels
Tyres, changing
DANGER
Changing tyres involves large risks.
Danger to life!
Tyre replacement should be performed by service dept.
with tyre handling expertise!
The rims must be checked when tyres are changed, see Maintenance
manual section 6 Suspension.

6 Suspension – Rim 6:23
6.3.2 Rim
Rim, description
The rim is split to make it possible to fit a tyre. The rim consists of the
1 2 3 4 5 6 following parts.
• Rim
• Rim bead seat
• Rim edge
• Lock ring
• Lock lugs
• Hub plate
7
016829
1. Lock ring
2. Rim edge
3. Tapered rim
4. O-ring
5. Rim
6. Rim edge
7. Wheel nut
8. Wheel clamp

6:24 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.
1 2 3 4 5 6
The number of nuts and clamps varies depending on the type of drive
axle and steering axle used.
7
016829
1. Lock ring
2. Rim edge
3. Tapered rim
4. O-ring
5. Rim
6. Rim edge
7. Wheel nut
8. Wheel clamp
Wheel bolt, replacement

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

6 Suspension – Tyre pressure monitoring 6:25
4. Knock out the bolt with a sledge hammer.

5. Replace the bolt.
6.3.4 Tyre pressure monitoring

Tyre pressure monitoring, description
1 The tyre pressure monitoring system monitors the air pressure in all
tyres. The system is an independent system which communicates with
the machine's control system and gives warnings in the event of tyre
pressure that is high or low. The warnings are shown on the display in
the machine's cab.
The tyre pressure monitoring system comprises the following parts.
• Sensor tyre pressure
The tyre pressure sensor is screwed onto the nipple on the valve
extender on the tyres. There is a sensor on each tyre. The sensor
detects the air pressure in the tyre and sends this information at a
predetermined interval to Control unit tyre pressure monitoring, via
Antenna tyre pressure monitoring. The sensor has a built-in battery
which cannot be replaced, but the sensor is replaced with a new
one when the battery is discharged.
2 • Antenna tyre pressure monitoring
Antenna tyre pressure monitoring is connected to Control unit tyre
pressure monitoring and receives the signals from Sensor tyre
pressure. The antenna is fitted together with Control unit tyre pres-
sure monitoring on the frame in the engine compartment.
• Control unit tyre pressure monitoring
018358
Control unit tyre pressure monitoring receives signals from Sensor

tyre pressure via Antenna tyre pressure monitoring. The control
1. Sensor tyre pressure unit communicates with the machine's control system. The control
2. Control unit tyre pressure monitoring with unit is fitted together with Antenna unit tyre pressure monitoring on
antenna the frame in the engine compartment.
Sensor tyre pressure, replacement

For replacement of Sensor tyre pressure, see Maintenance manual.

6:26

7:1
7 Load handling
Contents 7 Load handling

7 Load handling ...................................................................................................... 7:3
7.1.1 Control lever ................................................................................................. 7:6
7.1.2 Switch lock twistlocks ................................................................................. 7:12
7.1.3 Switch, automatic spreading ...................................................................... 7:13
7.1.5 Switch, extra stop spreading ...................................................................... 7:13
7.1.6 Switch support jacks................................................................................... 7:14
7.1.7 Switch lowering front legs .......................................................................... 7:14
7.1.8 Switch lowering rear legs ........................................................................... 7:15
7.1.9 Switch clamp/release legs.......................................................................... 7:15
7.1.31 Switch overheight-legs ............................................................................... 7:15
7.2 Lifting/lowering ................................................................................................ 7:17
7.2.2 Servo filter .................................................................................................. 7:22
7.2.4 Accumulator servo circuit ........................................................................... 7:22
7.2.5 Control valve lift, lower and extension ....................................................... 7:23
7.2.7 Valve block lift cylinder ............................................................................... 7:24
7.2.8 Lift cylinder ................................................................................................. 7:26
7.2.9 Sensor, hydraulic pressure lift cylinder ...................................................... 7:29
7.2.10 Lift boom..................................................................................................... 7:30
7.2.11 Sensor boom angle .................................................................................... 7:30
7.2.12 Pipes and hoses......................................................................................... 7:30
7.2.16 Sensor damping attachment ...................................................................... 7:31
7.2.17 Valve block servo pressure ........................................................................ 7:32
7.3 Extension ........................................................................................................ 7:33
7.3.2 Servo filter .................................................................................................. 7:37
7.3.4 Accumulator servo circuit ........................................................................... 7:37
7.3.5 Control valve lift, lower and extension ....................................................... 7:38
7.3.7 Valve block extension cylinder ................................................................... 7:39
7.3.8 Extension cylinder ...................................................................................... 7:41
7.3.10 Lift boom..................................................................................................... 7:44
7.3.11 Sensor boom length ................................................................................... 7:46
7.3.12 Pipes and hoses......................................................................................... 7:46
7.4 Side shift ......................................................................................................... 7:47
7.4.3 Control valve, attachment .......................................................................... 7:49
7.4.5 Side shift cylinder ....................................................................................... 7:53
7.4.6 Side shift frame .......................................................................................... 7:53
7.4.7 Main beam, attachment.............................................................................. 7:57
7.4.8 Relief valve top lift ...................................................................................... 7:57
7.4.9 Pipes and hoses......................................................................................... 7:57
7.5 Spreading (positioning)................................................................................... 7:58
7.5.5 Valve block spreader motor........................................................................ 7:71
7.5.6 Spreader motor .......................................................................................... 7:71
7.5.7 Spreader chains ......................................................................................... 7:75
7.5.8 Spreader beam........................................................................................... 7:79
7.5.9 Main beam, attachment.............................................................................. 7:81
7.5.10 Position sensor, spreading ......................................................................... 7:82
7.5.12 Pipes and hoses......................................................................................... 7:84
7.5.13 Buzzer, automatic spreading 20'-40' .......................................................... 7:84

7:2 7 Suspension – Tyre pressure monitoring
7.5.14 Spreading cylinder ..................................................................................... 7:84

7.6 Rotation........................................................................................................... 7:89
7.6.5 Valve block rotation motor .......................................................................... 7:93
7.6.6 Rotation motor unit ..................................................................................... 7:93
7.6.7 Rotation yoke ............................................................................................. 7:95
7.6.8 Ring gear .................................................................................................... 7:98
7.6.9 Side shift frame .......................................................................................... 7:99
7.6.10 Sensor rotation stop ................................................................................... 7:99
7.6.11 Relief valve top lift .................................................................................... 7:100
7.6.12 Pipes and hoses....................................................................................... 7:100
7.6.14 Valve block servo pressure ...................................................................... 7:100
7.7 Tilt.................................................................................................................. 7:101
7.7.1 Hydraulic oil pump.................................................................................... 7:109
7.7.3 Damping block tilt ..................................................................................... 7:109
7.7.4 Lock valve tilt .............................................................................................7:111
7.7.5 Control valve, attachment .........................................................................7:112
7.7.7 Tilt cylinder ................................................................................................7:113
7.7.8 Lift boom....................................................................................................7:113
7.7.9 Rotation yoke ............................................................................................7:113
7.7.10 Relief valve top lift .....................................................................................7:113
7.7.11 Pipes and hoses........................................................................................7:113
7.7.14 Valve block servo pressure .......................................................................7:113
7.7.15 Sensor, tilt angle attachment.....................................................................7:114
7.8 Levelling .........................................................................................................7:117
7.8.1 Hydraulic oil pump.................................................................................... 7:121
7.8.3 Control valve, attachment ........................................................................ 7:122
7.8.5 Overcentre valve levelling ........................................................................ 7:123
7.8.6 Valve block levelling cylinders.................................................................. 7:123
7.8.7 Levelling cylinders .................................................................................... 7:124
7.8.8 Side shift frame ........................................................................................ 7:125
7.8.9 Relief valve top lift .................................................................................... 7:125
7.8.10 Pipes and hoses....................................................................................... 7:125
7.9 Load carrier ................................................................................................... 7:127
7.9.1 Twistlocks ................................................................................................. 7:127
7.9.2 Lift legs ..................................................................................................... 7:143
7.9.3 Tool changer............................................................................................. 7:170
7.10 Other functions.............................................................................................. 7:171
7.10.1 Support jacks............................................................................................ 7:171
7.10.2 Weight indicator........................................................................................ 7:179
7.10.3 Container counter..................................................................................... 7:179
7.10.4 Synchronised lift ....................................................................................... 7:179
7.10.5 Radio control ............................................................................................ 7:180
7.10.6 Indicator, eccentric load ........................................................................... 7:180

7 Load handling – Load handling 7:3
7 Load handling
Load handling, general
The load handling function means e.g. to lift, lower, rotate, tilt and se-
cure the load. Load handling also includes auxiliary functions for han-
dling loads, e.g. support jacks.
Load handling is divided into different subfunctions:
• Lifting/lowering
Lifting/lowering 015597
• Extension
015598
Extension
• Side shift
001113
Side shift
• Spreading (positioning)
30'-stop
Automatic spreading 20' - 40'
001114
Spreading (positioning)
• Rotation
Rotation stop ±25°
016202
Rotation
• Tilt
Damping
Damping with tilt lock
Damping with controllable tilt
Damping with controllable tilt and tilt lock
016203
Damping with controllable tilt, tilt lock and extended tilt function
Tilt
• Levelling ±5°
Hydraulic levelling with levelling lock
001117
Levelling

7:4 7 Load handling – Load handling
• Load securing
– Twistlocks
Overheight legs
004868
– Lift legs
– Lifting hooks
Twistlock • Other
– Support jacks
– Weight indicator
– Container counter
– Synchronised lift
– Height limitation
– LC limitation
– Speed limitation, load position
– Indicator, eccentric load
Load handling is preferably controlled using the control lever while cer-
tain functions have separate switches.

7 Load handling – Load handling 7:5
2
1
3 5 3
10, 11 9
6
9
023753
3 12
1. Sensor rotation stop 6. Sensor support jacks up
2. Sensor steering deflection (only for mini-wheel or joy- 7. Sensor support jacks down
stick control)
8. Sensor overheight legs up
3. Sensor, contact
Sensor overheight-legs down
Sensor, twistlocks (angle sensor)
9. Sensor lift legs
Sensor, contact, overheight-legs
4. Sensor spreader 10. Sensor, contact
Sensor, extra stop spreading 11. Sensor clamping position

5. Sensor, twistlocks (position sensor) 12. Sensor knee
Sensor, lifting tool

2. Check that the sensor in question is free of damage and dirt.
3. Check that the distance between the position sensor and indicator
is 4±1 mm Adjust if necessary.
A maximum distance of 1.5 mm applies for Sensor steering
deflection.

7:6 7 Load handling – Controls and instruments

7.1.1 Control lever
Control lever (Ego), description
The control lever (S8150) is used to control boom and attachment. The
lever sends voltage signals to Control unit KCU (D7901).
1 Lifting/lowering or straight lift
8 7
Lifting/lowering is controlled by moving the control lever (position 1) for-
ward (lower boom) or backward (lift boom). See Lifting/lowering, func-
2 6 tion description, page 7:17.
If the shift-button (position 6) is depressed while the control lever (posi-
tion 1) is moved forward then lowering straight down is activated (boom
3 in and lower at the same time for a vertical movement). If the shift-but-
ton (position 6) is depressed while the control lever (position 1) is pulled
4 backward then lifting straight up is activated (boom out and lift at the
same time for a vertical movement). See Synchronised lift, function de-
5 scription, page 8:25.
The signal can be checked with the diagnostic menu, see 7.1 Controls
and Instr 5/XX DIAGNOSE, page 8:53.
Extension or levelling
016846
Extension is controlled by moving the control lever (position 1) right

1. Lift, lower, boom in and boom out (whole lever) (boom out) or left (boom in). See Extension, function description, page
7:33.
2. Side shift, spreading, rotation and tilt
3. Selection of travel direction and cab movement
4. Levelling lock If the shift button (position 6) is depressed while the control lever (posi-
5. Tilt lock tion 1) is moved to the right then levelling clockwise is activated. If the
6. Alternative function (Shift button) shift button (position 6) is depressed while the control lever (position 1)
is moved to the left then levelling anticlockwise is activated. See Hy-
7. Opening the twistlocks
draulic levelling, function description, page 7:118.
8. Horn
The signal from the control lever can be checked with the diagnostic
menu, see 7.1 Controls and Instr 5/XX DIAGNOSE, page 8:53. The sig-
nal from the shift button can be checked with the diagnostic menu, see
7.1 Controls and Instr 6/XX DIAGNOSE, page 8:53.
Side shift or spreading

When the thumb joystick (position 2) is moved to the right, side shift
right is activated and when the thumb joystick (position 2) is moved to
the left, side shift left is activated. See Side shift, function description,
page 7:47.
If the shift button (position 6) is depressed in at the same time as side
shift right (position 2), spreading out is activated. If the shift button (po-
sition 6) is depressed in at the same time as side shift left (position 2),
spreading in is activated. See Spreading, function description, page
7:58.
The signal from the thumb joystick can be checked with the diagnostic

7 Load handling – Control lever 7:7
Rotation or tilt
When the thumb control (position 2) is moved backwards, rotation anti-
clockwise is activated and when the thumb control (position 2) is moved
forward, rotation clockwise is activated. See Rotation, function descrip-
tion, page 7:89.
If the shift button (position 6) is depressed at the same time as the

thumb control (position 2) is moved backwards then tilt backwards is
activated. If the shift button (position 6) is depressed at the same time
as the thumb control (position 2) is moved forwards then tilt forwards is
activated. See Tilt control, function description, page 7:104.
The signal from the thumb control can be checked with the diagnostic
Selection of travel direction or cab movement

Gear selector (S1310-2) (position 3) can be used to change travel di-
rection and select neutral position when the parking brake is released.
Move the control forward to select travel direction forwards. Move the
control backward to select travel direction backwards. Move the control
up or down to select neutral position.
The control is connected in parallel with the travel direction selector on
the steering column. The signal can be checked with the diagnostic
menu, see 2.1 Controls & Instr 6/XX DIAGNOSE, page 8:41.
If the shift button (position 6) is depressed at the same time as Gear se-
lector (S1310-2) (position 3) is moved backwards then cab movement
backwards is activated. If the shift button (position 6) is depressed at
the same time as Gear selector (S1310-2) (position 3) is moved for-
wards then cab movement forwards is activated. The function is acti-
vated with the initiation menus, see 9.10 Cab Suspension 8/XX
INITIATE, page 8:241.
Levelling lock
Switch levelling lock (S1037) (position 4) activates levelling lock. The

indicator light in the switch illuminates when levelling lock is activated.
See Levelling lock, function description, page 7:120.
Tilt lock
Switch tilt lock (S7251) (position 5) activates tilt lock. The indicator light
in the switch illuminates when tilt lock is activated. See Tilt lock, func-
tion description, page 7:102.

7:8 7 Load handling – Control lever
Shift button
Switch shift button (S1991) changes the function of other buttons on
the control lever.
If lift is activated while the shift button is depressed then synchronised
lift is activated. See Synchronised lift, function description, page 8:25.
If side shift is activated while the shift button is depressed then spread-
ing is activated. See Spreading, function description, page 7:58.
If extension is activated while the shift button is depressed then lev-
elling is activated. See Hydraulic levelling, function description, page
7:118.
If rotation is activated while the shift button is depressed then tilt
control is activated. See Tilt control, function description, page 7:104.
If selection of travel direction is activated while the shift button is de-
pressed then cab movement is activated. See Hydraulic sliding cab,
function description , page 9:107.
Opening the twistlocks

Switch open twistlocks (S1002) (position 7) opens twistlocks if the con-
ditions for this are met. See Twistlocks, function description, page
7:127.
Horn
Switch horn (S1490) (position 8) activates the horn.
Control lever (EGO), adjusting the hand grip

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

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

Control lever (EGO), replacement

2. Remove the panel's screws.
Screws
3. Turn the panel round and undo the control lever's nuts.
4. Remove the control lever from the panel.
5. Connect the new control lever in the same way as the old one.
6. Fit the new control lever on the panel.
Screws
7. Fit the upper section of the panel.
CAUTION
Exercise caution when the upper section of the panel is
fitted.
The panel may be damaged.
Position the cable harness in the panel so that the
upper section of the panel can be aligned correctly with-
out the cable harness being trapped.
Screws

7:10 7 Load handling – Control lever
Control lever (Cobra), description
The control lever is used to control boom and attachment. The lever
1 2 sends voltage signals to Control unit, cab (D7901).
3
The control lever has three or four potentiometer-controlled functions
4 and six on/off functions.
Lifting/lowering
5
7 Lifting/lowering is controlled by moving the control lever forwards (lower
boom) or backwards (lift boom). See Lifting/lowering, function descrip-
6
tion, page 7:17.
8 If the shift-button (position 8) is depressed while the control lever is

moved forwards then lowering straight down is activated (boom in and
lower at the same time for a vertical movement). If the shift-button (po-
sition 8) is depressed while the control lever (position 1) is pulled back-
wards then lifting straight up is activated (boom out and lift at the same
000442
time for a vertical movement). See Synchronised lift, function descrip-

tion, page 8:25.
1. Levelling lock (S1037)
2. Tilt lock (S7251) and Instr 5/XX DIAGNOSE, page 8:53.
3. Rotation (S8070-4)
4. Side shift right (S1990-8) Extension
5. Side shift left (S1990-3) Extension is controlled by moving the control lever right (boom out) or
6. Opening of twistlocks (S1002) upon full contact left (boom in). See Extension, function description, page 7:33.
7. Tilting (S8070-3)
8. Shift button (S1991): Changes the function of: menu, see 7.1 Controls and Instr 5/XX DIAGNOSE, page 8:53.
– side shift to spreading out (S8150T1.2) and
spreading in (S8150-T1.1), Side shift or spreading
– rotation to levelling clockwise and When switch (position 4) is pressed down, side shift right is activated,
anticlockwise,
and when switch (position 5) is pressed down, side shift left is activated.
– lift to straight lift , See Side shift, function description, page 7:47.
If the shift button (position 8) is depressed in at the same time as side
shift right (position 4), spreading out is activated. If the shift button (po-
sition 8) is depressed in at the same time as side shift left (position 5),
spreading in is activated. See Spreading, function description, page
7:58.
The signal can be checked with the diagnostic menu, see . The signal
from the shift button can be checked with the diagnostic menu, see 7.1
Controls and Instr 7/XX DIAGNOSE, page 8:53.
Rotation
When the potentiometer (position 3) is pressed down on the left-hand
side, rotation clockwise is activated, and when the right-hand side is
pressed down, rotation anticlockwise is activated. See Rotation, func-
tion description, page 7:89.
Levelling
If the shift button (position 8) is depressed at the same time as the po-
tentiometer (position 3) then levelling anticlockwise or clockwise is acti-
vated. See Hydraulic levelling, function description, page 7:118.

Tilting
When the top edge of the potentiometer (position 7) is pressed down,

tilt out is activated, and when the bottom edge is pressed down, tilt in is
activated. See Tilt control, function description, page 7:104.
The signal from the potentiometer can be checked with the diagnostic
menu, see 7.1 Controls and Instr 6/XX DIAGNOSE, page 8:53.
Opening the twistlocks
Switch open twistlocks (position 6) opens twistlocks if the conditions for
this are met. See Twistlocks, function description, page 7:127.
The signal can be checked with the diagnostic menu, see 7.9 Load Car-
rier 7/XX DIAGNOSE, page 8:69.
Tilt lock
Switch tilt lock (position 1) activates tilt lock. The indicator light in the
switch illuminates when tilt lock is activated. See Tilt lock, function de-
scription, page 7:102.
The signal can be checked with the diagnostic menu, see 7.7 Tilt 6/XX
DIAGNOSE, page 8:65.
Levelling lock
Switch levelling lock (position 2) activates levelling lock. The indicator

light in the switch illuminates when levelling lock is activated. See Lev-
elling lock, function description, page 7:120.
The signal can be checked with the diagnostic menu, see 7.8 Levelling
Shift button
The shift button changes the function of other buttons on the control
lever.
• If side shift is activated while the shift button is depressed then
spreading is activated. See Spreading, function description, page
7:58.
• If lift is activated at the same time as the shift-button is pressed
in, straight lift is activated if the machine is equipped with this op-
tion. See Synchronised lift, function description, page 8:25.
• If rotation is activated while the shift button is depressed then level-
ling is activated. See Hydraulic levelling, function description, page
7:118.
Control lever (Cobra), replacement

3. Turn the panel round and undo the control lever's attaching bolts.
4. Unplug the connector from the control lever.
5. Remove the control lever from the panel.
6. Fit the new control lever on the panel.

7:12 7 Load handling – Switch lock twistlocks
7. Plug the connector into the control lever.

8. Fit the upper section of the panel.
CAUTION
fitted.
7.1.2 Switch lock twistlocks

Switch lock twistlocks, description
Switch lock twistlocks (S1003) controls locking the twistlocks. The
switch has three positions: two fixed and one spring-loaded with the fol-
lowing functions.
1. Manual locking of twistlocks at full contact (spring-loaded).
015587
1 0 2
0. Twistlocks open (off).
2. Automatic locking of the twistlocks at full contact and released
parking brake.
Twistlocks are opened with the switch on the control lever, see Control
lever (Ego), description, page 7:6.
The switch is supplied with voltage by, and sends a voltage signals to
Control unit (D7902).
Switch right-hand dashboard panel centre section,

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

7 Load handling – Switch, automatic spreading 7:13
4. Detach the connector from the switch.

5. Replace the switch.
CAUTION
fitted.
7.1.3 Switch, automatic spreading

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

When the switch is in position 1, spreading automatically moves to the
next position (20, 30 or 40 feet) if spreading is activated with the control
015593
0 1
lever. This is on condition that the parking brake is released and the
doors are closed.
The switch is supplied with voltage from, and sends a voltage signal to
Control unit (D7902) when the switch is activated.
The signal can be checked with the diagnostic menu, see 7.5 Spread-
ing 7/XX DIAGNOSE, page 8:60.
WARNING
Risk of crushing and damage to the product!
Automatic spreading is stopped by activating spreading
in the opposite direction, or by deactivating the function
with the switch, or by applying the parking brake.

replacement
See Switch right-hand dashboard panel centre section, replacement,
page 7:12.
7.1.5 Switch, extra stop spreading

Switch, extra stop spreading, description
Switch, extra stop spreading (S1004) activates extra stop for the
spreading function. When the switch is in position 1, the function for
015590
spreading is changed from 20'–40' to extra stop (normally at 30' or 35').

0 1
If the switch for automatic spreading (S1012-2) is activated at the same
time as this switch then the function is changed to automatic stop at the
next extra stop.

7:14 7 Load handling – Switch support jacks

replacement
page 7:12.
7.1.6 Switch support jacks

Switch support jacks, description
Switch support jacks (S1013) controls the support jacks. The switch
has three positions: one fixed and two spring-loaded with the following
015594
functions.
1 0 2
1. Lower support jacks (spring-loaded). This is on condition that the
parking brake is released and the doors are closed.
0. Legs stationary.
2. Raise support jacks (spring-loaded). This is on condition that the
parking brake is released and the doors are closed.
Switch right-hand dashboard panel front section,

replacement
See Switch right-hand dashboard panel front section, replacement,
page 9:10.
7.1.7 Switch lowering front legs

Switch lowering front legs, description
Switch lowering front legs (S1006-FR) controls the front leg pair on the
bottom lift attachment. The switch has three positions; one fixed and
015584
two spring-loaded with the following functions.

1 0 2
1. Lower legs (spring-loaded).
0. Legs stationary.
2. Raise legs (spring-loaded).

replacement
page 7:12.

7 Load handling – Switch lowering rear legs 7:15
7.1.8 Switch lowering rear legs

Switch lowering rear legs, description
Switch lowering rear legs (S1006-RE) controls the rear leg pair on the
bottom lift attachment. The switch has three positions; one fixed and
015585
two spring-loaded with the following functions.
1 0 2
0. Legs stationary.

replacement
page 7:12.
7.1.9 Switch clamp/release legs

Switch clamp/release legs, description
Switch clamp/release legs (S1008) controls the clamping position for

the leg pairs on the bottom lift attachment. The switch has three posi-
tions; one fixed and two spring-loaded with the following functions.
015588
1 0 2
1. Leg pair open (spring-loaded).
0. Legs stationary.
2. Leg pair closed (spring-loaded).

replacement
page 7:12.
7.1.31 Switch overheight-legs

Switch overheight-legs, description
Switch overheight-legs (S1031) controls the extension legs on the top

lift attachment with overheight-legs. The switch has three positions;
015589
one fixed and two spring-loaded with the following functions.

1 0 2
0. Legs stationary.

7:16 7 Load handling – Switch overheight-legs

replacement
page 7:12.

7 Load handling – Lifting/lowering 7:17
7.2 Lifting/lowering
Lifting/lowering, description
Lifting/lowering means angling the boom up and down so that the at-
tachment is lifted and lowered. The lift boom is angled by two lift cylin-
ders, which are pressurised by Control valve lift, lower and extension.
The lift function is controlled by Control lever (S8150).
Damping
015597
Damping means that the speed of functions is reduced automatically
approaching the end positions. This means that the mechanics are
loaded less when stopping in the end positions.
Angle sensors detect when damping should be activated. When damp-
ing is activated, Control unit KFU (D7971) reduces the control current
to the solenoid valve for the function in question.
As an option, the machine can be equipped with a sensor on the at-

tachment which activates damping before the attachment reaches the
container during lowering.
Regeneration
To increase the speed during lift, oil from the rod side (2) is re-used for
1 2 the piston side (1), this is called regeneration. Engagement of regener-
ation is controlled by the control system.
000455
Lifting/lowering, function description

Control breaker Disengaged Control breaker voltage, function description,
page 11:20
Sensor, operator-in-seat Not activated (operator in seat) Sensor operator in seat, description, page 9:25
Twistlocks Locked or unlocked, not intermediate position Twistlocks, description, page 7:138
(can be bypassed)
Overload system Boom up: passive Overload system, description, page 8:5
Boom down: passive or bypass activated Bypass, description, page 8:6
Contact Boom down: no contact Twistlocks, function description, page 7:127
Height limitation Bypassed or boom height lower than height Height limitation, description, page 8:7
limitation.
Combi attachment Boom up: Approved lift (contact within time -
limit)
Doors Machine with vertically adjustable cab: Doors, description, page 9:102
Boom up: Doors closed when cab in lower
position.
Boom down: Doors closed when cab is raised.
ECO Drive Mode Depending on setting, pumps and engine -
speed are controlled at different rotation
speeds.

7:18 7 Load handling – Lifting/lowering
D1
1 1
2
D7902
D7971 D7911
3, 7, 17, 22, 29, 30 28
5, 32
D7940 D7
D26 D27
D21
D7930 8 8 D17 18 23 26 27
4, 6, 31, 33 D22
PSS PSL
Pa 20,
P C-M
9 VA 25,
16
15 PP
C- 34
D
C+
LS P T
LSP1 A H
C+M Pa
LSPR
LSP2
10, 814 21
LSHY 19, 24
LSP3
35 LSO
PT T P LSM 16
13
C11
C12
36
022678
11 12

1 Control lever (S8150-R8070-1) sends a Lower: UR8070-1 = 0.5–2.0 V Control lever (Ego), description, page
voltage signal to Control unit KPU (D7902) Zero position: UR8070-1 = 2.0– 7:6
proportional to lever movement. 3.0 V D1: Diagnostic menu, see 7.1 Con-
Lift: UR8070-1 = 3.0–4.5 V trols and Instr 5/XX DIAGNOSE, page
0.5 V is the fastest lowering 8:53
speed and 4.5 V is the fastest
lift speed. Lower voltage than
0.5 V and higher voltage than
4.5 V is used to detect faults in
cable harnesses and controls.
1 Control lever (S8150-P2) sends a voltage Lower: US8150/P2 = 0.5–2.0 V Control lever (Cobra), description,
signal to Control unit KPU (D7902) propor- Zero position: US8150/P2 = 2.0– page 7:10
tional to lever movement. 3.0 V D1: Diagnostic menu, see 7.1 Con-
Lift: US8150/P2 = 3.0–4.5 V trols and Instr 5/XX DIAGNOSE, page
0.5 V is the fastest lowering 8:53
lift speed. Lower voltage than
0.5 V and higher voltage than
4.5 V is used to detect faults in
cable harnesses and controls.
2 Control unit KPU (D7902) sends a request Checked by control system, er- 11.5.3.2 KPU control unit (D7902),
for Boom up or Boom down with informa- ror shown with error code. page 11:30
tion on lever deflection on the CAN bus.
3 Control unit KFU (D7971) sends a request Checked by control system, er- 11.5.3.1 KCU control unit (D7901),
for engine speed requirement CAN bus ror shown with error code. page 11:27
drive-train based on information on lever
deflection.
4 Control unit transmission (D7930) sends a Checked by control system, er- Transmission, function description,
rotation speed request on CAN bus drive- ror shown with error code. page 2:3
train to Control unit engine (D7940).
5 Control unit, engine (D7940) increases the Checked by control system, er- 11.5.3.6 Control unit, engine (D7940),
engine speed. ror shown with error code. page 11:38

7 Load handling – Lifting/lowering 7:19

6 Control unit transmission (D7930) controls Checked by control system, er- Transmission, function description,
the ratio between drive and power take-off ror shown with error code. page 2:3
by changing the transmission's gear ratio.
7 Control unit KFU (D7971) activates Sole- I = 320–650 mA 11.5.3.4 Control unit KFU (D7971),
noid valve lift (Y6005) or Solenoid valve page 11:34
lower (Y6004). D7: Diagnostic menu, see 7.2 Lifting
Maximum current is adapted according to Lowering 6/XX DIAGNOSE, page
engine capacity (Electric Load Limit 8:56 or 7.2 Lifting Lowering 7/XX DI-
Control). AGNOSE, page 8:56
8 Solenoid valve lift (Y6005) or Solenoid - 7.2.5 Control valve lift, lower and ex-
valve lower (Y6004) pressurises the con- tension, page 7:23
trol valve's lift slide with servo pressure. D7: Diagnostic menu, 7.2 Lifting Low-
ering 6/XX DIAGNOSE, page 8:56
and 7.2 Lifting Lowering 7/XX DIAG-
NOSE, page 8:56
9 The control valve's lift slide changes posi- - 7.2.5 Control valve lift, lower and ex-
tion and pressurises Valve block, lift cylin- tension, page 7:23
der, and sends a load signal to Valve block,
servo pressure.
10 Valve block, servo pressure, distributes - Valve block servo pressure, descrip-
the load signal to hydraulic oil pump 1 and tion, page 10:25
2. Shuttle valves in the servo valve select
the strongest load signal if other functions
are activated at the same time.
11 Hydraulic oil pump 2 pumps oil from the See the pressure plate on the Axial piston pump with variable dis-
hydraulic oil tank to Control valve, lifting/ left-hand frame beam. placement, description, page 10:8
lowering and extension.
12 Hydraulic oil pump 1 pumps oil from the See the pressure plate on the Axial piston pump with variable dis-
hydraulic oil tank to Valve block, servo left-hand frame beam. placement, description, page 10:8
pressure, via the servo filter.
13 The servo filter cleans the servo oil before - Servo filter, description, page 7:22
Valve block, servo pressure.
14 The pressure reducer in Valve block, servo See the pressure plate on the Valve block servo pressure, descrip-
pressure, reduces the oil pressure to the left-hand frame beam. tion, page 10:25
servo pressure for the control valve.
15 The accumulator stores servo pressure. See the pressure plate on the Accumulator servo circuit, description,
The non-return valve in the pressure re- left-hand frame beam. page 10:31
ducer makes it possible to store the pres-
sure when the engine is switched off.
16 High-pressure filter - Hydraulic oil filter, description (high-
On machines with high-pressure filter, the pressure filter), page 10:43
oil is cleaned after the hydraulic oil pumps.
17 Boom down U = 24 V 11.5.3.4 Control unit KFU (D7971),
Control unit KFU (D7971) activates Sole- page 11:34
noid valve blocking right (Y6045-RI) and D17: Diagnostic menu, see 7.2 Lifting
Solenoid valve blocking left (Y6045-LE). Lowering 8/XX DIAGNOSE, page
8:57
18 Boom down - Valve block lift cylinder, description,
Solenoid valve blocking right (Y6045-RI) page 7:24
and Solenoid valve blocking left (Y6045- D17: Diagnostic menu, see 7.2 Lifting
LE) act on the blocking valves in the valve Lowering 8/XX DIAGNOSE, page
blocks for the left and right-hand lift cylin- 8:57
der respectively.

7:20 7 Load handling – Lifting/lowering

19 Boom up - Valve block lift cylinder, description,
The blocking valves in the valve blocks for page 7:24
left and right-hand lift cylinder respectively
are opened by the hydraulic pressure from
the control valve.
Boom down
The blocking valve is opened so that the
pressure from the lift cylinder can be
released.
20 The lift cylinders' piston side is pressurised - Lift cylinder, description, page 7:26
and the boom is lifted.
21 Regeneration U=5V Sensor hydraulic pressure lift cylinder,
Sensor, hydraulic pressure lift cylinder, pis- U=0V description, page 8:15
ton side left (B7226-1) sends a voltage sig- U = 0.5-4.5 V D21: Diagnostic menu, see 8.2 Moni-
nal to Control unit KFU (D7971) Regeneration is activated toring 17/XX DIAGNOSE, page 8:104
proportional to the oil pressure. when the pressure in the lift
cylinders is 8.5 MPa. Regener-
ation is stopped if the pressure
NOTE reaches 18.5 MPa.
Regeneration is not possible near end-
position or in case of overload.
22 Control unit KFU (D7971) activates Sole- U = 24 V 11.5.3.4 Control unit KFU (D7971),
noid valve, regeneration right (Y6051-LE) page 11:34
and Solenoid valve, regeneration left D22: Diagnostic menu, see 7.2 Lifting
(Y6051-RI) if the pressure is sufficiently Lowering 9/XX DIAGNOSE, page
low for regeneration. 8:57
23 Solenoid valve regeneration right (Y6051- - Valve block lift cylinder, description,
LE) and Solenoid valve regeneration left page 7:24
(Y6051-RI) pressurise the regeneration D22: Diagnostic menu, see 7.2 Lifting
valve. Lowering 9/XX DIAGNOSE, page
8:57
24 The regeneration valve changes position - Valve block lift cylinder, description,
and leads oil from the rod side of the lift page 7:24
cylinder to the piston side.
25 Lift speed increases. - -
26 Damping Checked by control system, er- Sensor boom angle, description, page
When the boom is approx. 4° from an end- ror shown with error code. 8:17
position, damping is activated. D26: Diagnostic menu, see 8.2 Moni-
Sensor, boom angle (B7241) sends volt- toring 16/XX DIAGNOSE, page 8:103
age signals proportional to the boom angle
to Control unit KFU (D7971) requesting
damping on the CAN bus.
27 Damping, load Checked by control system, er- Sensor damping attachment, descrip-
Damping is activated when the attachment ror shown with error code. tion, page 7:31
approaches the load. D27: Diagnostic menu, see 7.9 Load
Ultrasonic sensor (B7230) sends a voltage Carrier 78/XX DIAGNOSE, page 8:88
signal proportional to the distance to the
load to Control unit KAU (D7911).
28 Control unit KAU (D7911) requests damp- 11.5.3.8 Control unit KAU (D7911),
ing on the CAN bus when a predetermined page 11:40
distance is detected.
29 Control unit KFU (D7971) reduces the con- - 11.5.3.4 Control unit KFU (D7971),
trol current to Solenoid valve lower page 11:34
(Y6004) or Solenoid valve boom in
(Y6007).
30 Control unit KFU (D7971) sends a request Checked by control system, er- 11.5.3.4 Control unit KFU (D7971),
for reduced engine speed requirement ror shown with error code. page 11:34
CAN bus drive-train based on information
on lever deflection.

7 Load handling – Hydraulic oil pump 7:21

31 Control unit transmission (D7930) sends a Checked by control system, er- Transmission, function description,
rotation speed request on CAN bus drive- ror shown with error code. page 2:3
train to Control unit engine (D7940).
32 Control unit, engine (D7940) reduces the Checked by control system, er- 11.5.3.6 Control unit, engine (D7940),
engine speed. ror shown with error code. page 11:38
33 Control unit transmission (D7930) controls Checked by control system, er- Transmission, function description,
the ratio between drive and power take-off ror shown with error code. page 2:3
by changing the transmission's gear ratio.
34 Lift speed decreases. - Valve block lift cylinder, description,
page 7:24
35 If the feed pressure for Control valve lift, Opening pressure: 25 MPa Pressure limiting valve, description,
lower and extension, becomes too high, page 10:5
the pressure relief valve opens and directs
pressure to the hydraulic oil tank.
36 The return oil from the lift cylinders is - Hydraulic oil filter, description, page
cleaned by the hydraulic oil filters in the 10:42
hydraulic oil tank.

chine, page E:6.
Lowering speed, checking
DANGER
The lowering speed must be correct. If lowering speed
is too fast, there is a risk of tipping forward.
Extreme danger!
The machine must absolutely not be taken into service
before the lowering speed is verified after repair work
on functions or components that affect the lowering
function.
1. Operate the machine and hydraulics until the hydraulic oil reaches
0:00pm
the operating temperature of 50 °C.
a
75°C 50% 2. Lift a container weighing 35-45 tonnes.
b c 3. Move the machine away to a level and a safe place.
50°C 50°C NOTE

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

gradient.
4. Fully retract the extension and lift the boom to maximum angle.
b. Oil temperature hydraulic system 5. Note the time for how long it takes to lower from top position until
damping is activated.
Lowering should take 23–28 seconds.
6. If the time is not correct then contact Cargotec for further
instructions.

See Axial piston pump with variable displacement, description, page
10:8.

7:22 7 Load handling – Servo filter
7.2.2 Servo filter

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

Accumulator servo circuit, general
See Accumulator servo circuit, description, page 10:31.

7 Load handling – Control valve lift, lower and extension 7:23
7.2.5 Control valve lift, lower and extension

Control valve lift, lower, and extension, description
The control valve controls the speed and direction of lift and extension.
The control valve is fitted on a bracket in the space between the lifting
1 beam and front axle.
The valve has two sections, one for the lift function and one for boom
9 2 extension. The sections have many similarities, but are described sep-
arately under the respective function. For extension, see 7.3.5 Control
valve lift, lower and extension, page 7:38. Electric servo valves control
8 3 the flow from the valve.
The control valve is a proportional valve controlled by servo valves.
7 4 This means that both volume and direction of the flow from the valve
can be adjusted and that the valve also sends control signals to the var-
6 5 iable pumps.
Electrically controlled pressure reducing valves (servo valves) convert
electric current into a low hydraulic pressure that is proportional to the
current, so-called servo pressure. The servo pressure acts on the
spring-centred control slide in the control valve for the function in ques-
tion and thereby controls the main flow.
016839
The speed of the function is controlled by means of the flow being regu-
lated in proportion to the lever movement.
1. Connection, rod side, extension cylinder [B1]
2. Solenoid valve, boom out (Y6006) Lift slide
3. Solenoid valve, lift (Y6005) The lift slide controls the direction and flow of the oil to the lift cylinder.
4. Connection, rod side, right lift cylinder [B2]
5. Connection, piston side, right lift cylinder [A2] Servo valve, lift
6. Solenoid valve, lower (Y6004) Servo valve, lift controls servo pressure to the lift slide so that it controls
7. Solenoid valve, boom in (Y6007) oil pressure for lifting. The valve is controlled electrically with Solenoid
8. Connection, feed from hydraulic oil pumps [P] valve, lift (Y6005), which is activated by Control unit KFU (D7971).
9. Connection, piston side, extension cylinder [A1] The signals can be checked with the diagnostic menu, see 7.2 Lifting
Lowering 6/XX DIAGNOSE, page 8:56.
Servo valve, lower

Servo valve, lower, controls servo pressure to the lift slide so that it con-
trols oil pressure for lowering. The valve is controlled electrically with
Solenoid valve, lower (Y6004), which is activated by Control unit KFU
(D7971).
The signals can be checked with the diagnostic menu, see 7.2 Lifting
Control valve lift, lower, and extension, changing
DANGER
The lowering speed must be correct. If lowering speed
is too fast, there is a risk of tipping forward.
Extreme danger!
The machine must absolutely not be taken into service
before the lowering speed is verified after repair work
on functions or components that affect the lowering
function.
After replacing Control valve lift, lower, and extension, or parts of the
valve, lowering speed must be checked. See Lowering speed, check-
ing, page 7:21.

7:24 7 Load handling – Valve block lift cylinder
7.2.7 Valve block lift cylinder

Valve block lift cylinder, description
Valve block lift cylinder directs oil to the lift cylinder and is bolted directly
1 2 3 on the lower part of the lift cylinder. The valve block contains the block-
ing valve, regeneration valve, non-return valve and shock valve.
Blocking valve
4 The blocking valve prevents unwanted lowering and angling of the lift
8
cylinders. The blocking valve holds the load by ensuring that the con-
nection to the lift cylinder's piston side is closed. (The pressure travels
5 through a restriction as blocking pressure and holds the valve slide
closed.)
7
6 Solenoid valve blocking acts on the blocking valve. The servo valve is
controlled electrically with Solenoid valve blocking left (Y6045-LE) and
Solenoid valve blocking right (Y6045-RI), activated by Control unit KFU
(D7971).
The signal can be checked with the diagnostic menu, see 7.2 Lifting
Regeneration valve
016900
The regeneration valve directs oil from the rod side of the cylinder back
to the piston side. This allows the oil to be re-used during lifting. For
1. Connection, rod side, lift cylinder [C-] more information on regeneration, see Lifting/lowering, function de-
2. Connection tank [T] scription, page 7:17. The regeneration valve is regulated by servo valve
3. Connection, pressure feed [VA] regeneration.
4. Sensor hydraulic pressure lift cylinder piston side
Solenoid valve regeneration acts on the regeneration valve. The servo
(B7226-1 or B7226-2) [C+M]
valve is controlled electrically with Solenoid valve regeneration left
5. Draining servo valves [D]
(Y6051-LE) and Solenoid valve regeneration right (Y6051-RI), acti-
6. Solenoid valve blocking (Y6045-LE or Y6045-RI) vated by Control unit KFU (D7971).
7. Sensor hydraulic pressure lift cylinder rod side
(B7226-3 or B7226-4) [C-M] The signal can be checked with the diagnostic menu, see 7.2 Lifting
8. Solenoid valve regeneration (Y6051-LE or Lowering 9/XX DIAGNOSE, page 8:57.
Y6051-RI)
Shock valve
The shock valve protects the hydraulic system against pressure surges
which can occur when operating with a load. The shock valve opens a
connection between the lift cylinder's piston side and the tank if the
pressure becomes too high.
Non-return valve
The non-return valve prevents oil from flowing the wrong way during
regeneration.
Valve block lift cylinder, changing
NOTE
Safety.

NOTE

7 Load handling – Valve block lift cylinder 7:25
2 4. Mark and disconnect the cable harness from the valve block.
1 3
Remove the cable harness's clamping at the valve block.
5. Mark up and detach the hydraulic hoses from the valve block.
4 NOTE
8
from impurities.
5
7
6
016900
1. Connection, rod side, lift cylinder [C-]

2. Connection tank [T]
3. Connection, pressure feed [VA]
4. Sensor hydraulic pressure lift cylinder piston side
(B7226-1 or B7226-2) [C+M]
5. Draining servo valves [D]
6. Solenoid valve blocking (Y6045-LE or Y6045-RI)
7. Sensor hydraulic pressure lift cylinder rod side
(B7226-3 or B7226-4) [C-M]
8. Solenoid valve regeneration (Y6051-LE or
Y6051-RI)
6. Remove the valve block from the lift cylinder.
Remove the attaching bolts and lift away the valve block.
7. Transfer the connection adapters, sensors, and servo valves to the
new valve block.
NOTE
correctly.
NOTE
016927

mixed up.
8. Fit a new valve block to the lift cylinder.
NOTE
correctly.

7:26 7 Load handling – Lift cylinder
9. Connect the hydraulic hoses to the valve block according to the

marking.
NOTE
correctly.
10. Connect the cable harness to the valve block according to the
marking.
Clamp the cable harness as before.
hydraulic system.
NOTE
016901 Check that the accumulator drain valve is fully closed and tighten
the lock ring.
12. Turn on the main electric power and start the engine.
13. Activate the lift carefully.
CAUTION
product damage.
Activate the functions carefully and operate at the low-
est possible speed a couple of times to avoid cavitation.

manual.
16. Check the lowering speed, see Lowering speed, checking, page
7:21.
7.2.8 Lift cylinder

Lift cylinder, description
The lift cylinders lift and lower (angle) the lift boom. The lift cylinders
are fitted between boom and frame in the front edge of the machine,
one on the right and one on the left-hand side.
A valve block that controls pressurising and regeneration of the lift cyl-
inder is installed on each lift cylinder.
The lift cylinder is equipped with guide bearings both in the cylinder end
and the piston rod mounting. The piston rod mounting is threaded in
the piston rod and locked with a lock nut.
The lift cylinders are connected in parallel and are supplied from the
control valve for lift, lower, and extension, see 7.2.5 Control valve lift,
lower and extension, page 7:23.
001096

7 Load handling – Lift cylinder 7:27
Lift cylinder, changing
DANGER
A lift cylinder weighs approx. 2 tonnes.
Extreme danger!
Exercise caution when handling so that personal injury
and equipment damage are avoided.
WARNING
The boom may move when the pins are removed.
Risk of personal injury!
Make sure that the shafts are unloaded. Stand to the
side of the boom mounting so that it provides protec-
tion in the event of any movement.
CAUTION
The boom may drop.
Be certain to compensate for the lift cylinder's support
of the boom by lifting the boom's leading edge with the
lifting equipment.
1. Move the cab into the front position.

NOTE
4. Connect lifting equipment at the front edge of the boom.
5. Lift the boom at the front edge so that the bearings on the lift cylin-
ders are unloaded.

7:28 7 Load handling – Lift cylinder
6. Mark and release the hydraulic hoses and the cable harness from
Valve block lift cylinder.
016901
7. Connect the lifting equipment to the lift cylinder.
8. Remove the upper pin for the lift cylinder.

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

7 Load handling – Sensor, hydraulic pressure lift cylinder 7:29
12. Transfer Valve block lift cylinder to the new lift cylinder.
NOTE
correctly.
13. Lift the new lift cylinder into place.

14. Install the pins for the lift cylinder. Lubricate the shaft with a thin
layer of aluminium paste, exercise caution so that the aluminium
paste does not come into contact with the slide surface of the
bearings in the lift cylinder.
CAUTION
The bearings are lubricant-free and must not be
lubricated.
Product damage.
The slide surface of the bearings is specially treated
and must not be lubricated. When fitting the shafts, ex-
ercise additional caution and ensure that the lubricant
does not come into contact with the slide surface of the
bearings. After assembly, apply anti-corrosion protec-
tion to the bearings externally with a thin layer of Teflon
spray.
15. Connect the hydraulic hoses and the cable harness to Valve block
lift cylinder in accordance with the marking.
hydraulic system.
NOTE
the lock ring.
18. Carefully activate the lift function.
CAUTION
016901

product damage.

manual.
7:21.

7.2.9 Sensor, hydraulic pressure lift cylinder

Sensor hydraulic pressure lift cylinder, general
See Sensor hydraulic pressure lift cylinder, description, page 8:15.

7:30 7 Load handling – Lift boom
7.2.10 Lift boom

Lift boom, description
The lift boom lifts the load. The rear section of the boom is secured into
the frame with two bearing-mounted shafts. Fitted in the front edge is
the lift attachment and in the centre on each side of the boom are lift
cylinders which are secured with bearing-mounted shafts. The lift cylin-
ders angle the boom, and in this way raise the front section of the
boom. The lift boom is available in several versions depending on
reach and load capacity.
The boom consists of an outer boom and an inner boom manufactured
in high-strength steel with a minimum number of welds for maximum
strength.
The inner boom runs in the outer boom and can be extended longitudi-
nally with the extension cylinder. There are slide plates between inner
boom and outer boom that reduce the friction between inner boom and
outer boom. The slide plates are fitted in the front edge of the outer
boom and the rear edge of the inner boom.
Running along the left side is a cable chain for hydraulic hoses and ca-
bles between outer and inner boom.
1 2
001239
9 8 7 8 6 5 4 3
1. Outer boom
2. Inner boom
3. Tilt cylinder right side
4. Mounting attachment
5. Tilt cylinder left side
6. Extension cylinder
7. Lift cylinder
8. Mounting lift cylinder
9. Rear boom mounting
7.2.11 Sensor boom angle

Sensor boom angle, general
See Sensor boom angle, description, page 8:17.

Pipes and hoses, general

7 Load handling – Sensor damping attachment 7:31
7.2.16 Sensor damping attachment

Sensor damping attachment, description
Sensor damping attachment (B7230) is an ultrasonic sensor which

measures the distance to the load under the attachment. The sensor is
located on the lower edge in the centre of the attachment's side shift
frame.
The sensor is supplied with voltage by, and sends a voltage signal pro-
portional to the distance to the object under the attachment to Control
unit KAU (D7911).
Sensor damping attachment, replacement

2. Switch off the battery voltage with the battery disconnector.
3. Disconnect the wiring from the sensor, note how the wiring is
routed.
4. Replace sensor.
5. Connect the wiring to the sensor and route in the same way as it
was before.
6. Turn on the main electric power and start the machine.
7. Calibrate the sensor, see Sensor damping attachment, calibration,
page 7:31.
Sensor damping attachment, calibration
1. Machine parked with attachment fully lowered against a container

(full contact), engine idling.
10:23
CUSTOMER SETTINGS
0
014981

10:23
.

0 0
015625

7:32 7 Load handling – Valve block servo pressure
4. Select 7. LOAD HANDLING by scrolling with or and confirm

with .
7. LOAD HANDLING
018351
5. Select 7.9 Load Carrier by scrolling with or and confirm with
* 7. LOAD HANDLING * .

7.2 Lifting & Lowering
7.3 Extension
7.4 Side Shift
7.5 Spreading
7.6 Rotation
7.7 Tilt
7.8 Levelling
7.9 Load Carrier
019139

* 7. LOAD HANDLING *
7.3 Extension
7.4 Side Shift
7.5 Spreading
7.6 Rotation
7.7 Tilt
7.8 Levelling
7.9 Load Carrier
018353
7. Scroll to menu 1 Attachment lower auto damp with or .

8. When the attachment has full contact against the container, save
the signal value with .
9. Lift the attachment so that the distance between the contact sur-
face at the twistlocks on the attachment and the container is 1000
– 1500 mm.
10. Scroll to menu 2 Attachment lower auto damp with or .

11. When the distance is correct, save the signal value with .
12. Measure the distance between the contact surface at the twist-
locks on the attachment and the container. Check that the meas-
ured value corresponds with the row Height from calibration point
1.
If the value does not correspond, repeat the calibration.
7.2.17 Valve block servo pressure

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

7 Load handling – Extension 7:33
7.3 Extension
Extension, description
Extension means sliding the inner boom in and out of the outer boom.
The inner boom is slid in and out of the extension cylinder, which is
pressurised by Control valve lift, lower and extension. Extension is con-
trolled by Control lever (S8150).
Damping
015598
Length sensors detect when damping should be activated. When
damping is activated the relevant control unit reduces the control cur-
rent to the solenoid valve for the function in question.
Regeneration
To increase the speed during extension, oil from the rod side (2) is re-
1 2 used for the piston side (1), this is called regeneration. Engagement of
regeneration is controlled by the control system.
000455
Extension, function description

Control breaker Disengaged Control breaker voltage, function description, page 11:20
Sensor, operator-in-seat Not activated (operator in Sensor operator in seat, description, page 9:25
seat)
Overload system Boom out: passive Overload system, description, page 8:5
Load centre limitation Bypassed or the attachment is Load centre limitation, description, page 8:7
within the limit for the load
centre limitation.
Bypassed or boom height low- Height limitation, description, page 8:7
Height limitation er than height limitation.
ECO Drive Mode Depending on setting, pumps -

and engine speed are con-
trolled at different rotation
speeds.

7:34 7 Load handling – Extension
1 1 D1
2
D7902
Pa 21
D7971 D7911
3, 7, 17, 22, 23, 28, 29 D21
D27
5, 31
D7940 D23 m 27
8 D8 8 D17 18 24
D7930 D7
PSS PSL
P
4, 6, 30, 32 A1 VA
13 11 9
16 PP B1
C-
VB
C+
A LS P T
LSP1 H
LSPR 19, 25 20, 26, 33
LSP2
10, 815 LSHY
LSP3
34 LSO
PT T P LSM 13
14
C12
C12
35
022679
12 12

1 Control lever (S8150-R8070-2) sends Boom in: UR8070-2 = 0.5–2.0 V Control lever (Ego), description, page 7:6
a voltage signal to Control unit KPU Zero position: UR8070-2 = 2.0– D1: Diagnostic menu, see 7.1 Controls and
(D7902) proportional to lever 3.0 V Instr 5/XX DIAGNOSE, page 8:53
movement. Boom out: UR8070-2 = 3.0–4.5
V
0.5 V is the fastest retraction
extension speed. Lower volt-
age than 0.5 V and higher volt-
age than 4.5 V is used to
detect faults in cable har-
nesses and controls.
1 Control lever (S8150-P1) sends a volt- Boom in: US8150/P1 = 0.5–2.0 V Control lever (Cobra), description, page
age signal to Control unit KPU Zero position: US8150/P1 = 2.0– 7:10
(D7902) proportional to lever 3.0 V D1: Diagnostic menu, see 7.1 Controls and
movement. Boom out: US8150/P1 = 3.0–4.5 Instr 5/XX DIAGNOSE, page 8:53
V
0.5 V is the fastest retraction
extension speed. Lower volt-
age than 0.5 V and higher volt-
age than 4.5 V is used to
detect faults in cable har-
nesses and controls.
2 Control unit KPU (D7902) sends re- Checked by control system, 11.5.3.2 KPU control unit (D7902), page
quest for Boom out or Boom in with error shown with error code. 11:30
the speed information on the CAN bus.
3 Control unit KFU (D7971) sends a re- Checked by control system, 11.5.3.1 KCU control unit (D7901), page
quest for engine speed requirement error shown with error code. 11:27
CAN bus drive-train based on informa-
tion on lever deflection.

7 Load handling – Extension 7:35

4 Control unit transmission (D7930) Checked by control system, Transmission, function description, page
sends a rotation speed request on error shown with error code. 2:3
CAN bus drive-train to Control unit en-
gine (D7940).
5 Control unit, engine (D7940) in- Checked by control system, 11.5.3.6 Control unit, engine (D7940), page
creases the engine speed. error shown with error code. 11:38
controls the ratio between drive and error shown with error code. 2:3
power take-off by changing the trans-
mission's gear ratio.
7 Boom out I = 360-650 mA 11.5.3.4 Control unit KFU (D7971), page
Control unit KFU (D7971) activates 11:34
Solenoid valve boom out (Y6006). D8: Diagnostic menu, see 7.3 Extension 1/
Maximum current is adapted accord- XX DIAGNOSE, page 8:57
ing to engine capacity (Electric Load
Limit Control).
Boom in 11.5.3.4 Control unit KFU (D7971), page
Solenoid valve pump unloading D7: Diagnostic menu, see 10.4 Pumps 2/XX
(Y6093) and Solenoid valve boom in DIAGNOSE, page 8:134
(Y6007). D8: Diagnostic menu, see 7.3 Extension 2/
8 Boom out - 7.2.5 Control valve lift, lower and extension,
Solenoid valve boom out (Y6006) page 7:23
pressurises the control valve's exten- D8: Diagnostic menu, see 7.3 Extension 1/
sion slide with servo pressure. XX DIAGNOSE, page 8:57.
Boom in
Solenoid valve boom in (Y6007) pres-
surises the control valve's extension
slide with servo pressure.
9 The control valve's extension slide - 7.2.5 Control valve lift, lower and extension,
changes position and pressurises page 7:23
Valve block extension cylinder and
sends a load signal to Valve block ser-
vo pressure.
10 Valve block, servo pressure, distrib- - Valve block servo pressure, description,
utes the load signal to hydraulic oil page 10:25
pump 1 and 2. Shuttle valves in the
servo valves select the strongest load
signal if other functions are activated
at the same time.
11 Boom in - Solenoid valve pump unloading, description,
Solenoid valve pump unloading page 10:25
(Y6093) opens and drains the load D5: Diagnostic menu, see 10.4 Pumps 2/XX
signal to hydraulic oil pump 2 to the DIAGNOSE, page 8:134
tank, so that only hydraulic oil pump 1
generates pressure.
12 Boom out See the pressure plate on the Axial piston pump with variable displace-
Hydraulic oil pump 1 and 2 pump oil left-hand frame beam. ment, description, page 10:8
from the hydraulic oil tank.
Boom in
Hydraulic oil pump 1 pumps oil from
the hydraulic oil tank.
13 High-pressure filter - Hydraulic oil filter, description (high-pres-
On machines with high-pressure filter, sure filter), page 10:43
the oil is cleaned after the hydraulic oil
pumps.
14 The servo filter cleans the servo oil be- - Servo filter, description, page 7:22
fore Valve block, servo pressure.

7:36 7 Load handling – Extension

15 The pressure reducer in Valve block See the pressure plate on the Valve block servo pressure, description,
servo pressure reduces the oil pres- left-hand frame beam. page 10:25
sure from hydraulic oil pump 1 to the
servo pressure for the control valve.
16 The accumulator stores servo pres- See the pressure plate on the Accumulator servo circuit, description, page
sure. The non-return valve in the pres- left-hand frame beam. 10:31
sure reducer makes it possible to
store the pressure when the engine is
switched off.
17 Boom in U = 24 V 11.5.3.4 Control unit KFU (D7971), page
Solenoid valve blocking extension D17: Diagnostic menu, see 7.3 Extension 3/
(Y6050). XX DIAGNOSE, page 8:58
18 Boom in - Valve block extension cylinder, description,
For boom in, Solenoid valve, blocking page 7:39
extension (Y6050) acts on the block-
ing slide in valve block, extension
cylinder.
19 Boom out - Valve block extension cylinder, description,
The blocking slide in Valve block ex- page 7:39
tension cylinder is opened by hydraul-
ic pressure from the control valve.
Boom in
The blocking slide in the valve block
opens and releases pressure from the
extension cylinder.
20 Extension cylinder extends or retracts - Extension cylinder, description, page 7:41
the boom.
21 Regeneration U = 0.5-4.5 V Sensor hydraulic pressure lift cylinder, de-
Sensor, hydraulic pressure lift cylinder, scription, page 8:15
piston side left (B7226-1) sends a volt- D21 Diagnostic menu, see 8.2 Monitoring
age signal to Control unit KFU 17/XX DIAGNOSE, page 8:104
(D7971) proportional to the cylinder
pressure in the lift cylinders.
22 Control unit KFU (D7971) sends infor- Checked by control system, 11.5.3.4 Control unit KFU (D7971), page
mation about the pressure in the lift error shown with error code. 11:34
cylinders.
23 Control unit KFU (D7971) activates U = 24 V 11.5.3.4 Control unit KFU (D7971), page
Solenoid valve regeneration (Y6051- 11:34
1), if the pressure is low enough for 23: Diagnostic menu, see 7.3 Extension 4/
regeneration. XX DIAGNOSE, page 8:58.
24 Solenoid valve regeneration (Y6051- - Valve block extension cylinder, description,
1) pressurises the regeneration valve. page 7:39
25 The regeneration valve changes posi- - Valve block extension cylinder, description,
tion and leads oil from the rod side of page 7:39
the lift cylinder to the piston side.
26 Extension speed increases. - Extension cylinder, description, page 7:41
27 Damping - Sensor, boom length, description, page
When the extension is about 0.4 m 8:18
from the end-position damping is D27: Diagnostic menu, see 8.2 Monitoring
activated. 16/XX DIAGNOSE, page 8:103.
Sensor boom length (B7686) sends a
voltage signal proportional to the
boom extension to Control unit KFU
(D7971).
28 Control unit KFU (D7971) reduces the - 11.5.3.4 Control unit KFU (D7971), page
control current to Solenoid valve boom 11:34
out (Y6006) or Solenoid valve boom in
(Y6007).


29 Control unit KFU (D7971) sends a re- Checked by control system, 11.5.3.4 Control unit KFU (D7971), page
quest for reduced engine speed re- error shown with error code. 11:34
quirement CAN bus drive-train based
on information on lever deflection.
sends a rotation speed request on error shown with error code. 2:3
CAN bus drive-train to Control unit en-
gine (D7940).
31 Control unit, engine (D7940) reduces Checked by control system, 11.5.3.6 Control unit, engine (D7940), page
the engine speed. error shown with error code. 11:38
controls the ratio between drive and error shown with error code. 2:3
power take-off by changing the trans-
mission's gear ratio.
33 The extension speed decreases. - Valve block lift cylinder, description, page
7:24
34 If the feed pressure for Control valve Opening pressure: 25 MPa Pressure limiting valve, description, page
lift, lower and extension, becomes too 10:5
high, the pressure relief valve opens
and directs pressure to the hydraulic
oil tank.
35 The return oil from the lift cylinders is - Hydraulic oil filter, description, page 10:42
cleaned by the hydraulic oil filters in
the hydraulic oil tank.

chine, page E:6.

10:8.
7.3.2 Servo filter

Servo filter, general
See Servo filter, description, page 7:22.

Accumulator servo circuit, general
See Accumulator servo circuit, description, page 10:31.

7:38 7 Load handling – Control valve lift, lower and extension
7.3.5 Control valve lift, lower and extension

Control valve lift, lower, and extension, description
The control valve has two sections: one for the lift function and one for
boom extension. The sections have many similarities, but are de-
1 scribed separately under the respective function.
For general information on the control valve, refer to 7.2.5 Control valve
9 2 lift, lower and extension, page 7:23.
Extension slide
8 3
The extension slide controls direction (in or out) and oil flow to valve
block extension cylinder.
7 4
Servo valve, boom out
6 5 Servo valve boom out, controls servo pressure to the extension slide
so that it controls oil pressure for extension.
Servo valve boom out is controlled electrically with Solenoid valve
boom out (Y6006) which is activated by Control unit KFU (D7971).
The signal can be checked with the diagnostic menu, see 7.3 Extension
016839
Servo valve, boom in

1. Connection, rod side, extension cylinder [B1]
Servo valve boom in, controls servo pressure to the extension slide so
2. Solenoid valve, boom out (Y6006) that it controls oil pressure for boom retraction.
3. Solenoid valve, lift (Y6005)
Servo valve boom in is controlled electrically with Solenoid valve boom
4. Connection, rod side, right lift cylinder [B2]
in (Y6007) which is activated by Control unit KFU (D7971).
5. Connection, piston side, right lift cylinder [A2]
6. Solenoid valve, lower (Y6004) The signal can be checked with the diagnostic menu, see 7.3 Extension
7. Solenoid valve, boom in (Y6007) 1/XX DIAGNOSE, page 8:57.
8. Connection, feed from hydraulic oil pumps [P] Shock valve, extension
9. Connection, piston side, extension cylinder [A1]
Two shock valves protect the hydraulic system against surges which
can occur when operating on uneven ground or when stopping.
The shock valve opens a connection between the extension cylinder
piston side and rod side and tank if the pressure becomes too high.
Control valve lift, lower, and extension, changing

See Control valve lift, lower, and extension, changing, page 7:23.

7 Load handling – Valve block extension cylinder 7:39
7.3.7 Valve block extension cylinder

Valve block extension cylinder, description
Valve block extension cylinder routes pressure to the extension cylin-
1 der. The valve block is fitted at the rear edge of the extension cylinder
7 in the lift boom and contains a blocking valve, regeneration valve and
2 non-return valve.
6 Blocking valve
3
The blocking valve prevents unwanted lowering. The valve holds the
5 load by keeping the connection to the extension cylinder's piston side
4 closed. The pressure passes through a restriction providing a blocking
pressure and holds the valve slide closed.
Solenoid valve blocking extension (Y6050) acts on the blocking valve
and is activated by Control unit KFU (D7971).
The signal can be checked with the diagnostic menu, see 7.3 Extension
Regeneration valve
The regeneration valve routes oil from the rod side back to the piston
side. This allows the oil to be re-used during extension. For more infor-
mation on regeneration, see Extension, description, page 7:33 or Ex-
tension, function description, page 7:33. The regeneration valve is
regulated by servo valve regeneration.
016838
Solenoid valve regeneration (Y6051-1) pressurises the regeneration

valve. Solenoid valve regeneration (Y6051-1) is activated by Control
1. Connection, rod side [C-]
unit KFU (D7971).
2. Draining [D]
3. Solenoid valve regeneration (Y6051-1) The signal can be checked with the diagnostic menu, see 7.3 Extension
4. Connection, control valve [VB]
5. Connection, control valve [VA]
6. Connection, control valve [VA]
7. Solenoid valve blocking (Y6050)

7:40 7 Load handling – Valve block extension cylinder
Valve block extension cylinder, replacement
NOTE
Safety.
1. Fully retract the boom.

NOTE
NOTE
from impurities.
4. Mark and disconnect the cable harness from the valve block.
5. Remove the valve block from the extension cylinder.
6. Move the valve block to a clean area.
7. Transfer over connection adapters, solenoid valves to the new
valve block.
017410
NOTE
correctly.
NOTE
mixed up.
8. Fit the new valve on the extension cylinder.

9. Connect the hydraulic hoses to the valve block according to the
marking.
10. Connect the cable harness to the valve block according to the
marking.
Clamp the cable harness as before.
hydraulic system.
NOTE
017410
the lock ring.

manual.

7 Load handling – Extension cylinder 7:41
7.3.8 Extension cylinder

Extension cylinder, description
The extension cylinder forces out and retracts the inner boom. The ex-
tension cylinder is fitted in the lift boom. The rear section is secured in
the outer boom, the front section is secured in the inner boom. A valve
block that controls pressurising of the cylinder and regeneration for
boom out is fitted on the extension cylinder.
The extension cylinder piston rod end is designed as a lug with a flange
which is secured on the piston rod with hex bolts.
016840
Extension cylinder, changing
DANGER
An extension cylinder weighs between 1.5 to 2 tonnes
depending on machine model.
Extreme danger!
Exercise caution when handling so that personal injury
and equipment damage are avoided.
NOTE
Safety.
Removing
2. Run out the boom until the inspection holes in the side of the inner
boom become accessible.
NOTE

7:42 7 Load handling – Extension cylinder
4. Remove the lock rings and press out the pin for the front cylinder
mounting in the inner boom.
5. Remove Sensor boom length from the boom, see Sensor, boom
length, replacement, page 8:18.
6. Mark up and disconnect the hydraulic hoses from the extension
cylinder.
NOTE
from impurities.
7. Mark and disconnect the cable harness on the extension cylinder.

8. Remove the valve block from the extension cylinder.
NOTE
from impurities.
9. Remove the lock rings and press out the outer pins for the rear cyl-
inder mountings in the outer boom.
10. Connect lifting equipment to the rear extension cylinder's mounting.
11. Extend the extension cylinder carefully. When the cylinder has
come out a little way, connect a second lifting device that is moved
forward on the extension cylinder during the entire disassembly in
order to stabilise the lifting.
12. Place the cylinder on wooden blocks.
13. Transfer parts to the new extension cylinder.
When moving the brackets for the extension cylinder's rear bear-
Outer pins extension cylinder ing, note that the bearings in the extension cylinder are lubricant-
free. Lubricate the centre shaft with a thin layer of aluminium paste,
exercise caution so that the aluminium paste does not come into
contact with the slide surface of the bearings in the extension
cylinder.
CAUTION
lubricated.
Product damage.
spray.
Installing
14. Measure how long the old extension cylinder is and extend the
new cylinder to the same length.
NOTE
If this is not done, then the front cylinder mounting will not reach
far enough.

7 Load handling – Extension cylinder 7:43
15. Lift the extension cylinder into place.
CAUTION
Use the dual lifting devices in order to achieve balance
during the lifting. The front should be positioned behind
the support at the front edge of the cylinder so that it
can be slid into the boom.
16. Install the pin at the front cylinder mounting in the inner boom.
The extension cylinder's bearings are lubricant-free. Lubricate the
shaft with a thin layer of aluminium paste, exercise caution so that
the aluminium paste does not come into contact with the slide sur-
face of the bearings in the lift cylinder.
CAUTION
lubricated.
Product damage.
spray.
17. Install the locks on the pin.

18. Fit the outer shafts at the rear cylinder mountings.
Start with the right-hand shaft. The bushing at the left-hand mount-
ing is eccentric and must be turned so that the holes align before
the shaft is fitted.
NOTE
Lubricate the pin with grease before installing.
19. Install the locks on the pins.

20. Install the valve block on the extension cylinder.
Outer pins extension cylinder
NOTE
correctly.
21. Connect the hydraulic hoses and the cable harness to the exten-
sion cylinder.
22. Fit sensor boom length, see Sensor, boom length, replacement,
page 8:18.
hydraulic system.
NOTE
the lock ring.

7:44 7 Load handling – Lift boom
manual.
26. Calibrate sensor, boom length, see Load sensors, calibration,
page 8:12.

7.3.10 Lift boom

Lift boom, general
See Lift boom, description, page 7:30.
Slide plates lift boom, changing
NOTE
When adjusting the side-mounted slide plates, it is important to
check the clearance for the whole travel of the boom.
NOTE
The inner boom must be centred in the outer boom.
Front slide plates

1. Position the boom to the lowest position with the inner boom ex-
tended approx. 50 cm.
2. Remove the cover plate for the side-mounted slide plates and re-
move the shims and slid plate.
3 3. Lubricate the new slide plates with lubricating grease for slide
plates, see Lubricating grease, page F:11. Fit in the reverse order.
4. Check the clearance between the boom and slide plate, the clear-
ance should be 1 mm, adjust with shims as required.
1
NOTE
The inner boom must be centred in the outer boom.
2 5. Remove the lock screws and pull out the upper spacer plates.
6. Unload the lower slide plates, lift the inner boom at the front edge
and use steel wedges.
022928
1. Side-mounted slide plates

WARNING
2. Lower slide plates Risk of crushing!
3. Upper spacer plates
Secure the inner boom relative to the outer boom using
steel wedges.
7. Remove the lock screws and pull out the lower slide plates.
8. Transfer the nuts for the lock bolts for the lower slide plates to the
new slide plates.
9. Lubricate the new lower slide plates with lubricating grease for
slide plates, see Lubricating grease, page F:11. Fit the new lower
slide plates and lock screws.
10. Remove the steel wedges and ease down the inner boom so that it
rests on the lower slide plates.
11. Fit the upper spacer plates and lock screws.

7 Load handling – Lift boom 7:45
12. Check the clearance between boom and stop in the front edge/top
edge of the boom. If necessary, adjust the upper spacer plates with
shims so that a clearance of 2 mm is obtained with the new slide
plates.
Rear slide plates

13. Start the engine and run in the boom completely (fully retracted).
14. Remove the cover plate for the side-mounted slide plates and re-
move the shims and slid plate.
1
15. Lubricate the new slide plates with lubricating grease for slide
plates, see Lubricating grease, page F:11. Fit in the reverse order.
2 16. Check the clearance between the boom and slide plate, the clear-
ance should be 1 mm, adjust with shims as required.
17. Unload the lower slide plates, use steel wedges.
WARNING
3 Risk of crushing!
022929

1. Upper slide plates steel wedges.
2. Side-mounted slide plates
18. Remove the cover plates, shims and the lower slide plates.
3. Lower slide plates
plates, see Lubricating grease, page F:11. Install new slide plates,
spacer plates and cover plate.
20. Unload the upper slide plates, use steel wedges.
WARNING
Risk of crushing!
steel wedges.
21. Remove the lock screws and pull out the upper slide plates and
shims.
22. Transfer the nuts for the lock bolts for the upper slide plates to the
new slide plates.
plates, see Lubricating grease, page F:11. Fit the new slide plates,
shims and lock screws.
24. Check the clearance between the outer and inner boom, the clear-
ance should be max. 2 mm, adjust the slide plates with shims as
required.

7:46 7 Load handling – Sensor boom length
Lubrication
25. Run out the inner boom fully and make sure that all slide surfaces
are completely clean. Then lubricate the slide surfaces with lubri-
cating grease for slide plates, see Lubricating grease, page F:11.
016265
Slide surfaces, boom
26. Run the boom in and out about 10 times and stop with the boom
fully out.
27. Wipe away surplus lubricating grease at the slide plates and on
the slide surfaces.
7.3.11 Sensor boom length

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


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

7 Load handling – Side shift 7:47
7.4 Side shift

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

Reference
Condition value Reference
Sensor, operator-in- Not activated Sensor operator in seat, description, page 9:25
seat (operator in
seat)
1 1 D1
2
D7902
D7971 D7911
3, 8 12
D12
5
13 D7
D7940
D8 14
D7930 P1 Pa
7
9
4, 6 T1 A B
LSP1 A H
LSP2 LSPR
LSP3
108 LSHY
LSP3X PT T P LSM LSO
C11 15
11
022680

1 Control lever (S8150-R8070-3) sends a Left: UR8070-3 = 0.5–2.0 V Control lever (Ego), description, page 7:6
voltage signal to Control unit KPU Zero position: UR8070-3 = D1: Diagnostic menu, see 7.1 Controls and
(D7902). 2.0–3.0 V Instr 6/XX DIAGNOSE, page 8:53
Right: UR8070-3 = 3.0–4.5 V
1 Control lever (S8150-T1.1) sends a Left: US8150-T1.1 = 24 V Control lever (Cobra), description, page 7:10
voltage signal to Control unit KPU Right: US8150-T1.2 = 24 V D1: Diagnostic menu, see 7.1 Controls and
(D7902). Instr 6/XX DIAGNOSE, page 8:53
2 Control unit KPU (D7902) sends side Checked by control system, 11.5.3.2 KPU control unit (D7902), page
shift left or right on the CAN bus. error shown with error 11:30
code.
quest for engine speed requirement error shown with error 11:27
CAN bus drive-train based on informa- code.
tion on lever deflection.

7:48 7 Load handling – Side shift

4 Control unit transmission (D7930) Checked by control system, Transmission, function description, page 2:3
sends a rotation speed request on CAN error shown with error
bus drive-train to Control unit engine code.
(D7940).
5 Control unit, engine (D7940) increases Checked by control system, 11.5.3.6 Control unit, engine (D7940), page
the engine speed. error shown with error 11:38
code.
6 Control unit transmission (D7930) con- Checked by control system, Transmission, function description, page 2:3
trols the ratio between drive and power error shown with error
take-off by changing the transmission's code.
gear ratio.
7 Sensor, servo pressure attachment 0.5–4.5 V Sensor, servo pressure attachment (B7668),
(B7688) sends a voltage signal propor- page 7:50
tional to the oil pressure in the control D3: Diagnostic menu, see 10.4 Pumps 7/XX
valve for the attachment to Control unit DIAGNOSE, page 8:134
KAU (D7911).
8 Control unit KAU (D7971) controls Pro- U = 24 V 11.5.3.4 Control unit KFU (D7971), page
portional valve, load signal attachment 11:34
(Y6002), proportional to the attach- D4: Diagnostic menu, see 10.4 Pumps 6/XX
ment's pressure requirements. DIAGNOSE, page 8:134
9 Proportional valve, load signal attach- - Proportional valve, load signal attachment
ment (Y6002), opens and sends a load (Y6002), description, page 10:25
signal to hydraulic oil pump 1. The size
of the load signal is controlled by the
voltage signal from Sensor, oil pressure
attachment (B7688).
The load signal is 0.3–1.5 MPa greater
than the pressure detected by Sensor,
servo pressure attachment (B7668).
10 Valve block servo pressure sends the - Valve block servo pressure, description, page
load signal to hydraulic oil pump 1. 10:25
Shuttle valves in the servo valves se- Shuttle valve, description, page 10:26
lect the strongest load signal if other
functions are activated at the same
time.
11 Hydraulic oil pump 1 pumps oil from the See the pressure plate on Axial piston pump with variable displacement,
hydraulic oil tank. the left-hand frame beam. description, page 10:8
The amount of oil supplied to the con-
trol valve for the attachment depends
on the requirements of the attachment
functions.
12 Control unit KAU (D7911) activates Sol- I = 330–570 mA 11.5.3.8 Control unit KAU (D7911), page
enoid valve side shift left (Y6020) or 11:40
Solenoid valve side shift right (Y6021). D8: Diagnostic menu, see 7.4 Side Shift 3/XX
DIAGNOSE, page 8:59 or 7.4 Side Shift 4/XX
DIAGNOSE, page 8:59
13 Solenoid valve side shift left (Y6020) or - Attachment control valve, description, page
Solenoid valve side shift right (Y6021) 7:49
pressurises the side shift slide in con- D8: Diagnostic menu, see 7.4 Side Shift 3/XX
trol valve attachment. DIAGNOSE, page 8:59 or 7.4 Side Shift 4/XX
DIAGNOSE, page 8:59
14 The control valve's side shift slide - Attachment control valve, description, page
changes position and pressurises the 7:49
side shift cylinders.
15 The side shift cylinders push in the - Side shift cylinder, description, page 7:53
main beam sideways in relation to the
side shift frame.
Hydraulic diagram top lift, see Hydraulic diagram top lift, page E:8.
Hydraulic diagram top lift, overheight legs, see Hydraulic diagram top
lift, overheight-legs, page E:12.

Hydraulic diagram combi attachment, see Hydraulic diagram combi at-

tachment, page E:14.
Hydraulic diagram top lift hydraulic levelling, see Hydraulic diagram top
lift, hydraulic levelling, page E:10.

10:8.
7.4.3 Control valve, attachment

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

pressure-compensated directional control valve. Electrically controlled
servo valves convert current to servo pressure. The servo pressure
controls the spring-centred valve slides that control pressure and flow
for the function in question. The valve slides have a flow limit so that
several functions can be used simultaneously. This enables them to
control the main flow.
The control valve has a built-in supply of pilot pressure. This means
that the valve has a built-in pressure reduction that converts feed pres-
sure to servo pressure for the various functions. The supply of pilot
pressure is common for all functions. This reduces pressure variations
7 due to long hoses and reduces the number of hoses to the valve.
6 5 4
The control valve has the following sections:
• Side shift
• Rotation
• Twistlocks
• Controllable tilt
• Hydraulic levelling
022681
• Overheight legs
1. Solenoid valve, side shift left (Y6020) Side shift slide

2. Solenoid valve, side shift right (Y6021) The valve slide controls the direction and speed of side shift.
3. Drain to tank (unfiltered)
The valve slide is controlled by servo valve for side shift right and servo
4. Return to tank (through tank filter)
valve for side shift left.
5. Connection to side shift cylinder
6. Connection to side shift cylinder Servo valve, side shift left
7. Sensor, oil pressure, attachment (B7688)
Servo valve side shift left controls pressure to the side shift slide so that
8. Feed from hydraulic oil pump 1 the side shift slide opens and pressurises the side shift cylinder.
Servo valve, side shift left, is controlled electrically by Solenoid valve,
side shift left (Y6020), which is activated by Control unit KAU (D7911).
The servo valve directs servo pressure to the side shift slide proportion-
al to the control current to the solenoid valve.
The signal can be checked with the diagnostic menu, see 7.4 Side Shift

7:50 7 Load handling – Control valve, attachment
Servo valve, side shift right

Servo valve side shift right controls pressure to the side shift slide so
that the side shift slide opens and pressurises the side shift cylinder.
Servo valve, side shift right is controlled electrically by Solenoid valve,
side shift right (Y6021) which is activated by Control unit KAU (D7911).
The servo valve directs servo pressure to the side shift slide proportion-
al to the control current to the solenoid valve.
The signal can be checked with the diagnostic menu, see 7.4 Side Shift
Sensor, servo pressure attachment (B7668)

Sensor, servo pressure attachment (B7668), detects the pressure re-
quired for the attachment functions and sends a voltage signal to Con-
trol unit attachment (D7911). Control unit frame (D7971) controls
Proportional valve, load signal attachment (Y6002), which sends a load
signal to proportional to the attachment's pressure requirements to hy-
draulic oil pump 1. The load signal is 0.3–1.5 MPa greater than the
pressure detected by Sensor, servo pressure attachment (B7668).
The signal from Sensor, servo pressure attachment (B7668), can be
checked with the diagnostic menu, see 7.10 Other Functions 7/XX DI-
AGNOSE, page 8:100.
The signal to Proportional valve, load signal attachment (Y6002), can
be checked with the diagnostic menu, see 7.10 Other Functions 6/XX
For initiation/calibration of Proportional valve, load signal attachment
(Y6002), see Initiation/calibration of proportional valve, checking and
adjusting , page 10:28.
Control valve attachment, checking hydraulic

pressure
NOTE
Safety.
1. Operate and warm up the machine so that the hydraulic oil is at op-
0:00pm
erating temperature, at least 50 °C. As an alternative, operate until
a the cooling fan is activated.
75°C 50% sion and hydraulic system.
b c
50°C 50°C
016372


7 Load handling – Control valve, attachment 7:51
3. Connect a pressure gauge to measuring outlet (PL) on control

valve attachment.
4. Start the engine and run it at idle. Check the pressures in the at-
tachment's different functions by allowing each function go to its
end position and then reading off the pressure gauge.
Function Pressure
Side shift 16.0 MPa
Spreading (positioning) 12.0 MPa
Rotation 15.0 MPa
Tilt control 15.0 MPa
022774
Levelling 15.5 MPa
Measuring outlet, control valve attachment Twistlocks Same as feed pressure.
Overheight legs, lowering 10.0 MPa
Lift legs, knee in/out 13.0 MPa
Lift legs, jack up/down 10.0 MPa
Lift legs, clamping 13.0 MPa
measuring outlet.
Control valve attachment, replacement
NOTE
Safety.

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

8. Fit the valve.

Lift the valve into place and fit the attaching bolts.
9. Connect the cable harness to the control valve according to the
marking.
the marking.
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.
13. Check that the valve\qs hydraulic connections are sealed.
14. Initiate/calibrate Proportional valve, load signal attachment
(Y6002), see Initiation/calibration of proportional valve, checking
and adjusting , page 10:28.
Check the signal from Sensor, servo pressure attachment (B7668),
with the diagnostic menu, see 7.10 Other Functions 7/XX DIAG-
NOSE, page 8:100.
Check the signal to Proportional valve, load signal attachment
(Y6002), with the diagnostic menu, see 7.10 Other Functions 6/XX
15. Check that the attachment is working.
CAUTION
product damage.
manual.

7 Load handling – Side shift cylinder 7:53
7.4.5 Side shift cylinder

Side shift cylinder, description
The side shift cylinders are two hydraulic cylinders connected cross-
1 wise that extend the attachment's main beam laterally in relation to the
side shift frame. The side shift cylinders are fitted along the front and
10 rear of the attachment and are used to centre the load's centre of
gravity.
8 2
3
4
023665
7 6 5
1. Side shift frame

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

7.4.6 Side shift frame

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

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

7:54 7 Load handling – Side shift frame
Slide plates, side shift frame, changing

1. Loosen the cover plate's attaching bolt and remove the cover plate.
2. Remove the spacer plates and slide plate.
3. Repeat steps 1 - 3 on the other slide plates.
016902
4. Measure the distance between the edge of the cover plate and the
attachment's main beam slide surface on all slide plates.
5. Centre the boom so that the distance between the attachment's
main beam and edge is the same on all slide plates.
6. Install the new slide plate.

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

7 Load handling – Side shift frame 7:55
9. Install the cover plate.

10. Repeat steps 7 - 10 on the other slide plates.
Lubrication
11. Lubricate the slide surfaces of the attachment with lubricating
grease for the slide plates.
016902
004875
Slide surfaces, attachment
12. Operate full side shift from right to left approx. 10 times.
13. Wipe away excess lubricant at the slide plates and on the slide
surfaces.
Lower slide plates, side shift frame, changing

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

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

9. Park machine a completely level surface.
The figure shows loose cross member

7:56 7 Load handling – Side shift frame
10. Lower the boom and fully retract the extension and centre the
attachment.
11. Measure the distance between the extension beam and the ground
at all four corners of the attachment.
The difference between the dimensions (A) and (B) side must not
be more than 50 mm at 20' position, or 100 mm for 40' position.
Check the dimensions with the attachment in both 20'and 40'-
position.
NOTE
Take into account that the tilt of the attachment affects the posi-
A B tion. The dimensions refer to horizontal attachment and machine.
008217
12. If necessary, adjust the lower slide plates so that the attachment is
Measuring points, levelling, attachment
straight.
Lubrication
grease for slide plates, see Lubricating grease, page F:11.
004875
Slide plates, attachment
14. Operate full side shift from right to left approx. 10 times.
surfaces.

7 Load handling – Main beam, attachment 7:57
7.4.7 Main beam, attachment

Main beam attachment, description
The main beam attachment is fitted in the side shift frame. The main
1 2 3 4 5 6 beam contains equipment for spreading (spreader beams, hydraulic
motor, chains, slide plates and sensors). The control valves for the at-
tachment's hydraulic functions are also fitted on the attachment's main
beam.
000526
1. Main beam
2. Ring gear
4. Rotation yoke
6. Side shift frame
7.4.8 Relief valve top lift

Relief valve top lift, description
Relief valve top lift opens a connection between the attachment's pres-
sure feed and tank. This is used to drain the pressure in the hoses for
the attachment before working on the hydraulic system.
The relief valve is fitted in a connection to Valve block, servo pressure.
022267



7:58 7 Load handling – Spreading (positioning)
7.5 Spreading (positioning)

Spreading, description
Spreading means that the width between twistlocks is changed.
Spreading has 20-foot and 40-foot stops; extra stops at other distances
are available as options, such as 30-foot.
Control valve attachment pressurises Valve block spreader motor that
001114
controls the pressure to the spreader motor. The spreader motor pulls
the spreader chains that pull spreading booms in and out.
Spreading is controlled by Control lever (S8150). Inductive position
sensors indicates the position of the spreader units.
Damping
approaching the end positions. Three to four seconds after the damp-
ing has been activated the function is interrupted. This means that the
mechanics are loaded less when stopping in the end positions.
Position sensors detect when damping should be activated. When
Spreading, function description

Sensor, operator-in-seat Not activated (oper- Sensor operator in seat, description, page 9:25
ator in seat)
Twistlocks Unlocked or bypass Twistlocks, description, page 7:138
activated Bypass, description, page 8:6
Overload system Passive Overload system, description, page 8:5
1 1 D1
+ 2
+ D7902
5 D7971 D7911
3, 8 12, 18, 23
D7940 D12
D7930 13
19 D7
4, 6 C11
D8 D17 D22
P1 Pa
7
9
T1 A B 14, 20
LSP1 A H 17 22
LSP2 LSPR
LSP3
108 LSHY
15
C11 16, 21, 24
11
023692

7 Load handling – Spreading (positioning) 7:59

1 Switch shift button (S1991) and Control Shift button: U = 24 V Control lever (Ego), description, page 7:6
lever (S8150-R8070-3) send a voltage In: UR8070-3 = 0.5–2.0 V D1: Diagnostic menu, see 7.1 Controls and
signal to Control unit KPU (D7902). Zero position: UR8070-3 = Instr 6/XX DIAGNOSE, page 8:53 and 7.1
2.0–3.0 V Controls and Instr 7/XX DIAGNOSE, page
Out: UR8070-3 = 3.0–4.5 V 8:53.
1 Control lever (S8150-T1.x and S8150- Spreading: US8150-T4 = 24 V Control lever (Cobra), description, page
T4) sends a voltage signal to Control unit Out: US8150-T1.2 = 24 V 7:10
KPU (D7902). In: US8150-T1.1 = 24V D1: Diagnostic menu, see 7.1 Controls and
Instr 6/XX DIAGNOSE, page 8:53 and 7.1
Controls and Instr 7/XX DIAGNOSE, page
8:53.
2 Control unit KPU (D7902) sends spread- Checked by control system, 11.5.3.2 KPU control unit (D7902), page
ing in or out on the CAN bus. error shown with error 11:30
code.
quest for engine speed requirement CAN error shown with error 11:27
bus drive-train based on information on code.
lever deflection.
4 Control unit transmission (D7930) sends Checked by control system, Transmission, function description, page 2:3
a rotation speed request on CAN bus error shown with error
drive-train to Control unit engine (D7940). code.
code.
gear ratio.
KAU (D7911).
(Y6002), proportional to the attachment's D8: Diagnostic menu, see 10.4 Pumps 6/XX
pressure requirements. DIAGNOSE, page 8:134
signal to hydraulic oil pump 1. The size of
the load signal is controlled by the volt-
age signal from Sensor, oil pressure at-
tachment (B7688).
10 Valve block servo pressure sends the - Valve block servo pressure, description,
load signal to hydraulic oil pump 1. Shut- page 10:25
tle valves in the servo valves select the Shuttle valve, description, page 10:26
strongest load signal if other functions
The amount of oil supplied to the control
valve for the attachment depends on the
requirements of the attachment functions.
12 Control unit KAU (D7911) activates Sole- I = 340–480 mA 11.5.3.8 Control unit KAU (D7911), page
noid valve spreading out (Y6018) or Sol- 11:40
enoid valve spreading in (Y6019). D12: Diagnostic menu, see 7.5 Spreading
10/XX DIAGNOSE, page 8:61 or 7.5
Spreading 11/XX DIAGNOSE, page 8:61


13 Solenoid valve, spreading out (Y6018) or - Attachment control valve, description, page
Solenoid valve, spreading in (Y6019) 7:49
pressurises the spreader slide in the at-
tachment's control valve.
14 The control valve's spreader slide - Attachment control valve, description, page
changes position and direct pressure to 7:49
the spreader motor.
15 The motor valve block directs the pres- - Valve block spreader motor, description,
sure to the motor and prevents the motor page 7:71
from pumping (rotating faster than sup-
plied pressure).
16 The motor drives the chains that extend - Spreader motor, description, page 7:71
or retract the spreader beams.
17 Sensor, end position 20'-40' (B7690) Sensor directly opposite in- Position sensor spreading, description, page
sends a voltage signal to Control unit dicator plate: U = 24 V 7:82
KAU (D7911). D17: Diagnostic menu, see 7.5 Spreading 8/
18 Control unit KAU (D7911) reduces the - 11.5.3.8 Control unit KAU (D7911), page
control current to Solenoid valve, spread- 11:40
ing out (Y6018) or Solenoid valve, D12: Diagnostic menu, see 7.5 Spreading
spreading in (Y6019). 10/XX DIAGNOSE, page 8:61 or 7.5
19 Solenoid valve, spreading out (Y6018) or - Attachment control valve, description, page
Solenoid valve, spreading in (Y6019) re- 7:69
duces the pressure to the spreader slide
in the attachment's control valve.
20 The control valve's spreader slide - Attachment control valve, description, page
changes position and reduces the pres- 7:69
sure to the spreader motor.
21 The speed of the spreader motor is - Spreader motor, description, page 7:71
reduced.
22 Sensor, stop end position 20'-40' (B7770) Sensor directly opposite in- Position sensor spreading, description, page
sends a voltage signal to Control unit dicator plate: U = 24 V 7:82
KAU (D7911). D22: Diagnostic menu, see 7.5 Spreading 8/
23 Control unit KAU (D7911) interrupts the - 11.5.3.8 Control unit KAU (D7911), page
ing out (Y6018) or Solenoid valve, D12: Diagnostic menu, see 7.5 Spreading
spreading in (Y6019). 10/XX DIAGNOSE, page 8:61 or 7.5
24 The spreading (positioning) motor is - Spreader motor, description, page 7:71
stopped.

Spreading hydraulic cylinder, function

description
Sensor, operator-in-seat Not activated (oper- Sensor operator in seat, description, page 9:25
ator in seat)
D1
1 1
2
+ D7902
+
D7971 D7911
5 3, 8 12, 17, 22
D7940 D12
13 13
D7930 18 18 D16 D21
4, 6 C11 D7
D8
P1 Pa
14 14 7
9
19 19
T1 A B A B
LSP1 A H
LSP2 LSPR 16 21
LSP3
108 LSHY
C11 15, 20, 23 15, 20, 23
11
023373
Out: UR8070-3 = 3.0–4.5 V 8:53.
8:53.
ing in or out on the CAN bus. error shown with error 11:30
code.
quest for engine speed requirement CAN error shown with error 11:27
bus drive-train based on information on code.
lever deflection.
4 Control unit transmission (D7930) sends Checked by control system, Transmission, function description, page 2:3
a rotation speed request on CAN bus error shown with error
drive-train to Control unit engine (D7940). code.


code.
gear ratio.
KAU (D7911).
signal to hydraulic oil pump 1. The size of
the load signal is controlled by the volt-
tachment (B7688).
10 Valve block servo pressure sends the - Valve block servo pressure, description,
load signal to hydraulic oil pump 1. Shut- page 10:25
tle valves in the servo valves select the Shuttle valve, description, page 10:26
The amount of oil supplied to the control
12 Spreading out I = 340–480 mA 11.5.3.8 Control unit KAU (D7911), page
Control unit KAU (D7911) activates Sole- 11:40
noid valve, spreading out right (Y6018- D12: Diagnostic menu, see 7.5 Spreading
RI) and Solenoid valve, spreading out left 12/XX DIAGNOSE, page 8:61,
(Y6018-LE). 7.5 Spreading 13/XX DIAGNOSE, page
Spreading in 8:62,
Control unit KAU (D7911) activates Sole- 7.5 Spreading 14/XX DIAGNOSE, page
noid valve, spreading in right (Y6019-RI) 8:62
and Solenoid valve, spreading in left or
(Y6019-LE). 7.5 Spreading 15/XX DIAGNOSE, page
8:62
13 Spreading out - Attachment control valve, description, page
Solenoid valve, spreading out right 7:69
(Y6018-RI) and Solenoid valve, spread-
ing out left (Y6018-LE) pressurise the
spreading slides in the attachment's con-
trol valve.
Spreading in
Solenoid valve, spreading in right
(Y6019-RI) and Solenoid valve, spread-
ing in left (Y6019-LE) pressurise the
spreading slides in the attachment's con-
trol valve.
14 The control valve's spreader slides - Attachment control valve, description, page
change position and direct pressure to 7:69
the spreading cylinders.
15 The spreading cylinders slide the spread- - Spreading cylinder, description, page 7:84
ing beam in or out in the attachment.


16 Sensor, end position 20'-40' left (B7690- Sensor directly opposite in- Position sensor spreading, description, page
LE), and Sensor, end position 20'-40' dicator plate: U > 24V 7:82
right (B7690-RI) send a voltage signal to D16: Diagnostic menu, see 7.5 Spreading 9/
Control unit KAU (D7911). XX DIAGNOSE, page 8:60
17 Control unit KAU (D7911) reduces the - 11.5.3.8 Control unit KAU (D7911), page
ing out left (Y6018-LE) and Solenoid D12: Diagnostic menu, see 7.5 Spreading
valve, spreading out right (Y6018-RI) or 12/XX DIAGNOSE, page 8:61,
Solenoid valve, spreading in left (Y6019- 7.5 Spreading 13/XX DIAGNOSE, page
LE) and Solenoid valve, spreading in 8:62,
right (Y6019-RI). 7.5 Spreading 14/XX DIAGNOSE, page
8:62
or
7.5 Spreading 15/XX DIAGNOSE, page
8:62
18 Solenoid valve, spreading out left - Attachment control valve, description, page
(Y6018-LE) and Solenoid valve, spread- 7:69
ing out right (Y6018-RI) or Solenoid valve,
spreading in left (Y6019-LE) and Sole-
noid valve, spreading in right (Y6019-RI)
reduce the pressure to the spreading
slides on the attachment’s control valve.
19 The control valve's spreader slides - Attachment control valve, description, page
change position and reduce the pressure 7:69
to the spreading cylinders.
20 Spreader speed decreases. - Spreading cylinder, description, page 7:84
21 Sensor, stop end position 20'-40' left Sensor directly opposite in- Position sensor spreading, description, page
(B7770-LE), and Sensor, stop end posi- dicator plate: U > 24V 7:82
tion 20'-40' right (B7770-RI) send a volt- D21: Diagnostic menu, see 7.5 Spreading 9/
age signal to Control unit KAU (D7911). XX DIAGNOSE, page 8:60
22 Control unit KAU (D7911) disconnects - 11.5.3.8 Control unit KAU (D7911), page
the control current to Solenoid valve, 11:40
spreading out left (Y6018-LE) and Sole- D12: Diagnostic menu, see 7.5 Spreading
noid valve, spreading out right (Y6018- 12/XX DIAGNOSE, page 8:61,
RI) or Solenoid valve, spreading in left 7.5 Spreading 13/XX DIAGNOSE, page
(Y6019-LE) and Solenoid valve, spread- 8:62,
ing in right (Y6019-RI). 7.5 Spreading 14/XX DIAGNOSE, page
8:62
or
7.5 Spreading 15/XX DIAGNOSE, page
8:62
23 The spreading is stopped. - Spreading cylinder, description, page 7:84
Spreading, extra stops, description
As an option, spreading can be equipped with extra stops for spreading.

The stop can be selected to suit customer equipment. An extra stop is
activated with Switch, extra stop spreading. When extra stop spreading
is activated, spreading stops at the extra stop. At extra stop there is a
position sensor for controlling the function.

Spreading, extra stops, function description

Sensor, operator-in-seat Not activated (opera- Sensor operator in seat, description, page 9:25
tor in seat)
1
D1
2 2
+
+ 3
D2 D7902
D7971 D7911
4, 6, 8
D5 D7
D4
5 7
021237
1 Switch, extra stop spreading (S1004) Switch off: Switch, extra stop spreading, description ,
sends a voltage signal to Control unit Conn. 4: U = 0 V page 7:13
KPU (D7902). Switch on: D1: Diagnostic menu, see 7.5 Spreading 7/
Conn. 4: U = 24V XX DIAGNOSE, page 8:60
Out: UR8070-3 = 3.0–4.5 V 8:53.
8:53.
ing extra stop on the CAN bus. error shown with error code. 11:30
4 Spreading is activated in the same way - Spreading, function description, page 7:58
as the normal spreading. D4: Diagnostic menu, see 7.5 Spreading
5 When spreading approaches the next Sensor directly opposite in- Position sensor spreading, description,
stop, Sensor extra stop spreading dicator plate: U = 24 V page 7:82
(B7770) sends a voltage signal to Con- D5: Diagnostic menu, see 7.5 Spreading 8/
trol unit KAU (D7911). XX DIAGNOSE, page 8:60
7.5 Spreading 9/XX DIAGNOSE, page 8:60
6 Control unit KAU (D7911) dampens the - Spreading, function description, page 7:58
speed in the same way as in normal
spreading.


7 When spreading is at the position for ex- Sensor directly opposite in- Position sensor spreading, description,
tra stop, Sensor end position 20'-40' dicator plate: U = 24 V page 7:82
(B7690) sends a voltage signal. D7: Diagnostic menu, see 7.5 Spreading 8/
7.5 Spreading 9/XX DIAGNOSE, page 8:60
8 Spreading is interrupted by Control unit U=0V Attachment control valve, description, page
KAU (D7911) disconnecting the current 7:69
to Solenoid valve, spreading out (Y6018) D4: Diagnostic menu, see 7.5 Spreading
or Solenoid valve, spreading in (Y6019). 10/XX DIAGNOSE, page 8:61 or 7.5
Spreading hydraulic cylinder, extra stops,

function description

tor in seat)
1
D1
2 2
+
+ 3
D2 D7902
D7971 D7911
4, 6, 8
D5 D7
D4
5 7
023662

1 Switch, extra stop spreading (S1004) Switch off: Switch, extra stop spreading, description ,
sends a voltage signal to Control unit Conn. 4: U = 0 V page 7:13
KPU (D7902). Switch on: D1: Diagnostic menu, see 7.5 Spreading 7/
Conn. 4: U = 24V XX DIAGNOSE, page 8:60
Out: UR8070-3 = 3.0–4.5 V 8:53.


8:53.
ing extra stop on the CAN bus. error shown with error code. 11:30
4 Spreading is activated in the same way - Spreading, function description, page 7:58
as the normal spreading. D4: Diagnostic menu, see 7.5 Spreading
5 When spreading approaches the next Sensor directly opposite in- Position sensor spreading, description,
stop, Sensor, extra stop spreading left dicator plate: U = 24 V page 7:82
(B7770-LE) and Sensor, extra stop D5: Diagnostic menu, see 7.5 Spreading 9/
spreading right (B7770-RI) send a volt- XX DIAGNOSE, page 8:60
age signal to Control unit KAU (D7911).
6 Control unit KAU (D7911) dampens the - Spreading, function description, page 7:58
speed in the same way as in normal
spreading.
7 When spreading is in position for extra Sensor directly opposite in- Position sensor spreading, description,
stop, Sensor, end position 20'-40' left dicator plate: U = 24 V page 7:82
(B7690-LE) and Sensor, end position D7: Diagnostic menu, see 7.5 Spreading 9/
20'-40' right (B7690-RI) send a voltage XX DIAGNOSE, page 8:60
signal.
8 Spreading is interrupted by Control unit U=0V Attachment control valve, description, page
KAU (D7911) disconnecting the current 7:69
to Solenoid valve, spreading out (Y6018) D4: Diagnostic menu, see 7.5 Spreading
or Solenoid valve, spreading in (Y6019). 10/XX DIAGNOSE, page 8:61 or 7.5
Automatic spreading 20-40 foot, description
Automatic spreading 20'-40' is an option for spreading that is activated

with Switch, automatic spreading 20'-40'. When the switch is activated,
spreading automatically moves to the next end position when spread-
ing is activated with Control lever (S8150). During automatic spreading
the buzzer on the attachment sounds.
If the machine is also equipped with extra stop and this is activated,
016349
then spreading stops at this stop. Activate spreading again in order to

go to the next position.
Event menu automatic spreading 20'-40' Automatic spreading functions both during spreading in and spreading
out.

Automatic spreading 20-40 foot, function

description

Control breaker Not activated Control breaker voltage, function description, page 11:20
tor in seat)
Twistlocks Unlocked or bypass Twistlocks, function description, page 7:127
Doors Closed Doors, description, page 9:102
2 D2
1 1
+ 7
D7950
+ 3
D1 D7902
D7971 D7911
4, 5, 10, 13
D5 D8
D9
6 D4 9, 11 8, 12
023374
1 Switch shift button (S1991) and Shift button: U = 24 V Control lever (Ego), description, page 7:6
Control lever (S8150-R8070-3) In: UR8070-3 = 0.5–2.0 V D1: Diagnostic menu, see 7.1 Controls and Instr
send a voltage signal to Control unit Zero position: UR8070-3 = 6/XX DIAGNOSE, page 8:53 and 7.1 Controls
KPU (D7902). 2.0–3.0 V and Instr 7/XX DIAGNOSE, page 8:53.
Out: UR8070-3 = 3.0–4.5 V
1 Control lever (S8150-T1.x and Spreading: US8150-T4 = 24 V Control lever (Cobra), description, page 7:10
S8150-T4) sends a voltage signal to Out: US8150-T1.2 = 24 V D1: Diagnostic menu, see 7.1 Controls and Instr
Control unit KPU (D7902). In: US8150-T1.1 = 24V 6/XX DIAGNOSE, page 8:53 and 7.1 Controls
2 Switch, automatic spreading 20'-40' Switch off: Switch automatic spreading, description, page
(S1012-2) sends a voltage signal to Conn. 4: U = 0 V 7:13
Control unit KPU (D7902). Switch on: D2: Diagnostic menu, see 7.5 Spreading 7/XX
Conn. 4: U = 24V DIAGNOSE, page 8:60
3 Control unit KPU (D7902) sends Checked by control system, 11.5.3.2 KPU control unit (D7902), page 11:30
"automatic spreading out" or "auto- error shown with error code.
matic spreading in" on the CAN bus.
4 Control unit KAU (D7911) activates - Spreading, function description, page 7:58
the spreading in the same way as in D4: Diagnostic menu, see 7.5 Spreading 10/XX
normal spreading. DIAGNOSE, page 8:61 or 7.5 Spreading 11/XX
DIAGNOSE, page 8:61
5 Control unit KAU (D7911) activates Buzzer active: U = 24 V Buzzer automatic spreading 20'-40', description,
Buzzer, automatic spreading page 7:84
(H9003). D5: Diagnostic menu, see 7.5 Spreading 16/XX
DIAGNOSE, page 8:63
6 Buzzer automatic spreading Buzzer active: U = 24 V Buzzer automatic spreading 20'-40', description,
(H9003) generates acoustic warning page 7:84
signal. D5: Diagnostic menu, see 7.5 Spreading 16/XX
DIAGNOSE, page 8:63

7:68 7 Load handling – Hydraulic oil pump

7 When automatic spreading is active, - 11.5.3.3 Control unit, KID (D7950), page 11:32
the KID control unit (D7950) acti-
vates the Automatic Spreading
event menu.
8 When spreading approaches the 20' Sensor directly opposite in- Position sensor spreading, description, page
or 40' position, Sensor, end position dicator plate: U = 24 V 7:82
20'-40' (B7690 or B7690-LE/B7690- D8: Diagnostic menu, see 7.5 Spreading 8/XX
RI) send a voltage signal to Control DIAGNOSE, page 8:60
unit KAU (D7911). 7.5 Spreading 9/XX DIAGNOSE, page 8:60
9 When spreading approaches stop Sensor directly opposite in- Position sensor spreading, description, page
30' or 35' position, Sensor, extra dicator plate: U = 24 V 7:82
stop spreading (B7770 or B7770- D9: Diagnostic menu, see 7.5 Spreading 8/XX
LE/B7770-RI) sends a voltage sig- DIAGNOSE, page 8:60
nal to Control unit KAU (D7911). 7.5 Spreading 9/XX DIAGNOSE, page 8:60
10 Control unit KAU (D7911) dampens - Spreading, function description, page 7:58
the spreading in the same way as in
normal spreading.
11 When spreading is in 20' or 40' posi- Sensor directly opposite in- Position sensor spreading, description, page
tion, Sensor, extra stop spreading dicator plate: U = 24 V 7:82
(B7770 or B7770-LE/B7770-RI) D9: Diagnostic menu, see 7.5 Spreading 8/XX
sends a voltage signal to Control DIAGNOSE, page 8:60
unit KAU (D7911). 7.5 Spreading 9/XX DIAGNOSE, page 8:60
12 When spreading is in 30' or 35' posi- Sensor directly opposite in- Position sensor spreading, description, page
tion, Sensor, end position 20'-40' dicator plate: U = 24 V 7:82
(B7690 or B7690-LE/B7690-RI) D10: Diagnostic menu, see 7.5 Spreading 8/XX
sends a voltage signal to Control DIAGNOSE, page 8:60
unit KAU (D7911).
13 Control unit KAU (D7911) interrupts I = 0 mA Attachment control valve, description, page 7:69
the control current to Solenoid valve, D4: Diagnostic menu, see 7.5 Spreading 10/XX
spreading out (Y6018) or Solenoid DIAGNOSE, page 8:61 or 7.5 Spreading 11/XX
valve, spreading in (Y6019). DIAGNOSE, page 8:61

10:8.

7 Load handling – Control valve, attachment 7:69

Spreading is controlled by a separate section in the attachment's con-
1 2 3 trol valve. For a more detailed description of the valve and component
locations, see Attachment control valve, description, page 7:49.
Spreader slide
The valve slide controls the direction and speed of spreading. The
8 valve slide is controlled by the servo valve for spreading out and the
servo valve for spreading in.
Servo valve, spreading out

Servo valve spreading out controls the pressure to the spreader slide
so that it opens and pressurises the spreader motor.
The servo valve is controlled electrically by Solenoid valve, spreading
out (Y6018), which is activated by Control unit KAU (D7911). The servo
valve directs servo pressure to the spreader slide proportional to the
control current to the solenoid valve.
7 The signal can be checked with the diagnostic menu, see 7.5 Spread-
6 5 4 ing 10/XX DIAGNOSE, page 8:61.
For machines with spreading with hydraulic cylinders, two sections are
used in the attachment control valve .
out left (Y6018–LE) and Solenoid valve, spreading out right (Y6018–
RI), and is activated by Control unit KAU (D7911). The servo valve di-
rects servo pressure to the spreading slides proportional to the control
current to the solenoid valve.
022683
The signals can be checked with the diagnostic menu, see 7.5 Spread-
Attachment with chain spreading ing 12/XX DIAGNOSE, page 8:61 and 7.5 Spreading 14/XX DIAG-
NOSE, page 8:62.
1. Solenoid valve, spreading in (Y6019)
2. Solenoid valve, spreading out (Y6018) Servo valve, spreading in
Servo valve spreading in controls the pressure to the spreader slide so
that it opens and pressurises the spreader motor.
5. Connection to spreader motor
6. Connection to spreader motor The servo valve is controlled electrically by Solenoid valve, spreading
in (Y6019), which is activated by Control unit KAU (D7911). The servo
valve directs servo pressure to the spreader slide proportional to the
8. Feed from hydraulic oil pump 1
control current to the solenoid valve.
For machines with spreading with hydraulic cylinders, two sections are
used in the attachment control valve .
in left (Y6019–LE) and Solenoid valve, spreading in right (Y6019–RI),
and is activated by Control unit KAU (D7911). The servo valve directs
servo pressure to the spreading slides proportional to the control cur-
rent to the solenoid valve.
ing 13/XX DIAGNOSE, page 8:62 and 7.5 Spreading 15/XX DIAG-
NOSE, page 8:62.


See Sensor, servo pressure attachment (B7668), page 7:50.
1 2 3 4 5
10
9 8 7 6
023695
Attachment with spreading with hydraulic cylinders

1. Solenoid valve, spreading in left (Y6019-LE)
2. Solenoid valve, spreading out left (Y6018-LE)
3. Solenoid valve, spreading in right (Y6019-RI)
4. Solenoid valve, spreading out right (Y6018-RI)
7. Connection to right spreading cylinder
8. Connection to left spreading cylinder

See Control valve attachment, replacement, page 7:51.

7 Load handling – Valve block spreader motor 7:71
7.5.5 Valve block spreader motor

Valve block spreader motor, description
Valve block spreader motor regulates the oil's direction to the spreader
motor. The valve block is fitted on the spreader motor all the way out to
the left on the front side of the attachment's main beam.
The valve block maintains a balance between supply and spreading
speed. Balance means that the valve block prevents the motor from
pumping oil, i.e. rotates faster than the supply of oil allows. Valve block
spreading contains overcentre valves that block the outlet if the pres-
sure on the outlet side is higher than the pressure on the inlet side.
7.5.6 Spreader motor

Spreader motor, description
Via two chains, the spreader motor moves the spreader beams in and
out in the attachment's main beam. The spreader motor is fitted all the
1 way out to the left on the front side of the attachment's main beam.
The hydraulic motor is integrated with a planetary gear that reduces
speed and makes the motor more powerful. Fitted on the hydraulic con-
nections is a valve block with two overcentre valves that prevents the
motor from rotating faster than the supplied hydraulic pressure.
2
3
016953
Spreader motor
1. Filling point
2. Sight glass
3. Drain plug

7:72 7 Load handling – Spreader motor
Spreader motor, replacement
NOTE
Safety.

2. Remove the cover plate on the left-hand side of the attachment's
main beam.
3. Start the engine and run spreading out until the chain tensioners
are visible in the inspection holes.
NOTE
7. Slacken the chain tensioner on the engine side and remove the
chain from the tensioner.
8. Remove the protective plate from over the spreader motor.

7 Load handling – Spreader motor 7:73
9. Mark up and detach the hydraulic hoses from the valve block to
the spreader motor.
10. Remove the protective plate at the spreader motor's gear.

017411 11. Remove the spreader motor unit.
12. Transfer the valve block to the new motor unit.
NOTE
correctly.
13. Clean the contact surfaces between the planetary gear and the at-
tachment's main beam.

7:74 7 Load handling – Spreader motor
14. Fit the motor unit. Position the chain on the motor's chain wheel
before the motor and protection plate are bolted in.
Tighten the bolts crosswise in steps until 117 Nm is achieved.
15. Attach the hydraulic hoses to the valve block on the motor.
017411
16. Connect the spreader chain to the chain tensioner. Check that the
chain runs straight in the chain wheel on the hydraulic motor.
17. Tension the spreading chain.
18. Check the oil level in the spreader motor's planetary gear, see
Maintenance manual.
For oil volume and type, see section F Technical data.
hydraulic system.
NOTE
the lock ring.
21. Check that the hydraulic connections are sealed tightly.
22. Check that the spreading is working.
23. Check the tension of the spreader chains, see Maintenance
manual.
24. Fit the protective plate to the spreader motor's gear.
25. Fit the protective plate over the motor.
26. Lubricate the spreading chain with chain oil/chain spray, see F
Technical data, page F:3.
27. Fit the cover plates on the attachment's main beam.
manual.

7 Load handling – Spreader chains 7:75
7.5.7 Spreader chains

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

1. Park the machine with the attachment as far down as possible.
2. Remove the cover plates on the attachment's main beam.
3. Start the engine and run spreading out until the chain tensioners
are visible in the inspection holes.
4. Switch off the engine and switch off the main electric power.
005105

7:76 7 Load handling – Spreader chains
5. Slacken the chain tensioner on the defective chain and remove it

from the tensioner.
005105
6. Remove the chain wheel on the defective chain.
NOTE
Note the location of the spacer ring.
If the chain wheel on the engine side must be removed, first re-
move the spreader motor. See Spreader motor, replacement, page
7:72.
7. Pull the chain out through the hole for the chain wheel so that the
chain runs along the spreader beam.
8. Temporarily fasten the chain along the cable rack to prevent the
chain from being pinched.

7 Load handling – Spreader chains 7:77
9. Pull out the spreader beam.

Use a machine or similar to pull the spreader beam out of the at-
tachment's main beam. Stop when the spreader beam is close to
the 40-foot stop.
NOTE
Support the spreader beam to minimise breaks. If necessary, re-
move the upper slide plates to reduce resistance.
10. Remove the boom stop from the attachment's main beam.
11. Remove the hydraulic hoses' clamping on the attachment's main
beam.
12. Detach the cable rack from the attachment's main beam. Support
the cable rack so that it is not damaged.
13. Pull out the spreader beam until the chain mounting becomes
accessible.
14. Detach the chain from the spreader beam and cable rack.
15. Connect the new chain to the spreader beam.
16. Fasten the chain along the cable rack so that it runs straight along
the spreader beam.
17. Brush grease on the chain.

7:78 7 Load handling – Spreader chains
18. Slide in the spreader beam so that the extension stop can be fitted.
19. Fit the extension stop.
20. Connect the cable rack to the attachment's main beam.
21. Fit the hydraulic hoses' clamping on the attachment's main beam.
22. Slide in the spreader beam until it is inserted the same amount as
the other one. This is important in order to facilitate the fitting of the
chains.
23. Detach the chain from the cable rack and insert it through the chain
wheel's hole.
24. Fit the chain wheel. The spacer ring must be fitted on the under-
side of the chain wheel.
If the spreader motor has been removed, refit it. See Spreader mo-
tor, replacement, page 7:72.
NOTE
Check that the chain runs straight in the chain wheels.
25. Connect the chain to the chain tensioner.
NOTE
Use a new split pin.
005105

7 Load handling – Spreader beam 7:79
26. Lubricate the chain wheel's bearings with lubricating grease.

27. If the slide plates have been removed, refit them.
28. Check the tension of the spreader chains, see Maintenance
manual.
30. Check that spreading is working correctly.
32. Fit the cover plates on the attachment's main beam.
7.5.8 Spreader beam

Spreader beam, description
The spreader beams are the part of the attachment that grips the con-
1 tainer. Two spreader beams run along in the main beam. The spreader
beams are slid in and out via the spreader motor and spreader chains.
10 The spreader beam houses twistlocks. See Twistlocks, description,
page 7:138.
9
8 2
3
4
023665
7 6 5
1. Side shift frame

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

7:80 7 Load handling – Spreader beam
Slide plates extension beam, changing

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

ment's main beam.
3. Remove the attaching bolts for the slide plate's bracket.
4. Remove the slide plate's guide screw.
5. Pull out the slide plate with spacer plate and bracket.
The illustration shows inner slide plates in the attach-

ment's main beam.
6. Align the new slide plate in the correct position. Lubricate the slide
plates, see Lubricating grease, page F:11.
Check the clearance between extension beam and slide plate. The
clearance should be max. 1 mm with all slide plates fitted.
Use a spacer plate to adjust the clearance.
7. Fit the slide plate's bracket and guide screw.

7 Load handling – Main beam, attachment 7:81
Lubrication
grease for slide plates, see Lubricating grease, page F:11.
004875
9. Operate spreading in and out fully approximately 10 times and
check the spreading function.
surfaces.
11. Try to lift a container and then check the extension beams' clear-
ance again on the attachment's main beam.
7.5.9 Main beam, attachment

See Main beam attachment, description, page 7:57.

7:82 7 Load handling – Position sensor, spreading
7.5.10 Position sensor, spreading

Position sensor spreading, description
Attachment with chain spreading
The spreading position sensors indicate the position of the spreader
1 2 3 4 5 beams. The position sensors are used to control spreading so that the
twistlocks fit the container. The position sensors are fitted on the rear of
the attachment's main beam on the left-hand side.
Stop 20-foot and 40-foot position

Sensor, end position 20'-40' (B7690) indicates end position for 20 and
40-foot containers. The sensor detects the end positions of the spread-
ing beams via two indicator plates on the spreading beam. The sensor
is used to activate damping for 20-foot and 40-foot containers.
Sensor, extra stop spreading (B7770) indicates stop for 20-foot and 40-
foot containers. The sensor detects the end positions of the spreading
beams via two indicator plates on the spreading beam. The sensor is
used to stop spreading for 20-foot and 40-foot containers.
If the machine is equipped with extra stop 30'-35' on the spreading, an

extra indicator plate is fitted.
Sensor, extra stop spreading (B7770) indicates end position for 30-foot
and 35-foot containers. The sensor detects the end position for the 30-
foot and 35-foot spreading beams via an indicator plate on the spread-
ing beam. The sensor is used to activate damping for 30-foot and 35-
003165
foot containers.
Sensor, end position 20'-40' (B7690) indicates stop for 30-foot and 35-
1. Indicator plate 20'
foot containers. The sensor detects the end position for the 30-foot and
2. Sensor, end position 20'-40' (B7690)
35-foot spreading beams via an indicator plate on the spreading beam.
3. Sensor, extra stop spreading (B7770) The sensor is used to stop spreading for 30-foot and 35-foot containers.
4. Indicator plate, extra stop 30'-35' spreading
5. Indicator plate 40' Sensor signals
The sensors are supplied with voltage and send a 24V signal to Control
unit KAU (D7911). Indicator plates are fitted on the spreading beams in
such a way that the sensors generate a signal when the spreader unit
passes the sensor. The position of the indicator plates and the sensors
is adapted so that the distance between the spreaders will be 20', (ex-
tra stop) and 40'. The hydraulic spreading function of the attachment is
stopped when sensors give a signal but there is also a mechanical stop
for 20' and 40' positions fitted in the main beam.

7 Load handling – Position sensor, spreading 7:83
Attachment with cylinder spreading
The spreading position sensors indicate the position of the spreader

beams. The position sensors are used to control spreading so that the
twistlocks fit the container. The left-hand position sensors are fitted on
the rear of the attachment's main beam on the left-hand side. The right-
hand position sensors are fitted on the front of the attachment's main
beam on the right-hand side.

Sensors end position 20'-40' left/right (B7690–LE) and (B7690–RI) indi-
cate the end position for 20-foot and 40-foot containers. The sensors
detect the end positions of the spreading beams via two indicator plates
on each spreading beam. The sensors are used to activate damping
for 20-foot and 40-foot containers.
1 2 3 4 5 Sensor, extra stop spreading left/right (B7770–LE and B7770–RI) indi-
cates stop for 20-foot and 40-foot containers. The sensors detect the
end positions of the spreading beams via two indicator plates on each
spreading beam. The sensors are used to stop spreading for 20-foot
and 40-foot containers.
If the machine is equipped with extra stop 30'-35' on the spreading, an

extra indicator plate is fitted on each spreading beam.
Sensor, extra stop spreading left/right (B7770–LE and B7770–RI) indi-
cates end position for 30-foot and 35-foot containers. The sensors de-
tect the end position for the 30-foot and 35-foot spreading beams via
an indicator plate on each spreading beam. The sensors are used to
activate damping for 30-foot and 35-foot containers.
Sensors, end position 20'-40' left/right (B7690–LE) and (B7690–RI) in-
dicate stop for 30-foot and 35-foot containers. The sensors detect the
end position for the 30-foot and 35-foot spreading beams via an indica-
tor plate on each spreading beam. The sensors are used to stop
spreading for 30-foot and 35-foot containers.
Sensor signals
The sensors are supplied with voltage by, and send a 24 V signal to
Control unit KAU (D7911) when the indicator plates pass the sensor. In-
023666
dicator plates on the spreader units are fitted so that the sensors gener-
6 7 8 9 10
ate a signal when the spreader unit passes the sensor. The position of
1. Indicator plate 20' left the indicator plates and the sensors is adapted so that the distance be-
2. Sensor, end position 20'-40' left (B7690–LE) tween the spreaders will be 20', (extra stop) and 40'. The hydraulic
3. Sensor, extra stop spreading left (B7770–LE) spreading function of the attachment is stopped when sensors give a
4. Indicator plate, extra stop 30'-35' spreading left signal but there is also a mechanical stop for 20' and 40' positions fitted
in the main beam.
5. Indicator plate 40' left The signals can be checked with the diagnostic menu, see 7.5 Spread-
6. Indicator plate 20' right ing 9/XX DIAGNOSE, page 8:60.
7. Sensor, end position 20'-40' right (B7690–RI)
8. Sensor, extra stop spreading right (B7770–RI)
9. Indicator plate, extra stop 30'-35' spreading right
10. Indicator plate 40' right


7:84 7 Load handling – Relief valve top lift

See Relief valve top lift, description, page 7:57.

7.5.13 Buzzer, automatic spreading 20'-40'

Buzzer automatic spreading 20'-40', description
Buzzer, automatic spreading 20'-40' (H9003) is fitted on the front of the

attachment on machines equipped with automatic spreading 20'-40'.
The buzzer is supplied with voltage directly by Control unit KAU
(D7911) during automatic spreading movement.
018527
7.5.14 Spreading cylinder

Spreading cylinder, description
The spreading cylinders move the spreader beams in and out in the at-
tachment's main beam. The spreading cylinders are fitted inside the
spreading beams with the rod end attached into the spreading beam
and the piston end attached into the attachment's main beam. Spread-
ing uses two cylinders, one for each spreading beam, the spreading
cylinders are controlled individually by separate sections in Control
valve attachment.
008774
Spreading cylinder

7 Load handling – Spreading cylinder 7:85
Spreading cylinder, replacement
NOTE
Safety in the standard manual.
Removing
1. Machine in service position, see section B Safety in the standard
manual.
2. Run spreading out so that the hole for the inner attachment of the
spreading cylinder in the spreader beam is visible.
3. Depressurise the brake and hydraulic systems, see section B
Safety in the standard manual.
022949
Holes for inner attachment, spreading cylinder.

5. Mark up and disconnect the hydraulic connections for the spread-
A ing cylinder.
NOTE
from impurities.
6. Attach lifting equipment to the spreading cylinder.

023302
A. Hydraulic hoses, spreading cylinder.

7. Release the spreading cylinder's inner attachment. Remove the at-
taching bolt.
023301
Attaching bolt inner attachment spreading cylinder

7:86 7 Load handling – Spreading cylinder
1 2 3 8. Remove the spreading cylinder's attaching bolt (position 1) and re-

lease the spreading cylinder from the bracket.
9. Mark out the position of the spreading cylinder's brackets at the
outer attachment and release them from the attachment's main
beam.
IMPORTANT
It is important that the location of the brackets is
marked out so that they can be refitted in the same
place. If this is not done then the C-C distance between
the twistlocks will be wrong.
10. Lift out the spreading cylinder carefully, move the lifting equipment
023303
so that the spreading cylinder is kept in balance.
Outer attachment spreading cylinder.
1. Attaching bolt, spreading cylinder
2. Attaching bolt, bracket
3. Adjusting screw
Installing
11. Use a wooden beam, or similar (A), on which to position the new
A cylinder.
022936
12. Remove the end plugs at A and B.
B
022937

7 Load handling – Spreading cylinder 7:87
13. Install the air nipples as provided by the workshop at A and B.
022938
14. Loosen the bolts located on the piston rod end.
022939
15. Slowly apply air pressure at B until the new spreading cylinder is
the same length as the old one that was removed. Then adjust the
connector so that it is the same length as the one that was re-
moved. Then tighten the screws again.
IMPORTANT
B Measure and note the position of the inner attachment
lug and fit it in the same way on the new cylinder. If this
is not done then the C-C distance between the twist-
locks will be wrong.
015968
16. Lift the new spreading cylinder into place; check that the cylinder is
located above the bracket at the rear of the spreader beam.
17. Connect the inner attachment and fit the attaching bolt.
DANGER
Check that the nut is fitted in place on the attachment
for the spreading cylinder.
Danger to life!
If the nut is not fitted in place then the attachment may
loosen during operation and cause personal injury or
fatality.
023304
A
Nut inner attachment spreading cylinder.

1 2 3 18. Fit the outer attachment's brackets to the attachment's main beam
in accordance with the marking. Tighten to a torque of 390 Nm.
IMPORTANT
Fit the brackets in accordance with the marking. If this
is not done then the C-C distance between the twist-
locks will be wrong.
19. Connect the spreading cylinder to the outer attachment. Tighten to

a torque of 680 Nm. Use the adjusting screw (position 3) for fine
adjustment.
023303
1. Attaching bolt, spreading cylinder, 680 Nm
2. Attaching bolt, bracket, 390 Nm
3. Adjusting screw
20. Connect the hydraulic hoses to the spreading cylinder.
A
NOTE
correctly.

23. Check that the spreading is working.
023302
A. Hydraulic hoses, spreading cylinder.

24. Check the oil level in the hydraulic oil tank with the lift cylinders
fully lowered and the extension cylinder fully retracted. The oil level
should be at the top of the sight glass. Top up if necessary.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom fully
lowered and retracted.


7 Load handling – Rotation 7:89
7.6 Rotation
Rotation, description
The attachment can be rotated +195° - 105° in relation to the machine.
Control valve attachment pressurises Valve block rotation motor. Valve
block rotation motor routes pressure to the rotation motors that rotate
the attachment. Rotation is controlled by Control lever (S8150). The
voltage signal controls direction and speed (clockwise or anticlockwise).
016202
Rotation, function description
Reference
Sensor, operator-in-seat Not activated Sensor operator in seat, description, page 9:25
(operator in
seat)
1 1 D1
17
D7950
2
D7902
D7971 D7911
3, 8 8, 15, 16
5
D8
D7940
D7930 D4 C12 9 D3
4, 6 D14
P1 Pa
3
5 10
T1 A B
LSP1 A H
LSP2 LSPR
LSP3
68 LSHY
LSP3X PT T P LSM LSO 11
C7 12 14
13
023375

7:90 7 Load handling – Rotation

1 Control lever (S8150-R8070-4) Anticlockwise: UR8070-4 = 0.5– Control lever (Ego), description, page 7:6
sends a voltage signal to Control unit 2.0 V D1: Diagnostic menu, see 7.1 Controls and
KPU (D7902). Zero position: UR8070-4 = 2.0– Instr 6/XX DIAGNOSE, page 8:53.
3.0 V
Clockwise: UR8070-4 = 3.0–4.5
V
0.5 V and 4.5 V represent the
maximum rotation speed.
Lower voltage than 0.5 V and
higher voltage than 4.5 V is
used to detect faults in cable
harnesses and controls.
1 Control lever (S8150-P3) sends a Anticlockwise: US8150/P3 = 0.5– Control lever (Cobra), description, page 7:10
voltage signal to Control unit KPU 2.0 V D1: Diagnostic menu, see 7.1 Controls and
(D7902) proportional to lever Zero position: US8150/P3 = 2.0– Instr 6/XX DIAGNOSE, page 8:53.
movement. 3.0 V
Clockwise: US8150/P3 = 3.0–4.5
V
0.5 V and 4.5 V represent the
maximum rotation speed.
Lower voltage than 0.5 V and
higher voltage than 4.5 V is
used to detect faults in cable
harnesses and controls.
2 Control unit KPU (D7902) sends ro- Checked by control system, 11.5.3.2 KPU control unit (D7902), page
tation clockwise or rotation anticlock- error shown with error code. 11:30
wise on the CAN bus.
3 Control unit KFU (D7971) sends a Checked by control system, 11.5.3.1 KCU control unit (D7901), page
request for engine speed require- error shown with error code. 11:27
ment CAN bus drive-train based on
information on lever deflection.
sends a rotation speed request on error shown with error code.
CAN bus drive-train to Control unit
engine (D7940).
controls the ratio between drive and error shown with error code.
power take-off by changing the
transmission's gear ratio.
(B7688) sends a voltage signal pro- page 7:50
portional to the oil pressure in the D3: Diagnostic menu, see 10.4 Pumps 7/XX
control valve for the attachment to DIAGNOSE, page 8:134
Control unit KAU (D7911).
8 Control unit KAU (D7971) controls U = 24 V 11.5.3.4 Control unit KFU (D7971), page
Proportional valve, load signal at- 11:34
tachment (Y6002), proportional to D4: Diagnostic menu, see 10.4 Pumps 6/XX
the attachment's pressure DIAGNOSE, page 8:134
requirements.
9 Proportional valve, load signal at- - Proportional valve, load signal attachment
tachment (Y6002), opens and sends (Y6002), description, page 10:25
a load signal to hydraulic oil pump 1.
The size of the load signal is con-
trolled by the voltage signal from
Sensor, oil pressure attachment
(B7688).
The load signal is 0.3–1.5 MPa
greater than the pressure detected
by Sensor, servo pressure attach-
ment (B7668).

7 Load handling – Rotation 7:91

10 Valve block servo pressure sends - Valve block servo pressure, description, page
the load signal to hydraulic oil pump 10:25
1. Shuttle valves in the servo valves
select the strongest load signal if
other functions are activated at the
same time.
11 Hydraulic oil pump 1 pumps oil from See the pressure plate on the Axial piston pump with variable displacement,
the hydraulic oil tank. left-hand frame beam. description, page 10:8
The amount of oil supplied to the
control valve for the attachment de-
pends on the requirements of the at-
tachment functions.
12 Control unit KAU (D7911) activates I = 400–590 mA 11.5.3.8 Control unit KAU (D7911), page
Solenoid valve rotation clockwise 11:40
(Y6008) or Solenoid valve rotation D8: Diagnostic menu, see 7.6 Rotation 1/XX
anticlockwise (Y6009). DIAGNOSE, page 8:63 and 7.6 Rotation 2/
XX DIAGNOSE, page 8:63.
13 Solenoid valve rotation clockwise - Attachment control valve, description, page
(Y6008), or Solenoid valve rotation 7:92
anticlockwise (Y6009), pressurises
the rotation slide in control valve,
attachment.
14 The rotation slide in Control valve, - Attachment control valve, description, page
attachment changes position and 7:92
controls the pressure to the Valve
block hydraulic motor.
15 Valve block hydraulic motor routes - Valve block rotation motor, description, page
pressure to both the hydraulic mo- 7:93
tors and their disc brakes.
16 The hydraulic motors' disc brakes - Rotation motor unit, description, page 7:93
are disengaged.
17 The hydraulic motors rotate the - Rotation motor unit, description, page 7:93
attachment.
18 Rotation stop Sensor directly opposite indi- Sensor rotation stop, description, page 7:99
Sensor, rotation stop (B7225) sends cator plate: U = 24 V D4: Diagnostic menu, see 7.6 Rotation 3/XX
a voltage signal to Control unit KAU DIAGNOSE, page 8:64
(D7911).
19 Rotation stop - Attachment control valve, description, page
The rotation is stopped by Control 7:92
unit KAU (D7911) disconnecting the D8: Diagnostic menu, see 7.6 Rotation 1/XX
current to Servo valve rotation clock- DIAGNOSE, page 8:63 and 7.6 Rotation 2/
wise (Y6008) or Servo valve rotation XX DIAGNOSE, page 8:63.
anticlockwise (Y6009).
20 Rotation stop Checked by control system, 11.5.3.8 Control unit KAU (D7911), page
Control unit KAU (D7911) sends ro- error shown with error code. 11:40
tation stop on the CAN bus.
21 Rotation stop - 11.5.3.3 Control unit, KID (D7950), page
When the rotation stop has been 11:32
reached, the KID control unit
(D7950) activates the event menu
for rotation stop.
Use bypass to rotate past the rota-
tion stop

7:92 7 Load handling – Hydraulic oil pump

10:8.

Rotation is controlled by a separate section in the attachment's control
1 2 3 valve. For a general description of the valve and component locations,
see Attachment control valve, description, page 7:49.
Rotation slide
The valve slide controls the direction and speed of rotation. The valve
8 slide is controlled by Servo valve rotation clockwise and Servo valve ro-
tation anticlockwise.
Servo valve, rotation clockwise

Servo valve, rotation clockwise controls pressure to the rotation slide
so that the rotation slide opens and pressurises the rotation motors.
Servo valve rotation clockwise is controlled electrically by Solenoid
valve rotation clockwise (Y6008), which is activated by Control unit
KAU (D7911). The servo valve directs servo pressure to the rotation
slide proportional to the control current to the solenoid valve.
7 The signal can be checked with the diagnostic menu, see 7.6 Rotation
6 5 4 1/XX DIAGNOSE, page 8:63.
Servo valve, rotation anticlockwise

Servo valve, rotation anticlockwise controls pressure to the rotation
slide so that the rotation slide opens and pressurises the rotation
motors.
Servo valve rotation anticlockwise is controlled electrically by Solenoid
valve rotation anticlockwise (Y6009), which is activated by Control unit
022685
KAU (D7911). The servo valve directs servo pressure to the rotation
slide proportional to the control current to the solenoid valve.
1. Solenoid valve rotation anticlockwise (Y6009)
The signal can be checked with the diagnostic menu, see 7.6 Rotation
2. Solenoid valve rotation clockwise (Y6008)
4. Return to tank (through tank filter) Sensor, servo pressure attachment (B7668)
5. Connection to rotation motor
6. Connection to rotation motor
7. Sensor, servo pressure attachment (B7688)


7 Load handling – Valve block rotation motor 7:93
7.6.5 Valve block rotation motor

Valve block rotation motor, description
Valve block rotation motor controls pressure to the rotation motors. The
valve block is fitted on one of the rotation motors.
The valve block provides a controlled rotation by preventing the load
1 2 from pulling away and provides faster rotation than that provided by the
hydraulic motor. The valve block contains a shuttle valve and over-
centre valves.
6
3
5
016905
4
1. Hydraulic motor rotation
2. Valve block rotation motor
3. Ring gear
4. Gear wheel
5. Planetary gear
6. Disc brake
7.6.6 Rotation motor unit

Rotation motor unit, description
The rotation motors rotate the attachment in relation to the boom. The
motors are fitted at the front of the attachment's rotation yoke. The mo-
tors work against the ring gear between the rotation yoke and the side
shift frame. The rotation motor unit consists of hydraulic motor, disc
1 2 brake and planetary gear which are built together into one unit.
The hydraulic motor is fitted on the disc brake's housing. A gear wheel
6 is fitted between the motor and the discs.
3
5 The disc brake prevents accidental rotation. The disc brake is applied
with springs and is disengaged when the hydraulic pressure is built up
016905
to rotate the yoke.

4
The planetary gear reinforces the output in the motor and disc brake.
1. Hydraulic motor rotation The planetary gear changes down the motor's rotation speed so that
2. Valve block rotation motor motor power is greater.
3. Ring gear
4. Gear wheel
5. Planetary gear
6. Disc brake

7:94 7 Load handling – Rotation motor unit
Rotation motor unit, changing
NOTE
Safety.
Removing
NOTE
3. Mark up and disconnect the hydraulic hoses from motor.
NOTE
from impurities.
4. Remove the hydraulic motor's attaching bolts.

5. Lift away the rotation motor unit. Position the motor unit so that the
pinion and planetary gear are not damaged.
018587
Installing
6. Clean the contact surfaces on the motor unit and rotation yoke.
7. Transfer the parts that can be re-used to the new motor unit.
NOTE
correctly.
8. Lift the new motor unit into place on the rotation yoke.
9. Fit the motor unit. Tighten the bolts crosswise in steps until 80 Nm
Valve block left rotation motor is achieved.
10. Connect the hydraulic hoses to the motor and brake according to
the marking.
NOTE
correctly.
hydraulic system.
NOTE
018587
the lock ring.

7 Load handling – Rotation yoke 7:95
12. Top up the oil in rotation motor's planetary gear and brake unit.
a) Remove the bleed (position 1).
1 1 b) Remove the level plug (position 3).
c) Slowly fill oil throughout bleeding until oil emerges at the level
plug.
2 2
For oil volume and type, see section F Technical data.
d) Fit the level plug for oil (position 3).
3 3 e) Fill oil carefully until the level is in centre of the sight glass (po-
sition 2).
4 4 f) Fit the bleed (position 1).

018586
15. Check that the rotation works.
1. Bleeding (filling point)
2. Sight glass 16. Check the oil level in the hydraulic oil tank, see Maintenance
manual.
3. Level plug
4. Drain plug
7.6.7 Rotation yoke

Rotation yoke, description
The rotation yoke is the part of the attachment that connects the attach-
1 2 3 4 5 6 ment to the boom. The rotation yoke is secured on the inner boom with
two shafts that run in bearing-equipped attaching lugs. The ring gear is
fitted in the bottom of the rotation yoke with lead-through bolts.
Using the rotation motors, which act on the ring gear, the remaining
parts of the attachment can be rotated in relation to the lift boom.
The rotation yoke's mounting in the lift boom facilitates longitudinal
movement (so-called tilt). The oscillating motion is dampened by two
hydraulic cylinders that are secured between the upper yoke and the
upper edge of the inner boom.
000526
1. Main beam
2. Ring gear
4. Rotation yoke
6. Side shift frame
Rotation yoke, changing

1. Clean the attachment and boom nose.
2. Disconnect the attachment from the boom.
3. Remove the rotation motors from the rotation yoke, see Rotation
motor unit, changing, page 7:94.

7:96 7 Load handling – Rotation yoke
4. Install the lifting equipment on the rotation yoke.
5. Remove the pipes for ring gear lubrication.
The illustration shows removed rotation yoke and ring

gear.
6. Remove the rotation yoke's attaching bolts.
7. Lift away the rotation yoke.
8. Clean the contact surfaces on the ring gear.
9. Remove the plastic plugs and clean the threads and holes on the
new rotation yoke, clean the contact surface against the ring gear.
10. Transfer parts to the new rotation yoke.
• Grease cups
• Mounting pins
11. Transfer the lifting equipment to the new rotation yoke.

12. Lift the new rotation yoke into place.
NOTE
Align the position against that of the ring gear so that the lubrica-
tion lines can be installed.
13. Brush the rotation yoke's mounting pins with grease and install
them in the rotation yoke.

7 Load handling – Rotation yoke 7:97
1 14. Fit and tighten the ring gear's inner mounting parts crosswise in
accordance with the tightening schedule to a torque of 330 Nm
8 5 (oiled screw).
Number the mounting parts clockwise in order to be able to keep a
check on which have been tightened.
4 3
IMPORTANT
Counterhold the screw and tighten the nut.
6 7
2 15. When all the mounting parts are tightened, check the tightening
once more on all mounting parts crosswise in accordance with the
tightening schedule to a torque of 330 Nm (oiled screw).
40
1
017480
Tightening schedule and numbering of the ring gear's

mounting parts
16. Install the pipes for the ring gear's lubrication lines.
17. Lubricate the ring gear with grease.
Rotate the yoke during lubrication it so that the grease is distrib-
uted evenly.
18. Rotate the yoke so that it is aligned straight.
19. Install the rotation motors, see Rotation motor unit, changing, page
7:94.
NOTE
If necessary, rotate the rotation yoke slightly so that the rotation
motor's gear wheel aligns against the ring gear.
20. Connect the attachment to the boom.
NOTE
Make sure you lubricate the shaft and bearing surfaces with lu-
bricating grease before installation.
21. Start the motor and check that the rotation works.
22. Clean the attachment.
manual.
24. Retighten the rotation yoke's attaching bolts after 50 hours operat-
ing time. Check the tightening once more on all mounting parts
crosswise in accordance with the tightening schedule to a torque
of 330 Nm (oiled screw).

7:98 7 Load handling – Ring gear
7.6.8 Ring gear

Ring gear, description
The ring gear is the joint between the rotation yoke and the side shift
frame. The ring gear consists of gear wheel, bearings and mounting
parts. The unit is bolted into the rotation yoke and side shift frame.
1 2
6
3
5
016905
4
1. Hydraulic motor rotation
3. Ring gear
4. Gear wheel
5. Planetary gear
6. Disc brake
Ring gear, changing

1. Remove the rotation yoke, see Rotation yoke, changing, page
7:95.
2. Remove the lubricating pipes from the ring gear.
NOTE
Note the locations of the lubricating pipes to facilitate reinstalling.
3. Remove the attaching bolts between the ring gear and the side
The illustration shows removed rotation yoke and ring shift frame.
gear.
4. Lift away the ring gear.
5. Clean the contact surfaces on the side shift frame and ring gear.
6. Lift the new ring gear into place.
NOTE
Rotate it so that the connections for the lubricating pipes are in
the same positions as before.

1 7. Fit and tighten the ring gear's outer mounting parts crosswise in
accordance with the tightening schedule to a torque of 330 Nm
8 5 (oiled screw).
Number the mounting parts clockwise in order to be able to keep a
check on which have been tightened.
4 3
IMPORTANT
Counterhold the screw and tighten the nut.
6 7
2 8. Install the rotation yoke, see Rotation yoke, changing, page 7:95.
9. When all the mounting parts are tightened, check the tightening
once more on all mounting parts crosswise in accordance with the
tightening schedule to a torque of 330 Nm (oiled screw).
40
1
017480
Tightening schedule and numbering of the ring gear's

mounting parts
10. Install the lubricating pipes for the ring gear.
11. Lubricate the ring gear with grease.
12. Start the motor and check the function of the rotation.
manual.
The illustration shows removed rotation yoke and ring 14. Retighten the rotation yoke's attaching bolts after 50 hours operat-
gear. ing time. Check the tightening once more on all mounting parts
crosswise in accordance with the tightening schedule to a torque
of 330 Nm (oiled screw).

See Side shift frame, description, page 7:53.
7.6.10 Sensor rotation stop

Sensor rotation stop, description
Sensor, rotation stop (B7225) indicates when the rotation is ±25° from
the centre position and is used to activate rotation stop. The sensor is
fitted on a bracket on the left-hand side of the rotation yoke and detects
25° toward the rotation yoke's stop.
The sensor is supplied with voltage and sends a voltage signal to Con-
trol unit KAU (D7911) when the stop is in contact with the sensor. The
sensor is in contact with the stop ±25°.
The signal can be checked with the diagnostic menu, see 7.6 Rotation

7:100 7 Load handling – Relief valve top lift





7 Load handling – Tilt 7:101
7.7 Tilt
Tilt, description
The mounting for the rotation yoke is jointed and equipped with two hy-
draulic cylinders connected crosswise that dampen the oscillations.
The cylinders are pressurised by the hydraulic system and intercon-
nected with a damping block.
There are five different versions of tilt:
016203
• Damping
• Damping with tilt lock
• Damping with controllable tilt
• Damping with controllable tilt and tilt lock
• Damping with controllable tilt, tilt lock and extended tilt function
If the machine is equipped with tilt lock then an electrically controlled
blocking valve is used in the damping block.
If the machine is equipped with controllable tilt then the hydraulic cylin-
ders are supplied from a separate section in the control valve on the
attachment.
Tilt damping, description

Tilt means that the attachment can swing forward and back in the
mounting to the boom in order that the load should hang straight
throughout lifting movement. Tilt damping means that the tilt movement
is counteracted.
The attachment's mounting in the boom is jointed and equipped with
two hydraulic cylinders that dampen the oscillations. The hydraulic cyl-
inders are connected crosswise to Damping block tilt. Damping block
tilt is supplied with servo pressure from Control valve attachment that is
routed to the tilt cylinders and creates overpressure in the tilt cylinders.
Adjustable restrictions between the connections for piston and rod side
in the damping block create resistance that dampens the tilt movement.
Tilt damping, function description

2
C1-
P C2+
C1+ 3
T C2-
1
022686

1 Hydraulic oil pump 1 pumps oil at standby See the pressure plate Axial piston pump with variable displace-
pressure. on the left-hand frame ment, description, page 10:8
beam.
2 The tilt damping block distributes oil to the tilt - Damping block tilt, description, page 7:109
cylinders.
3 The tilt cylinders dampen the attachment's - Tilt cylinder, description, page 7:113
movements.

7:102 7 Load handling – Tilt

Tilt lock, description
Tilt lock is an option for tilt damping, which means that the tilt move-
ment can be locked.
Tilt lock uses two solenoid valves in the damping block. One blocks the
connection between the tilt cylinders and the damping block while the
other blocks the supply of servo pressure from Control valve attach-
ment. Tilt lock is activated by a switch on Control lever (S8150).
016342
When tilt lock is activated, the machine's speed is limited to max. 5 km/
h.
Event menu tilt lock
Tilt lock, function description
Reference
(operator in
seat)
D1
11
D7950
1 1 2
D7902
5, 13 D7971 D7911
3, 12 7
D7940
D7
D7930
8
4, 6, 14
C1-
P C2+
9 10
C1+
T C2-
023376

1 Switch, tilt lock (S7251) sends a voltage U = 24 V Control lever (Ego), description, page 7:6
signal to Control unit KPU (D7902). D1: Diagnostic menu, see 7.1 Controls and
Instr 7/XX DIAGNOSE, page 8:53
1 Switch, tilt lock (S8150-T3.2) sends a U = 24 V Control lever (Cobra), description, page 7:10
voltage signal to Control unit KPU D1: Diagnostic menu, see 7.1 Controls and
(D7902). Instr 7/XX DIAGNOSE, page 8:53, S7251
C4p7.


2 Control unit KPU (D7902) sends tilt lock Checked by control sys- 11.5.3.2 KPU control unit (D7902), page 11:30
on the CAN bus. tem, error shown with er-
ror code.
3 Control unit KFU (D7971) sends a re- Checked by control sys- 11.5.3.1 KCU control unit (D7901), page 11:27
quest for engine speed requirement CAN tem, error shown with er-
bus drive-train based on information on ror code.
lever deflection.
4 Control unit transmission (D7930) sends Checked by control sys- Transmission, function description, page 2:3
a rotation speed request on CAN bus tem, error shown with er-
drive-train to Control unit engine (D7940). ror code.
5 Control unit, engine (D7940) increases Checked by control sys- 11.5.3.6 Control unit, engine (D7940), page
the engine speed. tem, error shown with er- 11:38
ror code.
6 Control unit transmission (D7930) con- Checked by control sys- Transmission, function description, page 2:3
trols the ratio between drive and power tem, error shown with er-
take-off by changing the transmission's ror code.
gear ratio.
7 Control unit KAU (D7911) supplies volt- Float position: U = 24 V 11.5.3.8 Control unit KAU (D7911), page
age to Solenoid valve tilt lock 1 (Y6012- Lock position: U = 0 V 11:40
1) and Solenoid valve tilt lock 2 (Y6012- D3: Diagnostic menu, see 7.7 Tilt 6/XX DIAG-
2). NOSE, page 8:65
8 Solenoid valve tilt lock 1 (Y6012-1) and - Lock valve tilt, description, page 7:111
Solenoid valve tilt lock 2 (Y6012-2) pres- D3: Diagnostic menu, see 7.7 Tilt 6/XX DIAG-
surise the lock valve in the attachment's NOSE, page 8:65
control valve.
9 The lock valve changes position and - Lock valve tilt, description, page 7:111
blocks the connections to the tilt
cylinders.
10 The tilt cylinders lock the attachment's - Tilt cylinder, description, page 7:113
inclination.
11 When tilt lock is activated, Control unit - 11.5.3.3 Control unit, KID (D7950), page
KID (D7950) shows Event menu tilt lock if 11:32
the speed is approaching the maximum
limit (5 km/h).
When tilt lock is activated, the machine's
speed is limited to max. 5 km/h.
12 Control unit KFU (D7971) sends speed - 11.5.3.4 Control unit KFU (D7971), page
limitation on CAN bus drive-train. 11:34
13 Control unit, engine (D7940) limits the - 11.5.3.6 Control unit, engine (D7940), page
engine speed 11:38
14 Control unit transmission (D7930) limits - 11.5.3.7 Control unit, transmission (D7930),
the gear range. page 11:39
Tilt control, description
Tilt control is an option for tilt damping and means that tilting the attach-
ment can be controlled at least ±2° from straight position, regardless of
boom position at max. classified load. Depending on boom angle and
load, the possible tilt angle varies.

Tilt control is controlled by Control lever (S8150). An additional section

in Control valve attachment pressurises the tilt cylinders via Damping
block tilt so that the attachment is angled.
If the machine is equipped with tilt control then tilt lock is also included,
see Tilt lock, description, page 7:102.
Tilt control, function description
Reference
(operator in
seat)
1 D1
D7950 19
+
2
D7902
5 D7971 D7911
3, 8 12, 15
D7940 D15
D12
D7930
4, 6 16 D7 13
C10
D8 Pa
7
P P P1
9 T T 14
17 T1
A A B
C1+ C1-
LSP1 A H C2- C2+ B
LSP2 LSPR
LSP3
108 LSHY
C11
18
11
022688

Control lever (S8150-R8070-4) In: UR8070-4 = 0.5–2.0 V D1: Diagnostic menu, see 7.1 Controls and
send a voltage signal to Control Zero position: UR8070-4 = 2.0– Instr 6/XX DIAGNOSE, page 8:53 and 7.1
unit KPU (D7902). 3.0 V Controls and Instr 7/XX DIAGNOSE, page
Out: UR8070-4 = 3.0–4.5 V 8:53.
2 Control unit KPU (D7902) sends tilt Checked by control system, 11.5.3.2 KPU control unit (D7902), page 11:30
in or tilt out on the CAN bus. error shown with error code.


3 Control unit KFU (D7971) sends a Checked by control system, 11.5.3.1 KCU control unit (D7901), page 11:27
request for engine speed require- error shown with error code.
engine (D7940).
controls the ratio between drive error shown with error code.
and power take-off by changing the
(B7688) sends a voltage signal page 7:50
proportional to the oil pressure in D3: Diagnostic menu, see 10.4 Pumps 7/XX
the control valve for the attachment DIAGNOSE, page 8:134
to Control unit KAU (D7911).
8 Control unit KAU (D7971) controls U = 24 V 11.5.3.4 Control unit KFU (D7971), page 11:34
Proportional valve, load signal at- D3: Diagnostic menu, see 10.4 Pumps 6/XX
tachment (Y6002), proportional to DIAGNOSE, page 8:134
the attachment's pressure
requirements.
tachment (Y6002), opens and (Y6002), description, page 10:25
sends a load signal to hydraulic oil
pump 1. The size of the load signal
is controlled by the voltage signal
from Sensor, oil pressure attach-
ment (B7688).
ment (B7668).
the load signal to hydraulic oil 10:25
pump 1. Shuttle valves in the servo
valves select the strongest load
signal if other functions are acti-
vated at the same time.
11 Hydraulic oil pump 1 pumps oil See the pressure plate on the Axial piston pump with variable displacement,
from the hydraulic oil tank. left-hand frame beam. description, page 10:8
pends on the requirements of the
attachment functions.
12 Control unit KAU (D7911) activates I = 330–570 mA 11.5.3.8 Control unit KAU (D7911), page 11:40
Solenoid valve tilt out (Y6010) or D7: Diagnostic menu, 7.7 Tilt 4/XX DIAG-
Solenoid valve tilt in (Y6011). NOSE, page 8:64 or 7.7 Tilt 5/XX DIAGNOSE,
page 8:65
13 Solenoid valve, tilt out (Y6010) or - Attachment control valve, description, page
Solenoid valve, tilt in (Y6011) pres- 7:112
surises the tilt slide in the attach- D7: Diagnostic menu, 7.7 Tilt 4/XX DIAG-
ment's control valve. NOSE, page 8:64 or 7.7 Tilt 5/XX DIAGNOSE,
page 8:65
14 The control valve's tilt slide - Attachment control valve, description, page
changes position and pressurises 7:112
the damping valve.


15 Control unit KAU (D7911) discon- Float position: U = 24 V 11.5.3.8 Control unit KAU (D7911), page 11:40
nects the voltage feed to Solenoid Lock position: U = 0 V D10: Diagnostic menu, see 7.7 Tilt 6/XX DIAG-
valve tilt lock 1 (Y6012-1) and Sol- NOSE, page 8:65
enoid valve tilt lock 2 (Y6012-2).
16 Solenoid valve tilt lock 1 (Y6012-1) - Lock valve tilt, description, page 7:111
and Solenoid valve tilt lock 2 D10: Diagnostic menu, see 7.7 Tilt 6/XX DIAG-
(Y6012-2) pressurise the lock valve NOSE, page 8:65
17 The lock valve changes position - Damping block tilt, description, page 7:109
and directs oil crosswise to the tilt
cylinders.
18 The tilt cylinders change the at- - Tilt cylinder, description, page 7:113
tachment's inclination.
19 When tilt is controlled and speed is Checked by control system, 11.5.3.3 Control unit, KID (D7950), page 11:32
limited, Control unit KID (D7950) error shown with error code.
shows Event menu speed
limitation.
Extended tilt function, description
As an option, the machine can be equipped with extended tilt function,

attachment. This means that the attachment can tilt containers to high-
er tilt angles than standard machines. Which of the container lengths
that can be tilted with extended tilt depends on attachment model.
To tilt the attachment more than 10°, the tilt lock must be activated, see
Tilt lock, description, page 7:102. When the tilt lock is activated, the ma-
chine's speed is limited to 5 km/h.
Extended tilt function, function description
Reference
(operator in
seat)

Reference
Tilt lock Locked Tilt lock, function description, page 7:102
21
1 D1
+ D7950
2
D7902
5 D7971 D7911
3, 8 12, 15, 20
D7940 D15 D19
D7930 >° 19
4, 6 16 D7 13
C10 D12
D8 Pa
7
P P P1
9 T T 14
17 T1
A A B
C1+ C1-
LSP1 A H C2- C2+ B
LSP2 LSPR
LSP3
108 LSHY
C11
18
11
023378
Control lever (S8150-R8070-4) In: UR8070-4 = 0.5–2.0 V D1: Diagnostic menu, see 7.1 Controls and
send a voltage signal to Control Zero position: UR8070-4 = 2.0– Instr 6/XX DIAGNOSE, page 8:53 and 7.1
unit KPU (D7902). 3.0 V Controls and Instr 7/XX DIAGNOSE, page
Out: UR8070-4 = 3.0–4.5 V 8:53.
2 Control unit KPU (D7902) sends tilt Checked by control system, 11.5.3.2 KPU control unit (D7902), page 11:30
in or tilt out on the CAN bus. error shown with error code.
3 Control unit KFU (D7971) sends a Checked by control system, 11.5.3.1 KCU control unit (D7901), page 11:27
request for engine speed require- error shown with error code.
engine (D7940).
controls the ratio between drive error shown with error code.
and power take-off by changing the


(B7688) sends a voltage signal page 7:50
proportional to the oil pressure in D3: Diagnostic menu, see 10.4 Pumps 7/XX
the control valve for the attachment DIAGNOSE, page 8:134
to Control unit KAU (D7911).
8 Control unit KAU (D7971) controls U = 24 V 11.5.3.4 Control unit KFU (D7971), page 11:34
Proportional valve, load signal at- D3: Diagnostic menu, see 10.4 Pumps 6/XX
tachment (Y6002), proportional to DIAGNOSE, page 8:134
the attachment's pressure
requirements.
tachment (Y6002), opens and (Y6002), description, page 10:25
sends a load signal to hydraulic oil
pump 1. The size of the load signal
is controlled by the voltage signal
from Sensor, oil pressure attach-
ment (B7688).
ment (B7668).
the load signal to hydraulic oil 10:25
pump 1. Shuttle valves in the servo
valves select the strongest load
signal if other functions are acti-
11 Hydraulic oil pump 1 pumps oil See the pressure plate on the Axial piston pump with variable displacement,
from the hydraulic oil tank. left-hand frame beam. description, page 10:8
pends on the requirements of the
attachment functions.
12 Control unit KAU (D7911) activates I = 330–570 mA 11.5.3.8 Control unit KAU (D7911), page 11:40
Solenoid valve tilt out (Y6010) or D7: Diagnostic menu, 7.7 Tilt 4/XX DIAG-
Solenoid valve tilt in (Y6011). NOSE, page 8:64 or 7.7 Tilt 5/XX DIAGNOSE,
page 8:65
13 Solenoid valve, tilt out (Y6010) or - Attachment control valve, description, page
Solenoid valve, tilt in (Y6011) pres- 7:112
surises the tilt slide in the attach- D7: Diagnostic menu, 7.7 Tilt 4/XX DIAG-
ment's control valve. NOSE, page 8:64 or 7.7 Tilt 5/XX DIAGNOSE,
page 8:65
14 The control valve's tilt slide - Attachment control valve, description, page
changes position and pressurises 7:112
the damping valve.
15 Control unit KAU (D7911) discon- Float position: U = 24 V 11.5.3.8 Control unit KAU (D7911), page 11:40
nects the voltage feed to Solenoid Lock position: U = 0 V D10: Diagnostic menu, see 7.7 Tilt 6/XX DIAG-
valve tilt lock 1 (Y6012-1) and Sol- NOSE, page 8:65
enoid valve tilt lock 2 (Y6012-2).
16 Solenoid valve tilt lock 1 (Y6012-1) - Lock valve tilt, description, page 7:111
and Solenoid valve tilt lock 2 D10: Diagnostic menu, see 7.7 Tilt 6/XX DIAG-
(Y6012-2) pressurise the lock valve NOSE, page 8:65
17 The lock valve changes position - Damping block tilt, description, page 7:109
and directs oil crosswise to the tilt
cylinders.
18 The tilt cylinders change the at- - Tilt cylinder, description, page 7:113
tachment's inclination.
19 Sensor, tilt angle (B7253) sends a U = 0.5-4.5 V Sensor, tilt angle attachment, description,
voltage signal proportional to the tilt page 7:114
angle to Control unit KAU (D7911). D19: Diagnostic menu, 7.7 Tilt 9/XX DIAG-
NOSE, page 8:65


20 Control unit KAU (D7911) sends tilt Checked by control system, 11.5.3.8 Control unit KAU (D7911), page 11:40
angle on the CAN bus. error shown with error code.
21 When tilt is controlled and speed is Checked by control system, 11.5.3.3 Control unit, KID (D7950), page 11:32
limited, Control unit KID (D7950) error shown with error code.
shows Event menu speed
limitation.

10:8.
7.7.3 Damping block tilt

Damping block tilt, description
The damping block contains restrictions which create resistance to the
1 2 movements of the tilt cylinders, which in turn dampen the attachment's
oscillations. The damping block is fitted in the centre of the boom nose.
11 3
The damping block receives oil via the return from the attachment's
control valve. The supply means that the cylinders are always filled with
10 4 oil. Balanced restrictions mean the supply does not affect the tilting.
The constant feed means the tilt cylinders do not need to be bled after
9 5 work on the tilt.
The damping block contains two shock valves which protect the valve
6
against pressure shocks.
8 7 On machines with tilt lock there are two solenoid valves for tilt lock
on the damping block, see Lock valve tilt, description, page 7:111
018341
Damping block tilt, the illustration shows the version

with tilt lock.
1. Return line from attachment to tank [T]
2. Solenoid valve tilt lock 1 (Y6012-1)
3. Tank drain
4. Supply to attachment
5. Connection tilt cylinder piston side [C1+]
6. Connection tilt cylinder rod side [C1-]
8. Adjusting screw tilt damping
9. Connection tilt cylinder piston side [C2+]
10. Connection tilt cylinder rod side [C2-]
11. Adjusting screw tilt damping

7:110 7 Load handling – Damping block tilt
Damping block tilt, changing
NOTE
Safety.

NOTE
NOTE
from impurities.
4. Remove the valve block from the boom.

5. Transfer the connection adapters to the new valve. Transfer one
adapter at a time so that the marking is not mixed up.
NOTE
correctly.
6. Install a new valve block on the boom nose.

7. Connect the hydraulic hoses to the damping block according to the
marking.
NOTE
018344

correctly.
hydraulic system.
NOTE
the lock ring.
9. Start the machine and check sealing integrity and function.

Check both tilt and attachment functions.
10. Adjust the tilt damping, see Maintenance manual.
manual.

7 Load handling – Lock valve tilt 7:111
7.7.4 Lock valve tilt

Lock valve tilt, description
On machines with tilt lock there are two solenoid valves on the damping
1 block's return lines. When the solenoid valves are activated, the con-
nection between the cylinders is blocked and locks the tilt position. The
lock valves are fitted on the damping block.
Solenoid valve tilt lock 1 (Y6012-1) and Solenoid valve tilt lock 2
(Y6012-2) are supplied with voltage by Control unit KAU (D7911) when
tilt lock is not activated.
018343
Solenoid valve, tilt lock



1 2 3
Controllable tilt is regulated by a separate section in the attachment's
control valve. For a general description of the valve and component lo-
cations, see Attachment control valve, description, page 7:49.
Tilt slide
8 The valve slide controls the direction and speed of attachment tilt.
The valve slide is controlled by servo valve, tilt in and servo valve, tilt
out.
Servo valve, tilt out

Servo valve tilt out controls pressure to the tilt slide so that the tilt slide
opens and pressurises the tilt cylinders.
Servo valve tilt out is controlled electrically with Solenoid valve tilt out
(Y6010) which is activated by Control unit KAU (D7911). The servo
valve routes servo pressure to the tilt slide proportional to the control
7 current to the solenoid valve.
6 5 4
Servo valve, tilt in

Servo valve tilt in controls pressure to the tilt slide so that the tilt slide
opens and pressurises the tilt cylinders.
Servo valve tilt in is controlled electrically with Solenoid valve tilt in
022690
(Y6011) which is activated by Control unit KAU (D7911). The servo

valve routes servo pressure to the tilt slide proportional to the control
1. Solenoid valve, tilt out (Y6010) current to the solenoid valve.
2. Solenoid valve, tilt in (Y6011) The signal can be checked with the diagnostic menu, see 7.7 Tilt 5/XX
3. Drain to tank (unfiltered) DIAGNOSE, page 8:65.
5. Connection to tilt cylinder Sensor, servo pressure attachment (B7668)
6. Connection to tilt cylinder See Sensor, servo pressure attachment (B7668), page 7:50.


7 Load handling – Tilt cylinder 7:113
7.7.7 Tilt cylinder

Tilt cylinder, description
The tilt cylinders are located between the front edge of the inner boom
and the top of the rotation yoke. The two cylinders are aligned diago-
nally and can therefore effectively dampen or control the tilt
movements.
The piston rod mounting is welded to the piston rod, which is threaded
in the piston head and locked with a lock bolt. The cylinder head is
threaded in the cylinder pipe.
016904
Tilt cylinders

7.7.8 Lift boom

Lift boom, general
See Lift boom, description, page 7:30.
7.7.9 Rotation yoke

Rotation yoke, general
See group 7.6.7 Rotation yoke.




7:114 7 Load handling – Sensor, tilt angle attachment
7.7.15 Sensor, tilt angle attachment

Sensor, tilt angle attachment, description
Sensor, tilt angle (B7253) is fitted at the attachment's mounting to the

inner boom and measures the attachment's angle in relation to the in-
ner boom. The sensor consists of a sensor housing, potentiometer and
arm. The sensor housing is mounted on the inner boom. The arm is
connected to the attachment and turns the potentiometer when the
boom is angled.
Sensor, tilt angle (B7253) is supplied with voltage by, and sends volt-
age signals proportional to the angle to Control unit KAU (D7911). The
signal can be checked with the diagnostic menu, see 7.7 Tilt 9/XX DI-
AGNOSE, page 8:65.
019152
Sensor, tilt angle attachment, replacement

2. Replace the sensor.
3. Turn on the main electric power and turn the start key to position I.
4. Calibrate the sensor, see Sensor, tilt angle attachment, calibration,
page 7:115.
5. Check that extended tilting is working.
019152

7 Load handling – Sensor, tilt angle attachment 7:115
Sensor, tilt angle attachment, calibration
NOTE
It is very important for accuracy that all steps are performed in
the given order.
1. Warm up the hydraulic oil to operating temperature, min. 40 °C.

Use lift and extension during warming up in order to heat the oil in
the cylinders.
2. Park the machine on level ground without load, centre the attach-
ment and apply the parking brake.
10:23
CUSTOMER SETTINGS
0
014981
4. Enter service code with or . Confirm each figure with .

10:23

0 0
015625

*SETTINGS & DIAGNOSTICS* with .
7. LOAD HANDLING
018351
6. Select 7.7 Tilt by scrolling with or and confirm with .


7.3 Extension
7.4 Side Shift
7.5 Spreading
7.6 Rotation
7.7 Tilt
7.8 Levelling
7.9 Load Carrier
019139

7:116 7 Load handling – Sensor, tilt angle attachment

7.3 Extension
7.4 Side Shift
7.5 Spreading
7.6 Rotation
7.7 Tilt
7.8 Levelling
7.9 Load Carrier
019138
8. Scroll to menu 5 Tilt angle attachment with or and confirm
with .
9. Lower the boom to the lowest position (0°). Press to save this
value.
10. Scroll to menu 6 Tilt angle attachment with .

11. Lift the boom to its highest angle. Allow the value to stabilise.
Press to save this value.
12. Leave Calibration by scrolling out with .

7 Load handling – Levelling 7:117
7.8 Levelling
Mechanical levelling, description
Mechanical levelling means that the attachment is angled horizontally.
This means that the machine can handle a load on uneven ground.
The attachment's main beam is located in the side shift frame. The
clearance between the side shift frame and the attachment's main
001117
beam allows a movement of approx. 5° which makes it possible to lift
containers that are inclined in relation to the machine. It is the attach-
ment's own weight that adapts the attachment's inclination to the
container.
Hydraulic levelling, description
Hydraulic levelling means that the side shift frame is divided and the
parts are connected with four hydraulic cylinders. Hydraulic levelling in-
creases the mobility of the attachment. The hydraulic levelling has a
passive mode where the attachment floats freely and an active mode
where the inclination can be regulated. Levelling can be locked by
means of the connection to the levelling cylinders being blocked.
Passive levelling means that an unloaded attachment aligns in a float
position and adapts according to the inclination of the container to be
lifted.
Active levelling means that the inclination is controlled by means of
pressurising the hydraulic cylinders. Levelling is controlled by Control
lever (S8150).
001860
Levelling is monitored by sequence valves that close when the feed

pressure is high enough to position all the cylinders in the bottom.

7:118 7 Load handling – Levelling
Hydraulic levelling, function description
Reference
(operator in
seat)
1 1 D1
+
+ 2
D7902
5 D7971 D7911
3, 8 12, 16
D7940
D12 D16
D7930
C13 13
4, 6
D8 D7
Pa
P1 7
9 14
T1 A B
A
17
LSP1 H
LSP2 LSPR
LSP3
108 LSHY
15 18
C11
022691
11

lever (S8150-R8070-2) send a voltage sig- Levelling clockwise: D1: Diagnostic menu, see 7.1 Controls and
nal to Control unit KPU (D7902). UR8070-2 = 0.5–2.0 V Instr 5/XX DIAGNOSE, page 8:53 and 7.1
Zero position: UR8070-2 Controls and Instr 7/XX DIAGNOSE, page
= 2.0–3.0 V 8:53.
Levelling anticlock-
wise: UR8070-2 = 3.0–
4.5 V
1 Control lever (S8150-T1.x and S8150-P3) Spreading: US8150-T4 = Control lever (Cobra), description, page 7:10
sends a voltage signal to Control unit KPU 24 V D1: Diagnostic menu, see 7.1 Controls and
(D7902). Out: US8150-T1.2 = 24 V Instr 6/XX DIAGNOSE, page 8:53 and 7.1
In: US8150-T1.1 = 24V Controls and Instr 7/XX DIAGNOSE, page
8:53.
2 Control unit KPU (D7902) sends levelling Checked by control 11.5.3.2 KPU control unit (D7902), page 11:30
clockwise or levelling anticlockwise on the system, error shown
CAN bus. with error code.
3 Control unit KFU (D7971) sends a request Checked by control 11.5.3.1 KCU control unit (D7901), page 11:27
for engine speed requirement CAN bus system, error shown
drive-train based on information on lever with error code.
deflection.

7 Load handling – Levelling 7:119

4 Control unit transmission (D7930) sends a Checked by control Transmission, function description, page 2:3
rotation speed request on CAN bus drive- system, error shown
train to Control unit engine (D7940). with error code.
5 Control unit, engine (D7940) increases the Checked by control 11.5.3.6 Control unit, engine (D7940), page
engine speed. system, error shown 11:38
with error code.
6 Control unit transmission (D7930) controls Checked by control Transmission, function description, page 2:3
the ratio between drive and power take-off system, error shown
by changing the transmission's gear ratio. with error code.
(B7688) sends a voltage signal proportion- page 7:50
al to the oil pressure in the control valve for D7: Diagnostic menu, see 10.4 Pumps 7/XX
the attachment to Control unit KAU DIAGNOSE, page 8:134
(D7911).
8 Control unit KAU (D7971) controls Propor- U = 24 V 11.5.3.4 Control unit KFU (D7971), page
tional valve, load signal attachment 11:34
9 Proportional valve, load signal attachment - Proportional valve, load signal attachment
(Y6002), opens and sends a load signal to (Y6002), description, page 10:25
hydraulic oil pump 1. The size of the load
signal is controlled by the voltage signal
from Sensor, oil pressure attachment
(B7688).
than the pressure detected by Sensor, ser-
vo pressure attachment (B7668).
10 Valve block servo pressure sends the load - Valve block servo pressure, description, page
signal to hydraulic oil pump 1. Shuttle 10:25
valves in the servo valves select the stron-
gest load signal if other functions are acti-
11 Hydraulic oil pump 1 pumps oil from the See the pressure plate Axial piston pump with variable displacement,
hydraulic oil tank. on the left-hand frame description, page 10:8
The amount of oil supplied to the control beam.
12 Control unit KAU (D7911) activates Sole- I = 330–570 mA 11.5.3.8 Control unit KAU (D7911), page
noid valve levelling anticlockwise (Y6035) 11:40
or Solenoid valve levelling clockwise D12: Diagnostic menu, see 7.8 Levelling 3/XX
(Y6036). DIAGNOSE, page 8:66 or 7.8 Levelling 4/XX
DIAGNOSE, page 8:66
13 Solenoid valve levelling anticlockwise - Attachment control valve, description, page
(Y6035) or Solenoid valve levelling clock- 7:122
wise (Y6036) act on the levelling slide in
Control valve, attachment.
14 The control valve's levelling slide changes - Attachment control valve, description, page
position and pressurises the levelling over- 7:122
centre valve.
15 The overcentre valve opens and directs - Overcentre valve, levelling, description, page
pressure to Valve block levelling cylinders. 7:123
16 Control unit KAU (D7911) disconnects the Float mode: U = 24 V 11.5.3.8 Control unit KAU (D7911), page
voltage feed to Solenoid valve levelling Lock position: U = 0 V 11:40
lock 1 (Y6034-1) and Solenoid valve level- D16: Diagnostic menu, see 7.8 Levelling 5/XX
ling lock 2 (Y6034-2). DIAGNOSE, page 8:67
17 Solenoid valve levelling lock 1 (Y6034-1) - Levelling cylinders' valve block, description,
and Solenoid valve levelling lock 2 page 7:123
(Y6034-2) act on the lock valves in Valve
block, levelling cylinders.

7:120 7 Load handling – Levelling

18 The levelling cylinders' valve block directs - Levelling cylinders' valve block, description,
pressure on to the levelling cylinders. page 7:123
19 The levelling cylinders change the attach- - Levelling cylinders, description, page 7:124
ment's inclination.
Levelling lock, function description
Reference
Sensor, opera- Not activated Sensor operator in seat, description, page 9:25
tor-in-seat (operator in
seat)
D1
7
1 1 D7950
2
D7902
D7971 D7911
8 3
9
D7940 D3
4
D7930
10 5 6 023379

1 Switch, levelling lock (S1037) sends a US8510–10 = 24 V Control lever (Ego), description, page 7:6
voltage signal to Control unit KPU D1: Diagnostic menu, see 7.1 Controls and
(D7902). Instr 5/XX DIAGNOSE, page 8:53 and 7.1
8:53.
1 Switch, levelling lock (S8150-T3.1) sends US8150/T3.1 = 24 V Control lever (Cobra), description, page 7:10
a voltage signal to Control unit KPU D1: Diagnostic menu, see 7.1 Controls and
(D7902). Instr 5/XX DIAGNOSE, page 8:53 and 7.1
8:53.
2 Control unit KPU (D7902) sends levelling Checked by control sys- 11.5.3.1 KCU control unit (D7901), page 11:27
lock on the CAN bus. tem, error shown with er-
ror code.
3 Control unit KAU (D7911) stops the acti- Float mode: U = 24 V Levelling cylinders' valve block, description,
vation of Solenoid valve levelling lock 1 Lock position: U = 0 V page 7:123
(Y6034-1) and Solenoid valve levelling D3: Diagnostic menu, see 7.8 Levelling 5/XX
lock 2 (Y6034-2). DIAGNOSE, page 8:67


4 Solenoid valve levelling lock 1 (Y6034-1) - Levelling cylinders' valve block, description,
and Solenoid valve levelling lock 2 page 7:123
(Y6034-2) act on the lock slides in Valve D3: Diagnostic menu, see 7.8 Levelling 5/XX
block, levelling cylinders. DIAGNOSE, page 8:67
5 The lock slides in Valve block, levelling - Levelling cylinders' valve block, description,
cylinders change position and block the page 7:123
connections to the levelling cylinders in
Valve block, levelling cylinders.
6 The levelling cylinders lock the attach- - Levelling cylinders, description, page 7:124
ment's inclination.
7 When levelling lock is activated, Control - 11.5.3.3 Control unit, KID (D7950), page
unit KID (D7950) shows Event menu tilt 11:32
lock if the speed is approaching the maxi-
mum limit (5 km/h).
When levelling lock is activated, the ma-
chine's speed is limited to max. 5 km/h.
8 Control unit KFU (D7971) sends speed - 11.5.3.4 Control unit KFU (D7971), page
limitation on CAN bus drive-train. 11:34
9 Control unit, engine (D7940) limits the - 11.5.3.6 Control unit, engine (D7940), page
engine speed 11:38
10 Control unit transmission (D7930) limits - 11.5.3.7 Control unit, transmission (D7930),
the gear range page 11:39

10:8.


Hydraulic levelling is controlled by a separate section in Control valve,
1 2 3 attachment. For a general description of the valve and component loca-
tions, see Attachment control valve, description, page 7:49.
Levelling slide
The valve slide controls the direction and speed of attachment levelling.
8 The valve slide is controlled by Servo valve levelling anticlockwise and
Servo valve levelling clockwise.
Servo valve levelling anticlockwise

Servo valve levelling anticlockwise controls pressure to the levelling
slide so that it opens and pressurises the levelling cylinders.
Servo valve levelling anticlockwise is controlled electrically by Solenoid
valve levelling anticlockwise (Y6035), which is activated by Control unit
KAU (D7911). The servo valve routes servo pressure to the tilt slide
proportional to the control current to the solenoid valve.
7 The signal can be checked with the diagnostic menu, see 7.8 Levelling
6 5 4
Servo valve levelling clockwise

Servo valve levelling clockwise controls pressure to the levelling slide
so that it opens and pressurises the levelling cylinders.
Servo valve levelling clockwise is controlled electrically by Solenoid
valve levelling clockwise (Y6036), which is activated by Control unit
KAU (D7911). The servo valve routes servo pressure to the tilt slide
022692

1. Solenoid valve, levelling clockwise (Y6036) The signal can be checked with the diagnostic menu, see 7.8 Levelling
2. Solenoid valve levelling anticlockwise (Y6035) 4/XX DIAGNOSE, page 8:66.
Passive levelling
5. Connection to levelling cylinder The servo valves open a connection to the tank, in addition, hydraulic
oil can flow between right and left side levelling cylinders, from piston
6. Connection to levelling cylinder sides to rod sides, according to the inclination.
8. Feed from hydraulic oil pump 1 Active levelling
Levelling is monitored by the sequence valves in valve block, levelling
cylinder, which closes when the feed pressure is high enough to posi-
tion all the cylinders in the bottom. Following which, hydraulic oil is sup-
plied to the rod sides on one side's cylinders and the side is lifted.
Consequently, the other side will always be in its lowest position during
levelling. This always results in maximum levelling travel.



7 Load handling – Overcentre valve levelling 7:123
7.8.5 Overcentre valve levelling

Overcentre valve, levelling, description
The overcentre valve ensures that the levelling cylinders are fully ex-
tended. The valve is fitted to the right of Control valve, attachment on
the rear edge of the side shift frame under Valve block, levelling
cylinders.
Passive levelling
The overcentre valves allow the flow of hydraulic oil between right and
left levelling cylinders, from piston sides to rod sides, according to the
inclination.
Active levelling
The overcentre valves close when the feed pressure is high enough to
position all the levelling cylinders in the bottom. Following which, hy-
draulic oil is supplied through Valve block, levelling cylinders, to the rod
sides on one side's (right or left) cylinders and the side is lifted. Conse-
quently, the other side will always be in its lowest position during level-
ling. This always results in maximum levelling travel.
001062
7.8.6 Valve block levelling cylinders

Levelling cylinders' valve block, description
Valve block, levelling cylinders, routes the pressure from Control valve,
attachment, to the levelling cylinders. The valve block includes two lock
valves that block levelling when levelling lock is activated or if the ma-
chine becomes de-energised. The valve is fitted to the right of Control
valve, attachment, on the rear edge of the side shift frame above Over-
centre valve, levelling.
Lock valve
The lock valves are opened by Solenoid valve levelling lock 1 (Y6034-
1) and Solenoid valve levelling lock 2 (Y6034-2). When the lock valves
are closed, the oil to and from the levelling cylinders is blocked and lev-
elling is blocked. Solenoid valve levelling lock 1 (Y6034-1) and Sole-
noid valve levelling lock 2 (Y6034-2) are supplied with voltage by
The signal can be checked with the diagnostic menu, see 7.8 Levelling
001061

7:124 7 Load handling – Levelling cylinders
7.8.7 Levelling cylinders

Levelling cylinders, description
On machines with hydraulic levelling there are four hydraulic cylinders
between the side shift frame's parts, see Side shift frame, description,
page 7:125.
001860



The side shift frame is available in two different versions, see Side shift
1 2 3 4 frame, description, page 7:53.
Mechanical levelling
The side shift frame is larger than the attachment's main beam. The
main beam can move freely between the slide plates, this permits ap-
prox. 5° levelling.
Hydraulic levelling
001932
5 The side shift frame is in two parts. There are four levelling cylinders
1. Main beam, attachment between the two parts, see Levelling cylinders, description, page 7:124.
The outer part is attached into the rotation yoke via the ring gear. The
2. Side shift frame upper section
inner part holds the attachment's main beam. The main beam slides
3. Levelling cylinder against the slide plates. The stroke length of the hydraulic cylinders al-
4. Side shift frame lower section lows the main beam to be levelled approx. 5°. With hydraulically con-
5. Side shift cylinder trollable levelling, the angle of Main beam, attachment, is controlled
, and using the control lever.
To adjust the slide surfaces, see Maintenance manual.
2
017420
Slide surfaces, side shift frame

1. Slide surface, upper side shift frame
2. Slide surface, lower side shift frame





7 Load handling – Load carrier 7:127
7.9 Load carrier

Load carrier, description
The load carrier is used to secure a load. There are several ways of se-
curing the load.
• Twistlocks, rotatable lift pins that hold the load in oval holes in the
corners of the load.
• Lift legs, hold the load with legs that grip around and under the
load.
• Customised attachments adapted for a particular type of load.
This type of attachment is described if required in a separate sup-
plement for each attachment.
7.9.1 Twistlocks
Twistlocks, description
The container is held in place on the attachment with four twistlocks.
Twistlocks are controlled by Control lever (S8150) and Switch lock
twistlocks (S1003). A section in Control valve, attachment, pressurises
the two parallel-connected hydraulic cylinders, one in each spreader
004868
boom. Each hydraulic cylinder actuates a linkage that turns two twist-
locks. Four position sensors, two in each spreader boom, detect the po-
sition of the linkage and indicates whether twistlocks are open or
locked.
Indicator lamps on the boom and in the cab show the status for the
twistlocks.
Four position sensors, one at each twistlock, indicate when the attach-
ment is in contact with the container. This is used to control when the
twistlocks can be activated. An indicator light on the boom and one in
the cab indicate when the attachment has full contact. An event menu
shows which twistlocks have contact (1 - 4). All four twistlocks must
have contact in order for the twistlocks to be activated.
Twistlocks, function description

Sensor, operator-in-seat Not activated (operator Sensor operator in seat, description, page 9:25
in seat)
Contact Full contact or bypass Bypass, description, page 8:6
activated

7:128 7 Load handling – Twistlocks
D2 9, 29
2
D1
1 D8
5, 30
D7950
10 8, 28
D7902 D7901
13 D7971 D7911
11, 16 4, 6, 20, 25, 27 7, 26
D7940 D20
D6
D7930 C18 21
D16 D15
12, 14
P1 Pa
15 D24 D3
17 22
T1 A B
LSP1 A H
LSP2 LSPR 24 3
LSP3
188 LSHY
C19 23
19
023380
1 Switch, lock twistlocks (S1003) (auto- U = 24 V Switch lock twistlocks, description, page 7:12
matic mode) sends a voltage signal to D1: Diagnostic menu, see 7.9 Load Carrier 3/
Control unit KPU (D7902). XX DIAGNOSE, page 8:67
2 Switch open twistlocks (S1002) in the U = 24 V Control lever (Ego), description, page 7:6
control lever sends a voltage signal to D2: Diagnostic menu, see 7.1 Controls and
Control unit KPU (D7902) for opening Instr 7/XX DIAGNOSE, page 8:53
the twistlocks.
3 Sensor, contact left front (B7202-FL), Sensor directly opposite Sensor, contact, description, page 7:139
Sensor, contact right front (B7202-FR), indicator plate: U = 24 V D3: Diagnostic menu, see 7.9 Load Carrier 4/
Sensor, contact left rear (B7202-RL) and XX DIAGNOSE, page 8:68
Sensor, contact right rear (B7202-RR)
send a voltage signal to Control unit, at-
tachment, Control unit KAU (D7911).
4 Control unit KAU (D7911) sends contact Checked by control sys- 11.5.3.8 Control unit KAU (D7911), page 11:40
ror code.
5 Control unit KID (D7950) activates Event - 11.5.3.3 Control unit, KID (D7950), page 11:32
menu, contact.
6 Control unit KAU (D7911) activates Indi- U = 24 V D6: Diagnostic menu, see 7.9 Load Carrier 10/
cator light, contact (H5640-1) on the XX DIAGNOSE, page 8:69
boom's light panel.
7 Indicator light contact (H5640-1) U = 24 V D6: Diagnostic menu, see 7.9 Load Carrier 10/
illuminates. XX DIAGNOSE, page 8:69
8 Control unit KCU (D7901) activates Indi- U = 24 V 11.5.3.1 KCU control unit (D7901), page 11:27
cator light contact (H5640-2) in the cab's D8: Diagnostic menu, see 7.9 Load Carrier 14/
light panel. XX DIAGNOSE, page 8:70
9 Indicator light contact (H5640-2) in the D8: Diagnostic menu, see 7.9 Load Carrier 14/
cab's light panel illuminates. XX DIAGNOSE, page 8:70

7 Load handling – Twistlocks 7:129

10 Control unit KPU (D7902) sends "open Checked by control sys- 11.5.3.2 KPU control unit (D7902), page 11:30
twistlocks" or "lock twistlocks" on the tem, error shown with er-
CAN bus. ror code.
lever deflection.
ror code.
gear ratio.
KAU (D7911).
16 Control unit KAU (D7971) controls Pro- U = 24 V 11.5.3.4 Control unit KFU (D7971), page 11:34
portional valve, load signal attachment D12: Diagnostic menu, see 10.4 Pumps 6/XX
(Y6002), proportional to the attachment's DIAGNOSE, page 8:134
pressure requirements.
of the load signal is controlled by the volt-
tachment (B7688).
load signal to hydraulic oil pump 1. Shut- 10:25
tle valves in the servo valves select the
20 Control unit KAU (D7911) activates Sole- U = 24 V 11.5.3.8 Control unit KAU (D7911), page 11:40
noid valve "open twistlocks" (Y6039) or D16: Diagnostic menu, see 7.9 Load Carrier 6/
Solenoid valve "lock twistlocks" (Y6040). XX DIAGNOSE, page 8:68 or 7.9 Load Carrier
21 The "open twistlocks" solenoid valve - Attachment control valve, description, page
(Y6039) or the "lock twistlocks" solenoid 7:136
valve (Y6040) pressurises the twistlock
22 The control valve's twistlock slide valve - Attachment control valve, description, page
lock cylinders.
23 The lock cylinders rotate the twistlocks. - Lock cylinder, description, page 7:137


24 Sensor unlocked twistlocks left (B7204- Sensor directly opposite Sensor, twistlocks, description, page 7:141
LE) and Sensor unlocked twistlocks right indicator plate: U = 24 V D20: Diagnostic menu, see 7.9 Load Carrier 5/
(B7204-RI) or Sensor locked twistlocks XX DIAGNOSE, page 8:68
left (B7205-LE) and Sensor locked twist-
locks right (B7205-RI) send signals to
25 Control unit KAU (D7911) supplies volt- U = 24 V D6: Diagnostic menu, see 7.9 Load Carrier 8/
age to Indicator light "unlocked twist- XX DIAGNOSE, page 8:69 or 7.9 Load Carrier
locks" (H5620-1) or Indicator light 10/XX DIAGNOSE, page 8:69
"locked twistlocks" (H5630-1) on the
boom's light panel.
26 Indicator light unlocked twistlocks U = 24 V D6: Diagnostic menu, see 7.9 Load Carrier 8/
(H5620-1) or Indicator light locked twist- XX DIAGNOSE, page 8:69 or 7.9 Load Carrier
locks (H5630-1) on the boom's light pan- 10/XX DIAGNOSE, page 8:69
el illuminates
27 Control unit KAU (D7911) sends informa- Checked by control sys- 11.5.3.8 Control unit KAU (D7911), page 11:40
tion about "twistlocks unlocked" or "twist- tem, error shown with er-
locks locked" on the CAN bus. ror code.
28 Control unit KFU (D7901) supplies volt- U = 24 V 11.5.3.1 KCU control unit (D7901), page 11:27
age to Indicator light "unlocked twist- D8: Diagnostic menu, see 7.9 Load Carrier 12/
locks" (H5620-2) or Indicator light XX DIAGNOSE, page 8:70 or 7.9 Load Carrier
"locked twistlocks" (H5630-2) on the 13/XX DIAGNOSE, page 8:70
cab's light panel.
29 Indicator light unlocked twistlocks U = 24 V D8: Diagnostic menu, see 7.9 Load Carrier 12/
(H5620-2) or Indicator light locked twist- XX DIAGNOSE, page 8:70 or 7.9 Load Carrier
locks (H5630-2) in the cab's light panel 13/XX DIAGNOSE, page 8:70
illuminates.
30 Control unit KID (D7950) activates Event Checked by control sys- 11.5.3.3 Control unit, KID (D7950), page 11:32
menu, twistlocks. tem, error shown with er-
ror code.
Overheight-legs, description
Overheight-legs is an option for twistlocks that make it possible to lift

containers with parts higher than the twistlock brackets.
006701
Overheight-legs are mechanical extensions of twistlocks. The legs con-

sist of two leg pairs that are lowered and raised by hydraulic cylinders.
Overheight-legs are controlled with Switch overheight-legs (S1031). A
section in Control valve attachment pressurises four hydraulic cylinders
connected in parallel, two for each leg pair. On each cylinder there is
an overcentre valve which prevents the legs from lowering due to their
dead weight. Position sensors sense when the legs are fully raised and
fully lowered. An extra indicator lamp on the boom illuminates when the
legs are fully raised.
There are mechanical linkages in the legs to rotate the twistlocks. Four
position sensors, one at each twistlock, indicate when the overheight-
legs are in contact with the container. This is used to control when the
twistlocks can be activated. An indicator light on the boom and one in
the cab indicate when the attachment has full contact. An event menu
shows which twistlocks have contact (1 - 4). All four twistlocks must
have contact in order for the twistlocks to be activated.

Overheight legs, function description

Control breaker Not activated Control breaker voltage, function description, page 11:20
in seat)
Twistlocks Open Twistlocks, function description, page 7:127
D1
1
20
D7950
2
D7902
D7971 D7911
5, 23 3, 8, 21 12, 18 19
D7940
D7930
D8 C14 13
4, 6, 22
D7
Pa
P1 7 D17
9 14
T1 A B
LSP1 A H
LSP2 LSPR
LSP3
10
8 LSHY 15
C11
16
023381
11

1 Switch, overheight-legs (S1031) sends a volt- U = 24 V Switch overheight-legs, description, page
age signal to Control unit KPU (D7902). 7:15
2 Control unit KPU (D7902) sends a message Checked by control 11.5.3.1 KCU control unit (D7901), page
to lower Overheight-legs on the CAN bus. system, error shown 11:27
with error code.
3 Control unit KFU (D7971) sends a request for Checked by control 11.5.3.1 KCU control unit (D7901), page
engine speed requirement CAN bus drive- system, error shown 11:27
train based on information on lever deflection. with error code.
4 Control unit transmission (D7930) sends a Checked by control Transmission, function description, page
rotation speed request on CAN bus drive- system, error shown 2:3
with error code.
6 Control unit transmission (D7930) controls Checked by control Transmission, function description, page
the ratio between drive and power take-off by system, error shown 2:3
changing the transmission's gear ratio. with error code.


7 Sensor, servo pressure attachment (B7688) 0.5–4.5 V Sensor, servo pressure attachment (B7668),
sends a voltage signal proportional to the oil page 7:50
pressure in the control valve for the attach- D5: Diagnostic menu, see 10.4 Pumps 7/
ment to Control unit KAU (D7911). XX DIAGNOSE, page 8:134
8 Control unit KAU (D7971) controls Propor- U = 24 V 11.5.3.4 Control unit KFU (D7971), page
tional valve, load signal attachment (Y6002), 11:34
proportional to the attachment's pressure D6: Diagnostic menu, see 10.4 Pumps 1/
requirements. XX DIAGNOSE, page 8:133
(Y6002), opens and sends a load signal to (Y6002), description, page 10:25
hydraulic oil pump 1. The size of the load sig-
nal is controlled by the voltage signal from
Sensor, oil pressure attachment (B7688).
The load signal is 0.3–1.5 MPa greater than
the pressure detected by Sensor, servo pres-
sure attachment (B7668).
10 Valve block servo pressure sends the load - Valve block servo pressure, description,
signal to hydraulic oil pump 1. Shuttle valves page 10:25
in the servo valves select the strongest load
signal if other functions are activated at the
same time.
11 Hydraulic oil pump 1 pumps oil from the hy- See the pressure plate Axial piston pump with variable displace-
draulic oil tank. on the left-hand frame ment, description, page 10:8
valve for the attachment depends on the re-
quirements of the attachment functions.
12 Control unit KAU (D7911) activates Solenoid U = 24 V Attachment control valve, description, page
valve overheight-legs up (Y6070) or Solenoid 7:136
valve overheight-legs down (Y6071).
13 Solenoid valve overheight-legs up (Y6070) or U = 24 V Attachment control valve, description, page
Solenoid valve overheight-legs down 7:136
(Y6071) controls the overheight-slide in Con-
trol valve attachment.
14 The overheight-slide pressurises overcentre - Attachment control valve, description, page
valve overheight-legs. 7:136
15 Overcentre valve opens and pressurises hy- - Overcentre valve (product alternative Over-
draulic cylinder overheight legs. height-legs), page 7:142
16 Hydraulic cylinder overheight-legs lowers the - Hydraulic cylinder, overheight-legs, page
overheight-legs. 7:142
17 Sensor overheight-leg up left (B7231-LE) Sensor directly oppo- Sensor, overheight-legs, page 7:143
and Sensor overheight-leg up right (B7231- site indicator plate: U = D15: Diagnostic menu, see 7.9 Load Carrier
RI) or Sensor overheight-leg down left 24 V 86/XX DIAGNOSE, page 8:88
(B7256-LE) and Sensor overheight-leg down
right (B7256-RI) send a voltage signal to
18 Control unit KAU (D7911) activates the indi- Sensor overheight-legs 11.5.3.8 Control unit KAU (D7911), page
cator light for overheight-legs up (H5001). up: U = 24 V 11:40
Overheight-legs down:
U=0V
19 Indicator light, overheight legs up (H5001) il- Sensor overheight-legs Section 9 Frame, body, cab and accesso-
luminates when the jacks are completely up: U = 24 V ries, group 9.1 Controls and instruments
raised. Overheight-legs down:
U=0V
20 When overheight-legs are down the ma- - 11.5.3.3 Control unit, KID (D7950), page
chine's speed is limited to 5 km/h. 11:32
When overheight-legs are down Control unit
KID (D7950) shows event menu overheight–
legs if the speed approaches the max. limit (5
km/h).

21 Control unit KFU (D7971) sends speed limi- - 11.5.3.4 Control unit KFU (D7971), page
tation on CAN bus drive-train. 11:34
22 Control unit transmission (D7930) sends a Checked by control Transmission, function description, page
rotation speed request on CAN bus drive- system, error shown 2:3
23 Control unit, engine (D7940) decreases the Checked by control 11.5.3.6 Control unit, engine (D7940), page
with error code.
Twistlocks, function description (product alternative

Overheight-legs)

Overheight legs Lowered Overheight legs, function description, page 7:131
in seat)
Contact Full contact or bypass Bypass, description, page 8:6
activated
D2 9, 29
2
D1
1 D8
5, 30
D7950
10 8, 28
D7902 D7901
13 D7971 D7911
11, 16 4, 6, 20, 25, 27 7, 26
D7940 D20
D6
D7930 21
D16 D15 D24
12, 14
P1 Pa
15 D3
17 22
T1 A B
LSP1 A H
LSP2 LSPR 24 3
LSP3
188 LSHY
C19 23
023382
19


1 Switch, lock twistlocks (S1003) (auto- U = 24 V Switch lock twistlocks, description, page 7:12
matic mode) sends a voltage signal to D1: Diagnostic menu, see 7.9 Load Carrier 3/
Control unit KPU (D7902). XX DIAGNOSE, page 8:67
2 Switch open twistlocks (S1002) in the U = 24 V Control lever (Ego), description, page 7:6
control lever sends a voltage signal to D2: Diagnostic menu, see 7.1 Controls and
Control unit KPU (D7902) for opening Instr 7/XX DIAGNOSE, page 8:53
the twistlocks.
3 Sensor, contact left front (B7214-FL), Sensor directly opposite Sensor, contact, description, page 7:139
Sensor, contact right front (B7214-FR), indicator plate: U = 24 V D3: Diagnostic menu, see 7.9 Load Carrier 4/
Sensor, contact left rear (B7214-RL) and XX DIAGNOSE, page 8:68
send a voltage signal to Control unit, at-
tachment, Control unit KAU (D7911).
4 Control unit KAU (D7911) sends contact Checked by control sys- 11.5.3.8 Control unit KAU (D7911), page 11:40
ror code.
5 Control unit KID (D7950) activates Event - 11.5.3.3 Control unit, KID (D7950), page 11:32
menu, contact.
6 Control unit KAU (D7911) activates Indi- U = 24 V D6: Diagnostic menu, see 7.9 Load Carrier 10/
cator light, contact (H5640-1) on the XX DIAGNOSE, page 8:69
boom's light panel.
7 Indicator light contact (H5640-1) U = 24 V D6: Diagnostic menu, see 7.9 Load Carrier 10/
illuminates. XX DIAGNOSE, page 8:69
8 Control unit KCU (D7901) activates Indi- U = 24 V 11.5.3.1 KCU control unit (D7901), page 11:27
cator light contact (H5640-2) in the cab's D8: Diagnostic menu, see 7.9 Load Carrier 14/
light panel. XX DIAGNOSE, page 8:70
9 Indicator light contact (H5640-2) in the D8: Diagnostic menu, see 7.9 Load Carrier 14/
cab's light panel illuminates. XX DIAGNOSE, page 8:70
10 Control unit KPU (D7902) sends "open Checked by control sys- 11.5.3.2 KPU control unit (D7902), page 11:30
twistlocks" or "lock twistlocks" on the tem, error shown with er-
CAN bus. ror code.
lever deflection.
ror code.
gear ratio.
KAU (D7911).
16 Control unit KAU (D7971) controls Pro- U = 24 V 11.5.3.4 Control unit KFU (D7971), page 11:34
portional valve, load signal attachment D12: Diagnostic menu, see 10.4 Pumps 6/XX
(Y6002), proportional to the attachment's DIAGNOSE, page 8:134
pressure requirements.


of the load signal is controlled by the volt-
tachment (B7688).
load signal to hydraulic oil pump 1. Shut- 10:25
tle valves in the servo valves select the
20 Control unit KAU (D7911) activates Sole- U = 24 V 11.5.3.8 Control unit KAU (D7911), page 11:40
noid valve "open twistlocks" (Y6039) or D16: Diagnostic menu, see 7.9 Load Carrier 6/
Solenoid valve "lock twistlocks" (Y6040). XX DIAGNOSE, page 8:68 or 7.9 Load Carrier
21 The "open twistlocks" solenoid valve - Attachment control valve, description, page
(Y6039) or the "lock twistlocks" solenoid 7:136
valve (Y6040) pressurises the twistlock
22 The control valve's twistlock slide valve - Attachment control valve, description, page
lock cylinders.
23 The lock cylinders rotate the twistlocks. - Lock cylinder, description, page 7:137
24 Sensor unlocked twistlocks left (B7204- Sensor directly opposite Sensor, twistlocks, description, page 7:141
LE) and Sensor unlocked twistlocks right indicator plate: U = 24 V D19: Diagnostic menu, see 7.9 Load Carrier 5/
(B7204-RI) or Sensor locked twistlocks XX DIAGNOSE, page 8:68
left (B7205-LE) and Sensor locked twist-
locks right (B7205-RI) send signals to
25 Control unit KAU (D7911) supplies volt- U = 24 V D6: Diagnostic menu, see 7.9 Load Carrier 8/
age to Indicator light "unlocked twist- XX DIAGNOSE, page 8:69 or 7.9 Load Carrier
locks" (H5620-1) or Indicator light 10/XX DIAGNOSE, page 8:69
"locked twistlocks" (H5630-1) on the
boom's light panel.
26 Indicator light unlocked twistlocks U = 24 V -
(H5620-1) or Indicator light locked twist-
locks (H5630-1) on the boom's light pan-
el illuminates.
27 Control unit KAU (D7911) sends informa- Checked by control sys- 11.5.3.8 Control unit KAU (D7911), page 11:40
tion about "twistlocks unlocked" or "twist- tem, error shown with er-
locks locked" on the CAN bus. ror code.
28 Control unit KFU (D7901) supplies volt- U = 24 V 11.5.3.1 KCU control unit (D7901), page 11:27
age to Indicator light "unlocked twist- D8: Diagnostic menu, see 7.9 Load Carrier 12/
locks" (H5620-2) or Indicator light XX DIAGNOSE, page 8:70 or 7.9 Load Carrier
"locked twistlocks" (H5630-2) on the 13/XX DIAGNOSE, page 8:70
cab's light panel.
29 Indicator light unlocked twistlocks U = 24 V -
(H5620-2) or Indicator light locked twist-
locks (H5630-2) in the cab's light panel
illuminates.
30 Control unit KID (D7950) activates Event Checked by control sys- 11.5.3.3 Control unit, KID (D7950), page 11:32
menu, twistlocks. tem, error shown with er-
ror code.

7.9.1.1 Hydraulic oil pump

10:8.
7.9.1.3 Control valve, attachment

The twistlocks function is controlled by a separate section in the attach-
1 2 3 ment's control valve. For a general description of the valve and compo-
nent locations, see Attachment control valve, description, page 7:49.
Twistlocks slide, description

The valve slide controls the direction and the lock cylinder.
8 The valve slide is controlled by two servo valves, lock twistlocks and
open twistlocks.
Servo valve lock twistlocks, description

Servo valve "lock twistlocks" solenoid valve directs pressure to the
twistlock slide so that the slide and pressurises the lock cylinders.
Servo valve lock twistlocks is controlled electrically by Solenoid valve
lock twistlocks (Y6040), which is activated by Control unit KAU (D7911).
The servo valve directs servo pressure to the twistlocks slide propor-
tional to the control current to the solenoid valve.
7 The signal can be checked with the diagnostic menu, see 7.9 Load Car-
6 5 4
Servo valve open twistlocks, description

Servo valve "open twistlocks" solenoid valve directs pressure to the
twistlock slide so that the slide and pressurises the lock cylinders.
Servo valve open twistlocks is controlled electrically by Solenoid valve
open twistlocks (Y6039), which is activated by Control unit KAU
(D7911). The servo valve directs servo pressure to the twistlocks slide
022696

1. Solenoid valve, lock twistlocks (Y6040) The signal can be checked with the diagnostic menu, see 7.9 Load Car-
2. Solenoid valve, open twistlocks (Y6039) rier 7/XX DIAGNOSE, page 8:69.
4. Return to tank (through tank filter) Sensor, servo pressure attachment (B7668)
5. Connection to lock cylinder See Sensor, servo pressure attachment (B7668), page 7:50.
6. Connection to lock cylinder


7.9.1.5 Lock cylinder

Lock cylinder, description
The lock cylinder activates the lock mechanism so that the twistlocks
are rotated. Two lock cylinders, one in the right and one in the left
spreader beam, activate the lock mechanism. The lock cylinders are fit-
ted in the centre of the spreader beam's longitudinal section.
016906

7.9.1.6 Lock mechanism

Lock mechanism, description
The lock mechanism transfers the force of the lock cylinders to the
twistlocks. Two lock mechanisms, one in the right and one in the left
spreader beam, actuate the twistlocks. The lock mechanism runs along
the longitudinal section of the spreader beam between the twistlocks.
The lock mechanism consists of a rod with spherical plain bearings in
the end. The rod is fastened in levers that rotate the twistlocks. A re-
taining lug for the lock cylinder is fitted in the centre of the rod.
016907

7.9.1.7 Twistlocks
Twistlocks, description
1
WARNING
Dropped load.
Extreme danger!
2 Twistlocks hold the load during load handling and
therefore it is of the utmost importance that twistlocks
are checked according to instructions and are replaced
at the slightest sign of damage or wear.
5 Twistlocks secure the load and are located out in the corners of the
spreader beam's longitudinal section.
Twistlocks are manufactured from high-strength steel in accordance
4 with international standards. The lift pins are marked with serial
3 numbers.
016945
Twistlocks are connected in pairs via a linkage system to a hydraulic

cylinder which in turn is controlled via a section in the attachment's con-
1. Lock mechanism trol valve. Inductive sensors send signals when the twistlocks are
2. Sensor, contact locked and unlocked, respectively.
3. Contact pin
4. Lift pin
5. Lock guide
Twistlocks, description (product alternative

Overheight-legs)
WARNING
2
Dropped load.
Extreme danger!
3 Twistlocks hold the load during load handling and
therefore it is of the utmost importance that twistlocks
are checked according to instructions and are replaced
at the slightest sign of damage or wear.
5
Twistlocks secure the load and are located furthest out on the over-
4 height-legs.
Twistlocks are manufactured from high-strength steel in accordance
018584
with international standards. The lift pins are marked with serial
numbers.
1. Lock mechanism
2. Sensor, contact Twistlocks are connected in pairs via a linkage system to a hydraulic
3. Contact pin cylinder which in turn is controlled via a section in the attachment's con-
trol valve. Inductive sensors send signals when the twistlocks are
4. Lift pin
locked and unlocked, respectively.
5. Lock guide

7.9.1.8 Sensor, contact

Sensor, contact, description
Sensor, contact, detects when the attachment has contact with the con-
tainer. Four inductive sensors, one at each twistlock out in the corners
the longitudinal section of the spreader beam, are used to indicate
contact.
The sensor senses the position of a spring pin which is pressed in
when the attachment has contact up against the container. The sensor
is located above the pin. The position of the sensor can be adjusted so
that it gives a signal when the pin is pressed in and the head is level
with the lower edge of the spreader beam. The clearance between the
attachment and the container's corner boxes means the sensors stop
sending signals when the attachment is lifted.
Control unit KAU (D7911) when the indicator pin is pressed in.
016908
Sensor contact, description (product alternative

Overheight-legs)
1
Sensor contact overheight-legs detects when the overheight-legs have
contact with the container. Four inductive sensors, one at each twist-
lock furthest out on the overheight-legs are used to indicate contact.
2
The sensor detects the position of a spring pin which is pressed in
when the overheight-leg has contact against the container. The sensor
is located above the pin. The position of the sensor can be adjusted so
that it gives a signal when the pin is pressed in and the head is level
3
with the lower edge of the overheight-leg. The clearance between the
overheight-legs and the container's corner boxes means the sensors
stop sending signals when the attachment is lifted.
5
Control unit KAU (D7911) when the indicator pin is pressed in. Note
4 that the sensors are activated when the overheight-legs are fully
lowered.
018584
1. Lock mechanism
2. Sensor, contact
3. Contact pin
4. Lift pin
5. Lock guide

Sensor, contact, checking

2. Check that the indicator pins in the corner boxes can move up and
down freely. The indicator pins must spring down when they are
not loaded.
3. Check that the sensor is free of damage and dirt.
4. Start the machine.
5. Lower the attachment to a container and check that all twistlocks

indicate contact, filled circles in the event menu for contact, and
that the indicator light for contact illuminates.
6. Lift the attachment slightly so that contact is just broken (unfilled
circles in the event menu for contact or the indicator light for con-
tact goes out).
7. Check how much indicator pin movement is required to detect con-
tact. The movement should be 3–4 mm.
016350
8. Adjust sensor position if necessary. See Position sensor, checking

and adjustment, page 7:5.
Event menu, contact
Sensor contact, control (product alternative

Overheight-legs)

1
2. Check that the indicator pins in the ends of the overheight-legs can
move in and out freely. The indicator pins must spring out when
they are not loaded.
2 3. Check that the sensor is free of damage and dirt.
4. Start the machine.
5. Lower the overheight-legs, see Overheight-legs, description, page
3 7:130.
4
018584
1. Lock mechanism
2. Sensor, contact
3. Contact pin
4. Lift pin
5. Lock guide
6. Lower the overheight-legs to a container and check that all twist-
locks indicate contact, filled circles in the event menu for contact,
and that the indicator light for contact illuminates.
7. Lift the attachment slightly so that contact is just broken (unfilled
circles in the event menu for contact or the indicator light for con-
tact goes out).
8. Check how much indicator pin movement is required to detect con-
tact. The movement should be 3–4 mm.
016350
9. Adjust sensor position if necessary. See Position sensor, checking

and adjustment, page 7:5.
Event menu, contact


7.9.1.9 Sensor twistlocks

Sensor, twistlocks, description
Sensor, twistlocks, detects when twistlocks are locked or unlocked.
Four inductive position sensors, two in each spreader beam, detect the
position of the lock mechanism. The sensors are located at the lock cyl-
inder in the centre of the longitudinal section of the spreader beam.
Both sides function in the same way independently of one another. A
stop is fitted on the lock mechanism by the lock cylinder. When the lock
mechanism is in the position that locks the twistlocks, one of the sen-
sors sends a signal to Control unit KAU (D7911). When the lock mecha-
nism is in the position that unlocks the twistlocks, the second sensor
sends a signal to Control unit KAU (D7911). No signals are sent if the
016910 lock mechanism stops midway.
Control unit KAU (D7911) when the indicator pin is in front of the sensor.

7.9.1.10 Relief valve top lift

7.9.1.11 Pipes and hoses


7.9.1.12 Overcentre valve

Overcentre valve (product alternative Overheight-
legs)
1 The overcentre valve prevents the overheight-legs from lowering under

their own weight.
4
018589
1. Hydraulic cylinder, overheight-legs

2. Overcentre valve overheight-legs
3. Sensor, overheight-legs up (B7231-LE and
B7231-RI)
4. Sensor, overheight-legs down (B7259-LE and
B7259-RI)
7.9.1.13 Hydraulic cylinder, overheight-legs

Hydraulic cylinder, overheight-legs
1 The hydraulic cylinder lowers the overheight-legs. The hydraulic cylin-

der is controlled by a separate section in the attachment control valve,
see Attachment control valve, description, page 7:69.
2
4
018589

B7231-RI)
B7259-RI)


7 Load handling – Lift legs 7:143
7.9.1.14 Sensor, overheight-legs

Sensor, overheight-legs
1 Sensor overheight-legs detects when the legs are fully raised or fully
lowered. The machine has four sensors in order to detect the position
of the overheight-legs.
2
Two sensors, Sensor overheight-legs up left (B7231-LE) and Sensor
overheight-legs up right (B7231-RI) detect when their respective side's
3 overheight-legs are fully raised.
Two sensors, Sensor overheight-legs down left (B7256-LE) and Sensor
4 overheight-legs down right (B7256-RI) detect when their respective
side's overheight-legs are fully lowered.
The sensors send a voltage signal to Control unit KAU (D7911).
018589

B7231-RI)
B7259-RI)

7.9.1.14 Valve block servo pressure

7.9.2 Lift legs

Lift legs, general
1 2 3 2 4 1 1
The lift legs are designed to lift trailers from underneath by grabbing
around the object with four "legs". To facilitate loading and transport,
the front and rear legs can be controlled separately.
The lift legs are controlled with three switches on the instrument panel.
The lift legs are raised and lowered in a predetermined sequence that
is controlled by the machine's control system (sequence is reversed
when raising). The lift legs only have two approved positions, sequence
1 at the top or sequence 5 at the bottom. The position of the legs (steps
001854
1 2 3 2 3 in the sequence) can be checked with the diagnostic menu.

Overview combi attachment
1. Knee
2. Lift legs
3. Lifting shoe

7:144 7 Load handling – Lift legs
Operating position
Operating position is a predefined position for the rear lift legs that
gives the load correct centre of gravity if the machine is operated to-
wards the load with the rear legs lowered until contact is obtained for
the rear legs. If the front legs are lowered and clamped around the load
in this position, the load's centre of gravity is centred so that the load is
not tilted during lifting. Provided that the load has even weight
distribution.
The lift legs function includes the following components.
1 2 3 4 5 6 7 6 5 4 3 2 1
• Main beam, attachment
• Knee (4 pcs)
• Leg (4 pcs)
• Control valve (2 pcs)
• Control unit (2 pcs)
• Hydraulic cylinder (8 pcs)
• Position sensor leg (4 pcs)
• Position sensor knee (4 pcs)
001861
• Position sensor contact (4 pcs)

• Position sensor clamping position (4 pcs)
1. Sensor lift legs • Position sensor operating position (2 pcs)
2. Hydraulic cylinder lift legs
3. Lift legs
4. Knee
5. Sensor knee
6. Hydraulic cylinder knee and clamp
7. Sensor, operating position
Raising/lowering front lift legs, function description

in seat)

26 32
D27 27, 28 33, 34
1, 36
37 37
D1 D33
A B A B A B A B A B
T1
25 31
P1
24 30
2
11, 17, 23, D23 D29
D7902 D7912 29, 35
D7971 D7911 D11 D17 D35

3,7
D7940 12 18
5
D7 D7930
4, 6
P1
13 19
T1
A B A B A B A B A B
8
D21
LSP1 A H 37 37
LSP2 LSPR
LSP3
98 LSHY 21, 22
LSP3X PT T P LSM LSO 15, 16
D15
C10 14 20
10
022697
1 The switch for lowering the front legs U = 24 V Switch lowering front legs, description, page
(S1006-FR) sends a voltage signal to 7:14
Control unit KPU (D7902). D1: Diagnostic menu, see 7.9 Load Carrier
2 Control unit KPU (D7902) sends front lift Checked by control sys- 11.5.3.2 KPU control unit (D7902), page
legs down or up on the CAN bus. tem, error shown with er- 11:30
ror code.
3 Control unit KFU (D7971) sends a re- Checked by control sys- 11.5.3.1 KCU control unit (D7901), page
quest for engine speed requirement CAN tem, error shown with er- 11:27
lever deflection.
ror code.
gear ratio.


7 Control unit KFU (D7971) controls Pro- U = 24 V 11.5.3.4 Control unit KFU (D7971), page
(Y6002), with a predetermined voltage D7: Diagnostic menu, see 10.4 Pumps 6/XX
signal. DIAGNOSE, page 8:134
ment (Y6002), opens and actuates a pre- (Y6002), description, page 10:25
determined load signal.
9 Valve block, servo pressure, sends the - Valve block servo pressure, description, page
load signal to hydraulic oil pump 1. A 10:25
shuttle valve in Valve block, servo pres-
sure, selects the strongest load signal if
other functions are activated at the same
time.
10 Hydraulic oil pump 1 pumps oil from the See the pressure plate on Axial piston pump with variable displacement,
hydraulic oil tank. the left-hand frame beam. description, page 10:8
11 Control unit KAU2 (D7912) activates Sol- U = 24 V 11.5.3.9 Control unit KAU-2 (D7912), page
enoid valve knee out left front (Y6057- 11:42
LF). D11: Diagnostic menu, see 7.9 Load Carrier
12 Solenoid valve knee out left front - Control valve, lift legs, description, page
(Y6057-LF) pressurises the control 7:159
valve's valve slide with servo pressure.
13 The control valve's valve slide changes - Control valve, lift legs, description, page
position and pressurises Hydraulic cylin- 7:159
der knee left front.
14 Hydraulic cylinder knee left front lowers - Hydraulic cylinder knee and clamp, descrip-
knee left front. tion, page 7:163
15 Sensor knee left front (B7217-LF) sends U = 24 V Sensor knee, description, page 7:164
a voltage signal to Control unit KAU2 D15: Diagnostic menu, see 7.9 Load Carrier
(D7912) when the knee is lowered. 28/XX DIAGNOSE, page 8:72
16 Sensor knee left front (B7217-LF) stops U=0V Sensor knee, description, page 7:164
sending a signal to Control unit KAU2 D15: Diagnostic menu, see 7.9 Load Carrier
(D7912) when the knee reaches an end 28/XX DIAGNOSE, page 8:72
position.
enoid valve leg down left front (Y6059- 11:42
LF) when Sensor knee left front (B7217- D17: Diagnostic menu, see 7.9 Load Carrier
LF) stops sending a signal. 34/XX DIAGNOSE, page 8:74
18 Solenoid valve leg down left front - Control valve, lift legs, description, page
(Y6059-LF) pressurises the control 7:159
valve's valve slide with servo pressure. D13: Diagnostic menu, see 7.9 Load Carrier
der leg left front.
20 Hydraulic cylinder jack left front lowers - Hydraulic cylinder, jack, description, page
jack left front. 7:166
21 Sensor leg left front (B7219-LF) sends a U = 24 V Sensor, lift leg, description, page 7:166
voltage signal to Control unit KAU2 D21: Diagnostic menu, see 7.9 Load Carrier
(D7912) when the leg is lowered. 29/XX DIAGNOSE, page 8:73
22 Sensor leg left front (B7219-LF) stops U=0V Sensor, lift leg, description, page 7:166
position.
enoid valve knee out right front (Y6057- 11:42
RF) when Sensor leg left front (B7219- D23: Diagnostic menu, see 7.9 Load Carrier
LF) stops sending a signal. 37/XX DIAGNOSE, page 8:75


24 Solenoid valve knee out right front - Control valve, lift legs, description, page
(Y6057-RF) pressurises the control 7:159
der knee right front.
26 Hydraulic cylinder knee right front lowers - Hydraulic cylinder knee and clamp, descrip-
knee right front. tion, page 7:163
27 Sensor knee right front (B7217-RF) U = 24 V Sensor knee, description, page 7:164
sends a voltage signal to Control unit D27: Diagnostic menu, see 7.9 Load Carrier
KAU2 (D7912) when the knee is lowered. 28/XX DIAGNOSE, page 8:72
28 Sensor knee right front (B7217-RF) U=0V Sensor knee, description, page 7:164
stops sending a signal to Control unit D27: Diagnostic menu, see 7.9 Load Carrier
KAU2 (D7912) when the knee reaches 28/XX DIAGNOSE, page 8:72
an end position.
enoid valve leg down right front (Y6059- 11:42
RF) when Sensor knee right front D29: Diagnostic menu, see 7.9 Load Carrier
(B7217-RF) stops sending a signal. 38/XX DIAGNOSE, page 8:76
30 Solenoid valve leg down right front - Control valve, lift legs, description, page
(Y6059-RF) pressurises the control 7:159
der leg right front.
32 Hydraulic cylinder jack right front lowers - Hydraulic cylinder, jack, description, page
jack right front. 7:166
33 Sensor front leg right (B7219-RF) sends U = 24 V Sensor, lift leg, description, page 7:166
a voltage signal to Control unit KAU2 D33: Diagnostic menu, see 7.9 Load Carrier
(D7912) when the leg is lowered. 29/XX DIAGNOSE, page 8:73
34 Sensor front leg right (B7219-RF) stops U=0V Sensor, lift leg, description, page 7:166
position.
35 Control unit KAU2 (D7912) activates In- U = 24 V 11.5.3.9 Control unit KAU-2 (D7912), page
dicator lamp front leg down (H5800-LO). 11:42
D35: Diagnostic menu, see 7.9 Load Carrier
36 When the switch is released, activation of all solenoid valves is interrupted. Solenoid valves remain activated even
after the movement has been completed in order for it to be possible to complete the movement if the button is re-
leased when the lift leg is in an intermediate position.
37 Overcentre valves on the rod sides of the - Over-centre valve, lift legs, description, page
lowering cylinders ensure that the legs 7:170
are not lowered without being actively
pressurised by the control valves.


Raising/lowering rear lift legs, function description

in seat)
40
D40
26 39
27
D27 28
1
36
32
33
D1 34 42 42 D36
D33
A B A B A B A B A B
P1
31 25 38
T1
D29
30 24 37
2
11, 17, 23, 29,
D7902 D7912 D23
35, 41
D35
D7971 D7911 D11
5 25
3,7
D7940
18 12 37
D17
D7 D7930
4, 6
P1
T1
19 13 38
8 A B A B A B A B A B
LSP1 A H 21 42 42 D36
LSP2 LSPR
D21 22
LSP3
98 LSHY
36
20
C10 15
D15 16
14 39
10 D40 40
022752

1 The switch for lowering the rear legs U = 24 V Switch lowering rear legs, description, page
(S1006-RE) sends a voltage signal to 7:15
Control unit KPU (D7902). D1: Diagnostic menu, see 7.9 Load Carrier
2 Control unit KPU (D7902) sends rear lift Checked by control sys- 11.5.3.2 KPU control unit (D7902), page
legs down or up on the CAN bus. tem, error shown with er- 11:30
ror code.
3 Control unit KFU (D7971) sends a request Checked by control sys- 11.5.3.1 KCU control unit (D7901), page
for engine speed requirement CAN bus tem, error shown with er- 11:27
drive-train based on information on lever ror code.
deflection.


4 Control unit transmission (D7930) sends a Checked by control sys- Transmission, function description, page
rotation speed request on CAN bus drive- tem, error shown with er- 2:3
train to Control unit engine (D7940). ror code.
5 Control unit, engine (D7940) increases the Checked by control sys- 11.5.3.6 Control unit, engine (D7940), page
engine speed. tem, error shown with er- 11:38
ror code.
6 Control unit transmission (D7930) controls Checked by control sys- Transmission, function description, page
the ratio between drive and power take-off tem, error shown with er- 2:3
by changing the transmission's gear ratio. ror code.
7 Control unit KFU (D7971) controls Propor- U = 24 V 11.5.3.4 Control unit KFU (D7971), page
(Y6002), with a predetermined voltage D7: Diagnostic menu, see 10.4 Pumps 6/
signal. XX DIAGNOSE, page 8:134
(Y6002), opens and actuates a predeter- (Y6002), description, page 10:25
mined load signal.
9 Valve block, servo pressure, sends the - Valve block servo pressure, description,
load signal to hydraulic oil pump 1. A shut- page 10:25
tle valve in Valve block, servo pressure,
selects the strongest load signal if other
functions are activated at the same time.
11 Control unit KAU2 (D7912) activates Sole- U = 24 V 11.5.3.9 Control unit KAU-2 (D7912), page
noid valve knee out left rear (Y6057-LR). 11:42
12 Solenoid valve knee out left rear (Y6057- - Control valve, lift legs, description, page
LR) pressurises the control valve's valve 7:159
slide with servo pressure. D7: Diagnostic menu, see 7.9 Load Carrier
der knee left rear.
14 Hydraulic cylinder knee left rear lowers - Hydraulic cylinder knee and clamp, descrip-
knee left rear. tion, page 7:163
15 Sensor knee left rear (B7217-LR) sends a U = 24 V Sensor knee, description, page 7:164
voltage signal to Control unit KAU2 D11: Diagnostic menu, see 7.9 Load Car-
(D7912) when the knee is lowered. rier 28/XX DIAGNOSE, page 8:72
16 Sensor knee left rear (B7217-LR) stops U=0V Sensor knee, description, page 7:164
sending a signal to Control unit KAU2 D11: Diagnostic menu, see 7.9 Load Car-
(D7912) when the knee reaches an end rier 28/XX DIAGNOSE, page 8:72
position.
noid valve leg down left rear (Y6059-LR) 11:42
when Sensor knee left rear (B7217-LR) D13: Diagnostic menu, see 7.9 Load Car-
stops sending a signal. rier 42/XX DIAGNOSE, page 8:77
18 Solenoid valve leg down left rear (Y6059- - Control valve, lift legs, description, page
LR) pressurises the control valve's valve 7:159
slide with servo pressure. D13: Diagnostic menu, see 7.9 Load Car-
rier 42/XX DIAGNOSE, page 8:77
der leg left rear.
20 Hydraulic cylinder jack left rear lowers jack - Hydraulic cylinder, jack, description, page
left rear. 7:166


21 Sensor leg left rear (B7219-LR) sends a U = 24 V Sensor, lift leg, description, page 7:166
(D7912) when the leg is lowered. rier 29/XX DIAGNOSE, page 8:73
22 Sensor leg left rear (B7219-LR) stops U=0V Sensor, lift leg, description, page 7:166
position.
noid valve knee out right rear (Y6057-RR) 11:42
when Sensor leg left rear (B7219-LR) D19: Diagnostic menu, see 7.9 Load Car-
24 Solenoid valve knee out right rear (Y6057- - Control valve, lift legs, description, page
RR) pressurises the control valve's valve 7:159
slide with servo pressure. D20: Diagnostic menu, see 7.9 Load Car-
der knee right rear.
26 Hydraulic cylinder knee right rear lowers - Hydraulic cylinder knee and clamp, descrip-
knee right rear. tion, page 7:163
27 Sensor knee right rear (B7217-RR) sends U = 24 V Sensor knee, description, page 7:164
a voltage signal to Control unit KAU2 D23: Diagnostic menu, see 7.9 Load Car-
(D7912) when the knee is lowered. rier 28/XX DIAGNOSE, page 8:72
28 Sensor knee right rear (B7217-RR) stops U=0V Sensor knee, description, page 7:164
position.
29 Control unit KAU (D7911) activates Sole- U = 24 V 11.5.3.9 Control unit KAU-2 (D7912), page
noid valve leg down right rear (Y6059-RR) 11:42
when Sensor knee right rear (B7217-RR) D25: Diagnostic menu, see 7.9 Load Car-
30 Solenoid valve leg down right rear - Control valve, lift legs, description, page
(Y6059-RR) pressurises the control 7:159
valve's valve slide with servo pressure. D25: Diagnostic menu, see 7.9 Load Car-
der leg right rear.
32 Hydraulic cylinder jack right rear lowers - Hydraulic cylinder, jack, description, page
jack right rear. 7:166
33 Sensor rear leg right (B7219-RR) sends a U = 24 V Sensor, lift leg, description, page 7:166
(D7912) when the leg is lowered. rier 29/XX DIAGNOSE, page 8:73
34 Sensor rear leg right (B7219-RR) stops U=0V Sensor, lift leg, description, page 7:166
position.
35 When both rear lift legs are fully lowered, U = 24 V 11.5.3.9 Control unit KAU-2 (D7912), page
Control unit KAU2 (D7912) activates Sole- 11:42
noid valve operating position left (Y6053- D31: Diagnostic menu, see 7.9 Load Car-
LE) and Solenoid valve clamp close left rier 53/XX DIAGNOSE, page 8:80, 7.9
(Y6054-LE), as well as Solenoid valve op- Load Carrier 49/XX DIAGNOSE, page 8:79,
erating position right (Y6053-RI) and Sole- 7.9 Load Carrier 54/XX DIAGNOSE, page
noid valve clamp close right (Y6054-RI). 8:81 and 7.9 Load Carrier 51/XX DIAG-
NOSE, page 8:80


36 Solenoid valve operating position left - Control valve, lift legs, description, page
(Y6053-LE) closes the connection be- 7:159
tween control valve and hydraulic cylinder D31: Diagnostic menu, see 7.9 Load Car-
clamping left front. rier 53/XX DIAGNOSE, page 8:80 and 7.9
Solenoid valve operating position right Load Carrier 54/XX DIAGNOSE, page 8:81
(Y6053-RI) closes the connection between
control valve and hydraulic cylinder clamp-
ing right front.
37 Solenoid valve clamp close left (Y6054- - Hydraulic cylinder knee and clamp, descrip-
LE) and Solenoid valve clamp close right tion, page 7:163
(Y6054-RI) pressurise the control valve's
valve slides with servo pressure.
38 The control valve's valve slides change - Control valve, lift legs, description, page
position and pressurise Hydraulic cylinder 7:159
clamp left rear and Hydraulic cylinder
clamp right rear.
39 Hydraulic cylinder clamp left rear and Hy- - Hydraulic cylinder knee and clamp, descrip-
draulic cylinder clamp right rear press the tion, page 7:163
knee downward, and in this way press the
rear lift legs forward.
40 Sensor operating position left (B7212-LE) Sensor directly opposite Sensor operating position, description,
and Sensor operating position right indicator plate: U = 24 V page 7:163
B7212-RI) send a voltage signal to Control D36: Diagnostic menu, see 7.9 Load Car-
unit KAU2 (D7912) when leg pair is in op- rier 31/XX DIAGNOSE, page 8:73
erating position.
41 Control unit KAU2 (D7912) interrupts activation of Solenoid valve operating position left (Y6053-LE) and Solenoid
valve clamp close left (Y6054-LE), as well as Solenoid valve operating position right (Y6053-RI) and Solenoid valve
clamp close right (Y6054-RI).
42 Overcentre valves on the rod sides of the - Over-centre valve, lift legs, description,
lowering cylinders ensure that the legs are page 7:170
not lowered without being actively pressur-
ised by the control valves.


Clamping with lift legs, function description

Lift legs Lowered Raising/lowering front lift legs, function description, page 7:144
Raising/lowering rear lift legs, function description, page 7:148
in seat)
27 25 19 20 22 27
1
D27 D25 D22
D1
A
D27
A B A B B A B A B
P1
18
T1
29
D7950
2 17
11, 16, 23, 26,
D7902 D7912 D16 D23
28, 30
D28
D7971 D7911 D26
29
3, 7 D11
D7940 5 12
D7 D7930 4, 6
P1
13
T1
D27
8
LSP1 A H
D27
LSP2 LSPR D24 D21
LSP3
98 LSHY
27 24 15 14 21 27
C10
023383
10

1 Switch clamp/release legs (S1008) sends U = 24 V Switch clamp/release legs, description, page
a voltage signal to Control unit KPU 7:15
(D7902). D1: Diagnostic menu, see 7.9 Load Carrier
2 Control unit KPU (D7902) sends clamp or Checked by control 11.5.3.2 KPU control unit (D7902), page 11:30
release legs on the CAN bus. system, error shown
with error code.
3 Control unit KFU (D7971) sends a request Checked by control 11.5.3.1 KCU control unit (D7901), page 11:27
for engine speed requirement CAN bus system, error shown
drive-train based on information on lever with error code.
deflection.


with error code.
6 Control unit transmission (D7930) controls Checked by control Transmission, function description, page 2:3
the ratio between drive and power take-off system, error shown
by changing the transmission's gear ratio. with error code.
7 Control unit KFU (D7971) controls Propor- U = 24 V 11.5.3.4 Control unit KFU (D7971), page
(Y6002), opens and actuates a predeter- (Y6002), description, page 10:25
mined load signal.
load signal to hydraulic oil pump 1. A shut- 10:25
tle valve in Valve block, servo pressure,
selects the strongest load signal if other
functions are activated at the same time.
beam.
noid valve clamp close left (Y6054-LE) or 11:42
Solenoid valve clamp open left (Y6055- D7: Diagnostic menu, see 7.9 Load Carrier
LE). 49/XX DIAGNOSE, page 8:79 and 7.9 Load
Carrier 50/XX DIAGNOSE, page 8:80.
12 Solenoid valve clamp close left (Y6054- - Control valve, lift legs, description, page 7:159
LE) or Solenoid valve clamp open left D7: Diagnostic menu, see 7.9 Load Carrier
(Y6055-LE) pressurise the control valve's 49/XX DIAGNOSE, page 8:79 and 7.9 Load
valve slides with servo pressure. Carrier 50/XX DIAGNOSE, page 8:80.
13 The control valve's valve slides change - Hydraulic cylinder knee and clamp, descrip-
position and pressurise Hydraulic cylinder tion, page 7:163
clamp left front and Hydraulic cylinder
clamp left rear.
14 Hydraulic cylinder knee and clamp left - Hydraulic cylinder knee and clamp, descrip-
front act on knee left front so that left lift tion, page 7:163
legs clamp or release.
15 Hydraulic cylinder knee and clamp left rear - Hydraulic cylinder knee and clamp, descrip-
act on knee left rear so that left lift legs tion, page 7:163
clamp or release.
noid valve clamp close right (Y6054-RI) or 11:42
Solenoid valve clamp open right (Y6055- D12: Diagnostic menu, see 7.9 Load Carrier
RI). 51/XX DIAGNOSE, page 8:80and 7.9 Load
17 Solenoid valve clamp close right (Y6054- - Control valve, lift legs, description, page 7:159
RI) or Solenoid valve clamp open right D12: Diagnostic menu, see 7.9 Load Carrier
(Y6055-RI) pressurise the control valve's 51/XX DIAGNOSE, page 8:80and 7.9 Load
valve slides with servo pressure. Carrier 52/XX DIAGNOSE, page 8:80.
18 The control valve's valve slides change Hydraulic cylinder knee and clamp, descrip-
position and pressurise Hydraulic cylinder tion, page 7:163
clamp right front and Hydraulic cylinder
clamp right rear.
19 Hydraulic cylinder knee and clamp right - Hydraulic cylinder knee and clamp, descrip-
front act on knee right front so that right lift tion, page 7:163
20 Hydraulic cylinder knee and clamp right - Hydraulic cylinder knee and clamp, descrip-
rear act on knee right rear so that right lift tion, page 7:163


21 Sensor clamping position front leg left U = 24 V Sensor, clamping position, description, page
(B7215-LF) sends a voltage signal to Con- 7:169
trol unit KAU2 (D7912). D17: Diagnostic menu, see 7.9 Load Carrier
22 Sensor clamping position front leg right U = 24 V Sensor, clamping position, description, page
(B7215-RF) sends a voltage signal to 7:169
Control unit KAU2 (D7912). D18: Diagnostic menu, see 7.9 Load Carrier
23 Control unit KAU2 (D7912) activates Indi- U = 24 V 11.5.3.9 Control unit KAU-2 (D7912), page
cator light clamping position front leg 11:42
(H5780-FR). D19: Diagnostic menu, see 7.9 Load Carrier
24 Sensor clamping position rear leg left U = 24 V Sensor, clamping position, description, page
(B7215-LR) sends a voltage signal to Con- 7:169
trol unit KAU2 (D7912). D20: Diagnostic menu, see 7.9 Load Carrier
25 Sensor clamping position rear leg right U = 24 V Sensor, clamping position, description, page
(B7215-RR) sends a voltage signal to 7:169
Control unit KAU2 (D7912). D21: Diagnostic menu, see 7.9 Load Carrier
cator light clamping position rear leg 11:42
(H5780-RE). D22: Diagnostic menu, see 7.9 Load Carrier
27 When lifting is started, the following sen- U = 24 V Sensor, contact, description, page 7:168
sors send a signal to Control unit KAU2 D23: Diagnostic menu, see 7.9 Load Carrier
(D7912): 32/XX DIAGNOSE, page 8:74
• Sensor contact front leg left (B7213-
LF)
• Sensor contact rear leg left (B7213-
LR)
• Sensor contact front leg right (B7213-
RF)
• Sensor contact rear leg right (B7213-
RR)
If it takes longer than 4 seconds between
the first sensor's signal until all sensors
send signals, the lift function is blocked.
cator light contact for the corresponding lift 11:42
leg. D24: Diagnostic menu, see 7.9 Load Carrier
55/XX DIAGNOSE, page 8:81 – 7.9 Load
Carrier 58/XX DIAGNOSE, page 8:82
29 Control unit KID (D7950) activates the - 11.5.3.3 Control unit, KID (D7950), page 11:32
event menu contact bottom lift.
30 When more than two sensors indicate Checked by control Speed limitation, description, page 8:8
contact or clamping position, speed limita- system, error shown
tion is activated. with error code.


Lift legs, checking and adjusting

If necessary, the parts of the lift legs can be operated manually with the
diagnostic menu for the solenoid valves, see 7.9 Load Carrier 33/XX
DIAGNOSE, page 8:74 to 7.9 Load Carrier 54/XX DIAGNOSE, page
8:81.
1. Start key in position I.
2. Check that all sensors have voltage. The LED on the sensor
should be lit when the sensor indicates.
3. Check the distance between all sensors and their target surface,
the distance will be 4±1 mm when the sensor is directly opposite
the lug.
Sensor knee and Sensor jack should only be active during the
movement, not in the two end-positions.
4. Check that the attachment hangs horizontally, adjust the tilt func-
tion if necessary.
5. Lower all jacks completely.
6. Check that the jacks are vertical in the lateral direction.
7. If necessary, adjust the position on the lowering cylinder's rod
mounting by turning the piston rod.
After adjustment, the target surfaces for the jack sensors may
need to be precisely adjusted.
NOTE
Loosen the lock nuts on the piston head before adjustment.
8. Check the c-c measurement between right and left lift legs, the
measurement should be approximately 4876 mm at the bottom of
90˚ 90˚ the jacks.
c-c = 4876 mm
008205
Attachment, seen from the front

9. Operate the lift legs to clamping position.
10. Check that the lift legs are tilted 8.0° toward each other in the longi-
tudinal direction.
11. If necessary, adjust the position on the clamping cylinder's rod
mounting by turning the piston rod.
After adjustment, the target surfaces for the knee sensors may
need to be precisely adjusted.
NOTE
Loosen the lock bolts in the piston head before adjustment.
8,0˚ 8,0˚
007458
Clamping position, max. retracted jacks

12. Run apart the lift legs from clamping position.

13. Check that the rear lift legs are tilted 1.5° out (backward).
14. Check that the front lift legs are tilted 9.0° out (forward).
9,0˚ 1,5˚
007459
Clamping position, max. extended jacks.

15. Press the top of the rear lowering button, the rear lift legs should
move to operating position. (Operate clamping position apart in or-
der to return to end-position in order to test the operating position
again.)
16. Check that the lift legs stop at 1.0° inward (forward).
1,0˚
007460
Operating position, rear jacks

17. Adjust the position by moving the sensor operating position

laterally.
001856
Sensor, operating position

18. Press in the contact lug on one lift leg at a time and check that
each contact indicator light works.
If the light does not illuminate when the lug is pressed in, check the
light and contact sensor, see Sensor, contact, description, page
7:168.
008200
Indicator lights, contact

19. Press in the contact surfaces on the front and rear lift legs and
check that the indicator light is working for clamping position for
the relevant leg pair.
When both contact surfaces are pressed in the indicator light for
clamping position front and rear should turn on.
If the light does not turn on when the contact surfaces are pressed
in, check the light and clamping position sensor, see Sensor,
clamping position, description, page 7:169.
008201
Indicator lights, clamping position

20. Check that the indicator light for front jacks lowered is on when the
front lift legs are lowered.
008202
Indicator light, front jacks down
21. Operate the front lift legs up and check the indicator light for front
jacks lowered is off when the jacks are raised, and that the indica-
tor light for front jacks raised is on when the front lift legs are com-
pletely raised.
22. Check that the work lights on the attachment changes between
lighting the twistlocks and lighting the lift legs on the right and left
side when the rear lift legs on each side are raised and lowered.
008204
Indicator light, front jacks up

10:8.

7.9.2.3 Control valve, lift legs

Control valve, lift legs, description
The lift legs are controlled by two control valves, one for the left leg pair
1 2 3 4 5 6 7 8 9 10 and one for the right leg pair. The control valves are controlled by Con-
trol unit KAU2 (D7912) and Control unit KAU (D7911). The control
valves are fitted crosswise (left front and right rear) on the knee bracket
on the attachment's main beam.
The control valves are identical and have five sections each:
• Raising/lowering of front knee
19 • Raising/lowering of front jacks
11 • Raising/lowering of rear knee
• Raising/lowering of rear jacks
• Clamping position
The control valve is an electro-hydraulically controlled, proportional and
12 pressure-compensated directional control valve. Electrically controlled
pressure reducing valves convert electric current to servo pressure.
The servo pressure controls the spring-centred valve slides that control
18 17 16 15 14 13 pressure and flow for the function in question. The valve slide has a lim-
itation to the flow so that several functions can be used simultaneously.
Valve slide knee front

The valve slide controls the direction and speed of front knee lowering
by controlling the hydraulic pressure to hydraulic cylinder knee and
clamp.
The valve slide is controlled by servo valve, front knee out and servo
018375
valve, front knee in.
1. Solenoid valve leg up rear (Y6058-LR/RR) Servo valve knee front out
2. Solenoid valve leg down rear (Y6059-LR/RR) Servo valve front knee out, controls servo pressure to valve slide front
3. Solenoid valve knee in rear (Y6056-LR/RR) knee so that it controls oil pressure for front knee out.
4. Solenoid valve knee out rear (Y6057-LR/RR) Servo valve front knee out is controlled electrically with Solenoid valve
5. Solenoid valve clamp open (Y6055-LE/RI) knee out left front (Y6057-LF) or Solenoid valve knee out right front
6. Solenoid valve clamp close (Y6054-LE/RI) (Y6057-RF) which are activated by Control unit KAU2 (D7912).
7. Solenoid valve knee in front (Y6056-LF/RF)
8. Solenoid valve knee out front (Y6057-LF/RF) rier 33/XX DIAGNOSE, page 8:74 and 7.9 Load Carrier 37/XX DIAG-
9. Solenoid valve leg up front (Y6058-LF/RF) NOSE, page 8:75.
10. Solenoid valve leg down front (Y6059-LF/RF)
11. Drain to tank Servo valve knee front in
12. Feed from hydraulic oil pumps Servo valve front knee in, controls servo pressure to valve slide front
13. Connection hydraulic cylinder leg front knee so that it controls oil pressure for front knee in.
14. Connection hydraulic cylinder knee front
Servo valve front knee in is controlled electrically with Solenoid valve
15. Connection hydraulic cylinder for clamp knee in left front (Y6056-LF) or Solenoid valve knee in right front
16. Connection hydraulic cylinder knee rear (Y6056-RF) which are activated by Control unit KAU2 (D7912).
17. Connection hydraulic cylinder leg rear
18. Test outlet
rier 36/XX DIAGNOSE, page 8:75 and 7.9 Load Carrier 40/XX DIAG-
19. Return to tank (through tank filter) NOSE, page 8:76.
Valve slide leg front

The valve slide controls the direction and speed of front jack lowering
by controlling the hydraulic pressure to hydraulic cylinder jack.
The valve slide is controlled by Servo valve front leg down and Servo
valve front leg up.
Servo valve leg front down

Servo valve front leg down controls servo pressure to valve slide front
leg so that it controls oil pressure for lowering the leg.

Servo valve front leg down is controlled electrically with Solenoid valve
leg down left front (Y6059-LF) or Solenoid valve leg down right front
(Y6059-RF) which are activated by Control unit KAU2 (D7912).
NOSE, page 8:76.
Servo valve leg front up

Servo valve front jack up, controls servo pressure to valve slide front
jack so that it controls oil pressure for raising of jack.
Servo valve front leg up is controlled electrically with Solenoid valve leg
up left front (Y6058-LF) and Solenoid valve leg up right front (Y6058-
RF) which are activated by Control unit KAU2 (D7912).
NOSE, page 8:76.
Valve slide clamp

Valve slide clamp controls the direction and speed of clamping with the
jack pair by controlling the hydraulic pressure to hydraulic cylinder knee
and clamp.
The valve slide is controlled by servo valve clamp and servo valve
clamp release.
Servo valve clamp

Servo valve clamp, controls servo pressure to valve slide clamp so that
it controls oil pressure for clamping.
Servo valve clamp close is controlled electrically with Solenoid valve
clamp close left (Y6054-LE) or Solenoid valve clamp close right
(Y6054-RI) which are activated by Control unit KAU2 (D7912).
NOSE, page 8:80.
Servo valve clamp release

Servo valve clamp release, controls servo pressure to valve slide
clamping position so that it controls oil pressure for clamp release.
Servo valve clamp open is controlled electrically with Solenoid valve
clamp open left (Y6055-LE) or Solenoid valve clamp open right
(Y6055-RI) which are activated by Control unit KAU2 (D7912).
NOSE, page 8:80.
Valve slide knee rear

The valve slide controls the direction and speed of rear knee lowering
by controlling the hydraulic pressure to hydraulic cylinder knee and
clamp.
The valve slide is controlled by servo valve, rear knee out and servo
valve, rear knee in.
Servo valve knee rear out

Servo valve rear knee out, controls servo pressure to valve slide rear
knee so that it controls oil pressure for rear knee out.
Servo valve rear knee out is controlled electrically with Solenoid valve
knee out left rear (Y6057-LR) or Solenoid valve knee out right rear
(Y6057-RR) which are activated by Control unit KAU2 (D7912).

NOSE, page 8:78.
Servo valve knee rear in

Servo valve rear knee in, controls servo pressure to valve slide rear
knee so that it controls oil pressure for rear knee in.
Servo valve rear knee in is controlled electrically with Solenoid valve
knee in left rear (Y6056-LR) or Solenoid valve knee in right rear
(Y6056-RR) which are activated by Control unit KAU2 (D7912).
NOSE, page 8:79.
Valve slide leg rear

The valve slide controls the direction and speed of rear jack lowering
by controlling the hydraulic pressure to hydraulic cylinder jack.
The valve slide is controlled by servo valve rear jack down and servo
valve rear jack out.
Servo valve leg rear down

Servo valve rear leg down controls servo pressure to valve slide rear
leg so that it controls oil pressure for lowering the leg.
Servo valve rear leg down is controlled electrically with Solenoid valve
leg down left rear (Y6059-LR) which is activated by Control unit KAU2
(D7912) or Solenoid valve leg down right rear (Y6059-RR) which is ac-
tivated by Control unit KAU (D7911) depending on whether it is right or
left leg.
NOSE, page 8:78.
Servo valve leg rear up

Servo valve rear jack up, controls servo pressure to valve slide rear
jack so that it controls oil pressure for jack raising.
Servo valve rear leg up is controlled electrically with Solenoid valve leg
up left rear (Y6058-LR) which is activated by Control unit KAU2
(D7912) or Solenoid valve leg up right rear (Y6058-RR) which is acti-
vated by Control unit KAU (D7911).
NOSE, page 8:79.


7.9.2.5 Valve, operating position

Valve operating position, description
Valve operating position cuts the pressure to the front hydraulic cylinder
clamp. The valve is fitted on the attachment's main beam by the hy-
draulic cylinder knee and clamp.
When the valve is activated it cuts the hydraulic connection between
Control valve attachment lift leg and hydraulic cylinder knee and clamp.
This means that only the rear lift leg tilts forward.
Solenoid valve operating position (Y6053-LE/RI) is activated by Control
unit KAU2 (D7912).
NOSE, page 8:81.
001849
7.9.2.6 Main beam, attachment

The brackets for knee and hydraulic cylinder knee and clamp are lo-
cated on the attachment's main beam.
7.9.2.7 Knee
Knee, description
The knee is located between the attachment's main beam and the lift
leg. There are four knees, one for each lift leg. The knee makes it pos-
sible to fold in and clamp with the legs. The knee is controlled by hy-
draulic cylinder knee and clamp.
There is an indicator ring on the knee joint that rotates with the lift leg.
The indicator ring is used together with Sensor knee to determine
whether the leg is raised, in the intermediate position or lowered.
001851

7.9.2.8 Hydraulic cylinder knee and clamp

Hydraulic cylinder knee and clamp, description
Hydraulic cylinder knee and clamp has two pistons in separate cylin-
1 2 ders. There are four hydraulic cylinders, one for each lift leg. The hy-
draulic cylinder is fitted between the attachment and knee. One of the
hydraulic cylinder pistons opens the knee joint. The other piston clamps
with the lift legs by further angling the knee joint.
001852
1. Hydraulic cylinder, clamp
2. Hydraulic cylinder, knee

7.9.2.9 Sensor, operating position

Sensor operating position, description
Sensor operating position detects the position of the hydraulic cylinder
knee and clamp for the rear lift legs. This is used to indicate the operat-
ing position of the rear lift legs. There are two sensors, one on each
side (right and left).
Sensor, operating position left and right (B7212-LE/RI) sends a voltage
signal when the rear hydraulic cylinder lowering knee/clamp is in its in-
ner end position. The signal is used to interrupt activation of the sole-
noid valve operating position when lowering the rear lift legs.
001856


7.9.2.10 Sensor knee

Sensor knee, description
Sensor knee detects the position of the knee joints, this is used to con-
trol the lowering of the legs. There are four sensors, one for each knee.
Sensor front knee (B7217-LF/RF) and Sensor rear knee (B7217-LR/
RR) sends a voltage signal when the knee is between each end posi-
tion, the signal changes to 0 V when the end position is reached. This
applies to both retracting and extending. The signal is used to activate
the next step in the raise/lower sequence. If the signal does not go
down to 0 V the leg is not lowered.
001853


7.9.2.11 Lift legs

Lift legs, description
The lift legs grab around/under the load. In the lower ends of the legs
there are lifting shoes. The lift legs are raised and lowered using hy-
draulic cylinder lift legs.
There is an indicator ring on the lift leg's joint that rotates with the lift leg.
The indicator ring is used together with Sensor leg to determine
whether the leg is raised, in the intermediate position or lowered.
001866

7.9.2.12 Hydraulic cylinder, jack

Hydraulic cylinder, jack, description
Hydraulic cylinder lift leg is located between the knee and lift leg. The
hydraulic cylinder lifts the lift legs up and down.
001855

7.9.2.13 Sensor lift legs

Sensor, lift leg, description
Sensor lift leg detects the position of the lift legs, this is used to control
raising/lowering of the legs. There are sensors, one for each lift leg.
Sensor front lift leg (B7219-LF/RF) and Sensor rear lift leg (B7219-LR/
RR) send a voltage signal when the lift legs are between each end po-
sition. The signal goes down to 0 V when the end position is reached.
This applies to both raising and lowering. The signal is used to activate
the next step in the raise/lower sequence. If the signal does not go
down to 0 V the knee is not extended.
001859


7.9.2.14 Lifting shoe

Lifting shoe, description
The lifting shoe is fitted on the lower end of the lift legs. The lifting shoe
grabs under the load. There are two sensors fitted on each lifting shoe.
Sensor contact detects when the lifting shoe makes contact with the
load from above, see Sensor, contact, description, page 7:168. Sensor
clamping position detects when the lifting shoe is in contact against the
load longitudinally, see Sensor, clamping position, description, page
7:169.
3
001857
1. Indicator pin, sensor, clamping position

2. Indicator pin, sensor, contact
3. Lifting shoe

7.9.2.15 Sensor, contact

Sensor, contact, description
Sensor, contact (B7213-LF/RF/LR/RR) detects when the lifting shoe
makes contact with the load from above. The sensor is located behind
the lifting shoe and detects the position on a linkage. The linkage is ac-
tuated by a pin in the middle of the lifting shoe, which is pressed when
the load is located correctly in the lifting shoe.
1
2
001858
1. Sensor clamping position (B7215-LF/RF/LR/RR)

2. Sensor, contact (B7213-LF/RF/LR/RR)


7.9.2.16 Sensor clamping position

Sensor, clamping position, description
Sensor clamping position (B7215-LF/RF/LR/RR) detects when the lift-
ing shoe lies against the load longitudinally. The sensor is located be-
hind the lifting shoe and is activated by a screw fitted on a spring-
loaded plate on the lifting shoe.
1 The signal can be checked with the diagnostic menu, see 7.9 Load Car-
001858
1. Sensor clamping position (B7215-LF/RF/LR/RR)

2. Sensor, contact (B7213-LF/RF/LR/RR)

7.9.2.17 Relief valve top lift




7:170 7 Load handling – Tool changer
7.9.2.20 Overcentre valve lift legs

Over-centre valve, lift legs, description
Eight overcentre valves prevent legs and knees being lowered by the
dead weight of the lift legs when the system is not pressurised. The
1 2 overcentre valves are fitted between the hydraulic cylinder's rod side
and the control valve.
The lift legs have the following overcentre valves:
• Overcentre valve hydraulic cylinder knee left rear
• Overcentre valve hydraulic cylinder knee right rear
• Overcentre valve hydraulic cylinder knee left front
• Overcentre valve hydraulic cylinder knee right front
• Overcentre valve hydraulic cylinder leg left rear
018528
• Overcentre valve hydraulic cylinder leg right rear
3
• Overcentre valve hydraulic cylinder leg left front
1. Connection control valve • Overcentre valve hydraulic cylinder leg right front
2. Connection piston side (control pressure)
3. Connection rod side hydraulic cylinder
7.9.3 Tool changer

Tool changer, description
The machine can be equipped with a tool changer which is used to con-
nect customised attachments for various purposes. The tool changer is
adapted for the different attachments and is described in separate sup-
plements if necessary.
The tool changer connects the customised attachments with twistlocks.
For more information on twistlocks, see Twistlocks, description, page
7:127. The change interval for twistlocks on the tool changer is shorter
due to them being loaded for a longer time.
7.9.3.1 Sensor, lifting tool

Sensor for lifting tool, description
Tool changer and top lift can be equipped with a sensor indicator pin for
under the attachment (B7730) that detects when a lifting tool is con-
nected to the machine. The sensor indicates when the lifting tool is con-
nected. When the sensor detects that a lifting tool is connected, by-
pass must be activated in order to open twistlocks (the lifting tool must
be adapted for this function).
The sensor detects when a lifting tool is connected by means of a plate
on the tool pressing in a spring-loaded indicator pin. The sensor detects
when the indicator pin is depressed. The indicator pin and sensor are
fitted on the attachment or the tool changer on the beam where twist-
locks are attached.
The sensor is supplied with voltage by, and sends a 24 V signal to Con-
trol unit KAU (D7911) when the indicator pin is depressed.
The signals can be checked with the diagnostic menu, see 7.9 Load
019144

7 Load handling – Other functions 7:171
7.10 Other functions

7.10.1 Support jacks
Support jacks description
Support jacks increase stability forward and hence the load capacity
over a longer distance. The support jacks are controlled with Switch
support jacks (S1013). Control valve support jacks pressurises two par-
allel-connected cylinders that lower one support jack each. Four posi-
tion sensors, two for each support jack, detect whether the support
016317
jacks are fully lowered or fully raised. An indicator light in the cab indi-
cates when the support jacks are lowered. The support jacks are fitted
on the frame between the drive wheels.
The transmission must be in neutral position, the doors must be closed
and the machine must be stationary with the parking brake released in
order that the support jacks can be lowered. When the support jacks
are not fully raised, the transmission is locked in neutral position.
Lowering the support jacks can be set to automatic (short press of the
button lowers the jacks) or manual (the button must be held depressed
to end position) with the initiation menus, see 7.10 Other functions 11/
XX INITIATE, page 8:218.

7:172 7 Load handling – Support jacks
Support jacks, function description

Control breaker Disengaged Axial piston pump with variable displacement, description, page 10:8
in seat)
Doors Closed Doors, description, page 9:102.
Transmission Neutral position Transmission, function description, page 2:3
Machine stationary Speed = 0 km/h -
19
1
D7950 17
3 18
D7902 D7901
2, 5, 6
D7930 D7971 D7972
8, 6, 16
4
D7940
7
9 15
LSP1 A H C8
LSP2 LSPR
11
LSP3 LSHY LS A
LSP3X PT T P LSM LSO P 10 13
B
T
C12 14
023384
12

1 Switch, support jacks (S1013) sends a volt- U = 24 V Switch support jacks, description, page 7:14
age signal to Control unit KPU (D7902).
2 Control unit transmission (D7930) sends en- Checked by control 11.5.3.6 Control unit, engine (D7940), page
gine speed on the CAN bus. system, error shown 11:38
with error code.
3 Control unit KPU (D7902) sends support Checked by control 11.5.3.2 KPU control unit (D7902), page
jacks down or up on the CAN bus. system, error shown 11:30
Before a request for support jacks up is sent, with error code.
there is a check that the load does not ex-
ceed the limit for load curve without support
jacks. If the load exceeds the limit then
Event menu overload is shown when raising
is requested.
4 Control unit KFU (D7971) sends request for Checked by control 11.5.3.4 Control unit KFU (D7971), page
neutral position on CAN bus drive-train. system, error shown 11:34
with error code.
5 Control unit transmission (D7930) locks the Checked by control 11.5.3.7 Control unit, transmission (D7930),
transmission in neutral position. system, error shown page 11:39
with error code.

7 Load handling – Support jacks 7:173

with error code.
8 Control unit KFU-2 (D7972) activates Sole- U = 24 V 11.5.3.5 Control unit KFU-2 (D7972), page
noid valve support jacks down (Y6064) or 11:36
Solenoid valve support jacks up (Y6063).
9 Solenoid valve support jacks down (Y6064) - Control valve, option frame, description, page
or Solenoid valve support jacks up (Y6063) 7:174
pressurises the support jacks slide in Con-
trol valve, option frame.
10 Control valve option frame sends a load sig- - Control valve, option frame, description, page
nal to Valve block servo pressure and pres- 7:174
surises Valve block support jack cylinder.
11 Valve block servo pressure sends the load - Valve block servo pressure, description, page
signal to hydraulic oil pump 2. Shuttle valves 10:25
in the servo valves select the strongest load
signal if other functions are activated at the
same time.
12 Hydraulic oil pump 2 pumps oil from the hy- See the pressure plate Axial piston pump with variable displacement,
draulic oil tank. on the left-hand frame description, page 10:8
beam.
13 Valve block support jack cylinder pressur- - Valve block, support jacks, description, page
ises hydraulic cylinder support jacks. 7:179
14 The hydraulic cylinder lowers or raises the - Hydraulic cylinder, support jacks, description,
support jack. page 7:176
15 Sensor support jacks up (B7222-RI and Support jacks up or Sensor, support jacks up, description, page
B7222-LE) or Sensor support jacks down down: U = 24 V 7:177
(B7223-RI and B7223-LE) send a voltage Support jacks in inter- Sensor, support jacks down, description,
signal to Control unit KFU2 (D7972). mediate position: U = 0 page 7:178
V
16 Control unit KFU-2 (D7972) sends informa- Checked by control 11.5.3.5 Control unit KFU-2 (D7972), page
tion about the position of the support jacks system, error shown 11:36
on the CAN bus. with error code.
17 Control unit KID (D7950) activates Event - 11.5.3.3 Control unit, KID (D7950), page
menu, support jacks. 11:32
18 Control unit KCU (D7901) activates Indicator U = 24 V 11.5.3.1 KCU control unit (D7901), page
light support jacks down (H5740) on the light 11:27
panel in the cab.
When support jacks are lowered, Control
unit KCU (D7901) changes the load curve
(limit for overload system).
When support jacks are raised Control unit
KCU (D7901) allows shifting from neutral
position.
19 Indicator light support jacks down (H5740) U = 24 V
on the light panel in the cab illuminates.
Hydraulic diagram cab movement and support jacks, see Hydraulic dia-
gram cab movement and support jacks, page E:22.


10:8.

7.10.1.2 Control valve option frame

Control valve, option frame, description
1 2 3 On machines with support jacks, the lowering of the support jacks is

controlled by a separate section in Control valve, frame option. The
control valve is fitted on the frame at the front of the engine compart-
ment. The control valve is controlled by Control unit KFU-2 (D7972).
8
7 pressure reducing valves convert electric current to servo pressure.
6 pressure and flow for the function in question. The valve slide has a lim-
1 4
2 Valve slide, support jacks
5
The valve slide controls the direction and speed of support jack lower-
ing by controlling the hydraulic pressure to hydraulic cylinder, support
jacks.
The valve slide is controlled by servo valve, support jacks up and servo
valve, support jacks down.
Servo valve, support jacks down

016911
Servo valve, support jacks down controls servo pressure to valve slide
1. Connection hydraulic cylinder (A1 + A2) support jacks so that it controls oil pressure for support jacks down.
2. Connection hydraulic cylinder (B1 + B2) Servo valve, support jacks down, is controlled electrically with Solenoid
3. Tank return (T ) valve support jacks down (Y6064), which is activated by Control unit
4. Pressure feed (P) KFU-2 (D7972).
5. Solenoid valve support jacks up (Y6063)
6. Solenoid valve support jacks down (Y6064) Servo valve, support jacks up
7. Measurement connection Servo valve, support jacks up controls servo pressure to valve slide
8. Load signal (LS) support jacks so that it controls oil pressure for support jacks up.
Servo valve, support jacks up, is controlled electrically with Solenoid
valve support jacks up (Y6063), which is activated by Control unit KFU-
2 (D7972).

Control valve, option frame, changing
NOTE
Safety.

NOTE
1 2 3
NOTE
from impurities.
8
7 5. Remove the control valve.
6 on a clean and protected surface.
1 4
2
5 NOTE
correctly.
NOTE
016911
mixed up.
1. Connection hydraulic cylinder (A1 + A2)

2. Connection hydraulic cylinder (B1 + B2)
NOTE
3. Tank return (T ) Transfer one part at a time so that the marking is not mixed up.
5. Solenoid valve support jacks up (Y6063)
6. Solenoid valve support jacks down (Y6064) 8. Fit the valve.
7. Measurement connection 9. Connect the cable harness to the control valve according to the
8. Load signal (LS) marking.
the marking.
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.

CAUTION
product damage.
manual.
7.10.1.3 Hydraulic cylinder support jacks

Hydraulic cylinder, support jacks, description
1 2 3
Hydraulic cylinder support jacks operates the support jack up and
down. The hydraulic cylinder is fitted between support jack and frame.
018389
1. Valve block support jacks

2. Pressure feed from hydraulic oil pump 2 and re-
turn line tank
3. Hydraulic cylinder support jacks

7.10.1.4 Support jacks

Support jacks, description
1 The support jack consists of a linkage and support. The linkage is de-
signed so that it locks automatically when it is loaded from below in its
lowered position.
2
The support jack is secured in the frame and in the drive axle's attach-
ing bolts.
3
5
001870
7 6

2. Sensor support jacks up (B7222-LE or B7222-RI)
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
7. Sensor support jacks down (B7223-LE or B7223-
RI)
7.10.1.5 Sensor, raised support jacks

Sensor, support jacks up, description
1 Sensor support jacks up left (B7222-LE) and Sensor support jacks up

right (B7222-RI) are fitted under hydraulic cylinder support jacks and
detect when the support jack is raised. There is a sensor fitted by each
2 support jack. The sensor indicates when the support jack is fully raised.
This is used to control Event menu, support jacks.
3 Sensor support jacks up left (B7222-LE) and Sensor support jacks up

right (B7222-RI) send a voltage signal to Control unit KFU2 (D7972)
when the support jack is fully raised.
4
5
001870
7 6

3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
RI)

7.10.1.6 Sensor, lowered support jacks

Sensor, support jacks down, description
1 Sensor support jacks down left (B7223-LE) and Sensor support jacks
down right (B7223-RI) are fitted under the upper mounting for the sup-
port jack and detect when the support jack is lowered. There is a sen-
2 sor fitted by each support jack. This is used to control the support jacks
and activation of Indicator light, support jacks down.
3 Sensor support jacks down left (B7223-LE) and Sensor support jacks
down right (B7223-RI) send a voltage signal to Control unit KFU2
(D7972) when the support jack is fully lowered.
4
5
001870
7 6

3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
RI)


7 Load handling – Weight indicator 7:179
7.10.1.9 Valve block support jacks

Valve block, support jacks, description
1 2 3
Valve block, support jacks is located by the hydraulic cylinders and con-
tains two centre valves which protects against accidental raising and
lowering of the support jacks.
018389
1. Valve block support jacks

2. Pressure feed from hydraulic oil pump 2 and re-
turn line tank

7.10.2 Weight indicator

Weight indicator, general
See Weight indicator, description, page 8:20.
7.10.3 Container counter

Container counter, general
See Container counter, description, page 8:21.
7.10.4 Synchronised lift

Synchronised lift, general
Synchronised lift, description, page 8:25

7:180 7 Load handling – Radio control
7.10.5 Radio control

Radio control, description
1 4 5 As an option, the machine can be equipped with radio control of the

D7901 load functions. The radio control consists of a hand control and a
2 3
receiver.
019298
X039 D9001
The hand control is adapted for the machine and can control the ma-
chine's load functions and the engine's rotation speed. The range is ap-
prox. 25 m. To operate the hand control, see Operator's manual.
1. Control unit, cab (D7901) The receiver (D9001) is fitted in the cab behind the driver's seat and
2. Connector VDI (X039) communicates with the hand control via an antenna at the rear of the
3. Receiver, radio control (D9001) cab roof. The receiver communicates with Control unit KCU (D7901)
4. Antenna via Vehicle Data Interface (VDI) (X039), see Communication with the
5. Hand control machine, description, page 11:54.
7.10.6 Indicator, eccentric load

Indicator, eccentric load, description
Detection and indication of eccentric load (the load's lateral centre of

gravity) are available as options. The system compares the load in the
mountings for the attachment's levelling cylinders and side shift posi-
tion. The load's centre of gravity is shown with three lamps on the side
shift frame.
019117
Indication of eccentricity, function description
7
D7950
D7902
5
D7971 D7911 A7992
8 3, 6 4 D5
D1
D2
023385
1 1 2

7 Load handling – Indicator, eccentric load 7:181

1 Sensor, force levelling cylinder left front U = 0.5-4.5 V Sensor, force, levelling cylinder, description,
(B7235-LF), Sensor, force levelling cylinder, page 7:181
left rear (B7235-LR), Sensor, force levelling D1: Diagnostic menu, 7.9 Load Carrier 108/
cylinder right front (B7235-RF) and Sensor, XX DIAGNOSE, page 8:90, 7.9 Load Carrier
force levelling cylinder right rear (B7235-RR) 109/XX DIAGNOSE, page 8:90 and 7.9 Load
send voltage signals till Control unit KEM-2 Carrier 110/XX DIAGNOSE, page 8:91.
(A7992) which forwards the information on
the CAN bus to Control unit KAU (D7911).
2 Sensor, side shift (B7687) sends voltage sig- U = 0.5-4.5 V Position sensor, side shift, description, page
nal till Control unit KEM-2 (A7992) which for- 7:185
wards the information on the CAN bus to D2: Diagnostic menu 7.9 Load Carrier 111/
Control unit KAU (D7911). XX DIAGNOSE, page 8:91
3 Control unit KAU (D7911) calculates the Checked by control 11.5.3.8 Control unit KAU (D7911), page
load's lateral centre of gravity. system, error shown 11:40
with error code.
4 Control unit KEM-2 (A7992) activates Indi- U = 24 V I/O module KEM-2 (A7992), description,
cator light skewed load left (E5990-LE), Indi- page 11:43
cator light load centred (E5990) and D5: Diagnostic menu, 7.9 Load Carrier 112/
Indicator light skewed load right (E5990-RI). XX DIAGNOSE, page 8:91, 7.9 Load Carrier
113/XX DIAGNOSE, page 8:91 and 7.9 Load
5 Indicator light skewed load left (E5990-LE), U = 24 V Light panel, eccentric load, description, page
Indicator light load centred (E5990) and Indi- 7:186
cator light skewed load right (E5990-RI) D5: Diagnostic menu, 7.9 Load Carrier 112/
show the load's lateral centre of gravity. XX DIAGNOSE, page 8:91, 7.9 Load Carrier
113/XX DIAGNOSE, page 8:91 and 7.9 Load
6 Control unit KAU (D7911) sends centre-of- Checked by control 11.5.3.8 Control unit KAU (D7911), page
gravity information on the CAN bus. system, error shown 11:40
with error code.
7 Control unit KID (D7950) shows centre of - 11.5.3.3 Control unit, KID (D7950), page
gravity information in the operating menus. 11:32
8 If the load's centre of gravity is outside set Checked by control 11.5.3.4 Control unit KFU (D7971), page
limits, Control unit KFU (D7971) blocks the system, error shown 11:34
lift function. with error code.
The setting of max. permitted displacement
of the load's lateral centre of gravity is made
using the initiation menus, see 7.9 Load car-
rier 39/XX INITIATE, page 8:215 and 7.9
Load carrier 40/XX INITIATE, page 8:215.
7.10.6.1 Sensor, force, levelling cylinder

Sensor, force, levelling cylinder, description
Sensor, force, levelling cylinder (position A) measures the load on the
A
levelling cylinders to be able to calculate the load's lateral centre of
gravity. The sensors are fitted in the upper mounting for the levelling
cylinders on the attachment. A sensor is fitted in each shaft, total four
sensors (Sensor, force, levelling cylinder left front (B7235-LF), Sensor,
force, levelling cylinder, left rear (B7235-LR), Sensor, force, levelling
cylinder right front (B7235-RF) and Sensor, force, levelling cylinder
right rear (B7235-RR).
The sensors are supplied with voltage by, and send a voltage signal
proportional to the position to Control unit KEM-2 (A7992).
020624
Carrier 108/XX DIAGNOSE, page 8:90, 7.9 Load Carrier 109/XX DIAG-
NOSE, page 8:90 and 7.9 Load Carrier 110/XX DIAGNOSE, page 8:91.

7:182 7 Load handling – Indicator, eccentric load
Sensor, force, levelling cylinder, replacement

1. Machine in service position, see section B Safety.
B
2. Unload the attachment.
A 3. Undo the screws (position A) and remove the sensor.
4. Fit the new sensor.
NOTE
The arrow (position B) must point in the direction of the cylinder.
5. Turn on the system voltage and turn the start key to position I.
6. Calibrate the sensor, see Indication of eccentric load, calibration,
page 7:182.
020625
Indication of eccentric load, calibration
NOTE
the given order.

the cylinders.
10:23
CUSTOMER SETTINGS
0
014981

10:23

0 0
015625


with .
7. LOAD HANDLING
018351
6. Select 7.4 Side Shift by scrolling with or and confirm with .

7.3 Extension
7.4 Side Shift
7.5 Spreading
7.6 Rotation
7.7 Tilt
7.8 Levelling
7.9 Load Carrier
019139

7.3 Extension
7.4 Side Shift
7.5 Spreading
7.6 Rotation
7.7 Tilt
7.8 Levelling
7.9 Load Carrier
019916
8. Scroll to menu 1 Sideshift Right End pos with or and confirm

with .
9. Operate side shift fully to the right. Press to save this value.
10. Scroll to menu 2 Sideshift Left End pos with .

11. Operate side shift fully to the left. Press to save this value.

13. Select 7.9 Load Carrier by scrolling with or and confirm with
.
7.3 Extension
7.4 Side Shift
7.5 Spreading
7.6 Rotation
7.7 Tilt
7.8 Levelling
7.9 Load Carrier
019139
7.3 Extension
7.4 Side Shift
7.5 Spreading
7.6 Rotation
7.7 Tilt
7.8 Levelling
7.9 Load Carrier
020631
15. Scroll to the menu for Side shift position (111/XX) with or .
16. Operate side shift to centred position so that the menu shows ±0
mm.
17. Scroll to the menu for Load screw sensors (108/XX and 109/XX)
with or .
18. Check that the left and right-hand side show equal values, both in
mV (108/XX) and kg (109/XX).

19. If the difference is greater than 100 mV between front and rear
A B sensor, the cylinders must be adjusted. A cylinder with a high value
is slightly shorter and therefore carries a greater proportion of the
load. The cylinder must therefore be extended. Alternatively, the
corresponding cylinder (front/rear) can be shortened.
Adjusting:
a. Decide which cylinders should be adjusted, extended, or
shortened.
b. Unload the attachment.
c. Undo the screws (position A) a few turns.
d. Rotate the cylinder rod (position B) using a hook wrench in or-
der to extend the total length of the cylinder.
e. Raise to check the adjustment. Repeat until the values are
within reasonable limits.
f. Tighten the screws (position A).
020627
7.10.6.2 Position sensor, side shift

Position sensor, side shift, description
A
Position sensor, side shift (B7687, position A) measures the position of
the side shift to be able to calculate the load's lateral centre of gravity.
The position sensor is fitted on the attachment's side shift frame.
Position sensor, side shift is supplied with voltage by, and sends a volt-
age signal proportional to the force to Control unit KEM-2 (A7992).
020626
Position sensor, side shift, replacement

A B C
2. Disconnect the cable from the mounting (position A).
3. Unplug the connector on the length sensor (position B).
4. Undo the screws (position C) and replace the sensor. Fit in reverse
order.
5. Turn on the system voltage and turn the start key to position I.
6. Calibrate the sensor, see Indication of eccentric load, calibration,
page 7:182.
020630

7.10.6.3 Light panel, eccentric load

Light panel, eccentric load, description
Light panel, eccentric load, shows the load's lateral centre of gravity.
1 2 3 The light panel has three lights and is fitted at the rear of the attach-
ment's side shift frame.
Carrier 112/XX DIAGNOSE, page 8:91, 7.9 Load Carrier 113/XX DIAG-
0192986
NOSE, page 8:91 and 7.9 Load Carrier 114/XX DIAGNOSE, page 8:92.
1. Indicator light (white) skewed load left (E5990-

LE)
2. Indicator light (green) skewed load centred
(E5990)
3. Indicator light (white) skewed load right (E5990-
RI)

8:1
8 Control system
Contents 8 Control system

8 Control system..................................................................................................... 8:3
8.1.2 Information display ....................................................................................... 8:4
8.2 Monitoring ......................................................................................................... 8:5
8.2.1 Overload system .......................................................................................... 8:5
8.2.2 Bypass.......................................................................................................... 8:6
8.2.3 Load centre limitation ................................................................................... 8:7
8.2.4 Height limitation............................................................................................ 8:7
8.2.5 Speed limitation............................................................................................ 8:8
8.2.6 Service indicator........................................................................................... 8:9
8.2.11 Load sensors.............................................................................................. 8:10
8.2.12 Statistics ..................................................................................................... 8:19
8.2.13 Weight indicator.......................................................................................... 8:20
8.2.14 Container counter....................................................................................... 8:21
8.2.15 Synchronised lift ......................................................................................... 8:25
8.2.17 Printout of load receipts.............................................................................. 8:26
8.4 Diagnostics...................................................................................................... 8:27
8.4.1 Engine ........................................................................................................ 8:29
8.4.2 Transmission .............................................................................................. 8:39
8.4.4 Brakes ........................................................................................................ 8:44
8.4.5 Steering ...................................................................................................... 8:46
8.4.6 Suspension................................................................................................. 8:49
8.4.7 Load handling............................................................................................. 8:52
8.4.8 Control system ......................................................................................... 8:101
8.4.9 Frame, body, cab and accessories .......................................................... 8:107
8.4.10 Common hydraulics ................................................................................. 8:133
8.4.11 Common electrics .................................................................................... 8:135
8.4.13 Pin diagnostics ......................................................................................... 8:166
8.5 Setup ............................................................................................................. 8:168
8.5.1 Engine ...................................................................................................... 8:171
8.5.2 Transmission ............................................................................................ 8:177
8.5.4 Brakes ...................................................................................................... 8:178
8.5.5 Steering .................................................................................................... 8:179
8.5.6 Suspension............................................................................................... 8:188
8.5.7 Load handling........................................................................................... 8:189
8.5.8 Control system ......................................................................................... 8:220
8.5.9 Frame, body, cab and accessories .......................................................... 8:231
8.5.10 Common hydraulics ................................................................................. 8:245
8.5.11 Common electrics .................................................................................... 8:246

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 situa-
tions or if there are malfunctions in the machine.
The control system function is divided into the following functions:
• Instruments and controls
• Monitoring
• Error codes, machine (described together with error codes from
other systems under section D Error codes)
• Diagnostics
• Setup
Instruments and controls describes the information display in the cab,
which is the interface to the control system.
Monitoring describes the machine's various monitoring functions that
warn the operator or limit the machine's functions in the event of poten-
tially dangerous situations.
Error codes advises the operator and mechanic when faults are de-
tected by the control system.
Diagnostics describes the control system’s diagnostic menus. The di-
agnostics menus form a tool for performing service and troubleshooting
from the information display.
Settings describes the control system’s initiation menus. The initiation
menus form a tool for making settings and adapting machine functions
from the information display.

8:4 8 Control system – Controls and instruments

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

Initiation and Calibration is performed in the same way for all functions.
The Pop-up row for the key function changes in appearance and func-
tion depending on the menu. The different functions are explained
below.
b Confirm.
Select the highlighted function.
Activate the output manually.
Save a value.
Change the arrow function from the left/right arrows to up/
down arrows.
The symbol is only shown in menus where settings are
023664
possible.
c d e
Exit menu.
a. Display Cancel setting.
b. Pop-up for button function
Increase/decrease a signal value.
c. ENTER/YES/ON/SAVE/EDIT/MAN Step up/step down in a list.
d. Navigate menus/adjust values , , or
Go to next menu/back to previous menu.
e. EXIT/NO/OFF//LEAVE
Navigation in and to menus and settings can also be done using the
1 2 3
wheel for navigation on the right control panel, rear part, and the keys
to confirm and cancel.
After logging into the service menus, the buttons for adjusting the right-
hand control panel can also be used to navigate in the menus instead
4 of the buttons on the display.
017469
1. Forward/back corresponds to and or and

depending on what is shown on the display
2. Key confirm
3. Key cancel
4. Wheel for navigation
Navigation to a menu, work instruction

To navigate to a menu, do as follows:
1. Navigate to the service menu using or .
10:23
CUSTOMER SETTINGS 2. Confirm with or cancel with .
0
014981

8 Control system – Monitoring 8:5
8.2 Monitoring
8.2.1 Overload system
Overload system, description
The machine's load sensor continuously measures the weight of the
10:23 2
load, see Load sensors, description, page 8:10. The weight from the
10 20
0
rpm x 100
30 load sensor and the attachment's position are compared with a load
curve and are used for different warnings for overloading.
21° 1899999
km/h
Part of the overload system is a warning system, LLMC (Longitudinal
Load Moment Control). The system is used for stationary load handling,
in order not to jeopardise the machine's forward stability. LLMC is not
designed to control lateral stability or stability while driving. Nor does it
017470
35.0t take inclined ground conditions into account. Current load is shown in
D U
the main menu with a bar on the right.
Display of current load in the main menu
The bar's areas have different colours depending on how much of the
capacity is utilised in the current load position:
Blue green = 0-80 % of the max. load in current load position.
Yellow = 80-90 % of the max. load in current load position.
Red = 90-100 % of the max. load in current load position.
In the event of high load on the steering axle, machine speed is limited
dynamically depending on load, see Speed limitation, description, page
8:8.
If the operator exceeds the machine's load handling capacity (load
goes beyond permitted distance in accordance with the load curve)
then all hydraulics are blocked. With Switch bypass, certain parts of the
overload system are bypassed, see Bypass, description, page 8:6. This
makes it possible to lower and retract the boom in order to avoid
danger.
When the overload system blocks the functions, the following occurs:
016335
• the buzzer in the cab sounds (indication to operator)

• the event menu is shown in the display (indication to operator)
Event menu overload forward • the boom movement is interrupted
Using the bypass, extension can be activated in order to move
away from the overload situation. Retract the extension until the
buzzer stops and the display screen disappears.
NOTE
Retract the boom before lowering it! Applies for all load handling!
8.2.1.5 Sensor boom angle

8.2.1.6 Sensor boom length

8.2.1.7 Sensor, hydraulic pressure lift cylinder


8:6 8 Control system – Bypass
8.2.2 Bypass
Bypass, description
When the overload system engages and turns off the hydraulic controls,
it may take place in a situation where it is necessary to bypass the
safety system.
012733
0 1 Bypass is activated using the bypass switch by the safety system
(S1005).
Switch, bypass
Mode 0, normal function.
Mode 1, bypassing the safety system permits:
• lowering of load in case of overload
• locking and opening of twistlocks without complete contact
• 20'-40' spreading with locked twistlocks
• bottom lift without full contact
• release of parking brake in the event of malfunction of Switch,
parking brake or Sensor, operator-in-seat
• lifting above height limitation
• rotation past rotation stop
• load manoeuvring past limit for load centre limitation.
• lift, lower, and extension with active error in the overload system
• selection of travel direction in case of malfunction of Sensor, opera-
tor-in-seat, speed is limited to 10 km/h
(The machine shifts to neutral position when no one is sitting in the
driver's seat.)
• use load handling functions at reduced speed in the event of faults
in the sensor for operator-in-seat
The Bypass warning lamp illuminates when bypass of safety locks is
activated.
DANGER
Bypassing the safety systems results in a risk of tip-
ping. Use at your own risk.
Extreme hazard to personal health and risk of property
damage!
Only use the bypass of safety systems in emergency
situations.
By-pass with code lock
As an option, by-pass can be equipped with a code lock which means

that a code must be entered via the display when by-pass of certain
functions is required. Functions that can have a code lock are divided
into five groups. A service technician can activate or disengage the
code lock for each group individually.
By-pass with key
As an option, the by-pass can be equipped with a key lock, which

means that a key must first be inserted into the lock (S1005-2) and then
turned to by-pass certain functions when required. Functions that can
have a key lock are divided into five groups. A service technician can
activate or disengage the key lock for each group individually.

8 Control system – Load centre limitation 8:7
8.2.3 Load centre limitation

Load centre limitation, description
Load centre limitation prevents the load being moved too close to the
machine. Load centre limitation is controlled by the control system with
signals from the load sensor (and the cab's position on machines with
hydraulic cab movement ), see 8.2.11 Load sensors, page 8:10 and
Hydraulic sliding cab, function description , page 9:107. This is used,
for example, in conjunction with cab lift in order to prevent the container
from damaging the cab.
The load can be operated beyond the set limit by activating bypass,
see Bypass, description, page 8:6.
016228
8.2.4 Height limitation

Height limitation, description
Height limitation prevents the machine lifting higher than a set height
without the operator being informed. Height limitation is controlled by
the control system with signals from the load sensor, see 8.2.11 Load
sensors, page 8:10.
A When boom angle and boom extension indicate that the permitted
height is reached then lift and extension are blocked, and Event menu,
height limitation, is also activated.
The load can be operated beyond the set limit by activating bypass,
see Bypass, description, page 8:6.
016230

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

Speed limitation, description
Speed limitation prevents the machine's speed from exceeding the pre-
set value by regulating the engine speed.
Machine speed is also limited by certain events in order to reduce the
risk of damage, e.g. in the event of: faults in the transmission, high
brake oil temperature, lifting loads near the machine's maximum ca-
pacity, bypass activated, raised cab . In most of these cases the
016346
event menu is shown for the function that limits the speed, such as the
event menu for high brake temperature.
Event menu, general speed warning Some functions cannot be activated above certain speeds in order to
reduce the risk of inappropriate use of the machine. If the operator tries
to activate such a function above the speed limit then the event menu,
general speed warning, is shown.
Machine speed is limited when:
• The control breaker is activated.
• The configuration ID numbers of the control units are incorrect.
Maximum speed is 10 km/h.
• The hydraulic oil temperature is too high.
• The accumulator pressure for the brake function is too low. Maxi-
mum speed is 10 km/h.
• Tilt lock is activated. Maximum speed is 5 km/h .
• During bottom lift when more than two sensors indicate contact or
clamping position. Maximum speed is 5 km/h.
• With lowered overheight-legs. Maximum speed is 5 km/h.
• Levelling lock is activated. Maximum speed is 5 km/h.
• In the event of tyre pressure too high or too low (red indication).
Maximum speed is 10 km/h.
• Dynamic depending on the load on the steering axle, warning for
overload backwards.
Machine speed is limited depending on the load on the steering
axle. Event menu speed limitation steering axle is shown when the
speed is limited. Lower/extend the boom in order to reduce the
load on the steering axle.
NOTE
016336
In the event of overload on the steering axle, it is up to the operator to

exercise caution when manoeuvring, no functions are interrupted. To
Event menu speed limitation steering axle load reduce the load and regain full operating speed, the boom must be
lowered or extended.
• Dynamic depending on the load on the drive axle, warning for over-
load forwards.
Machine speed is limited depending on the load on the drive axle.
Event menu speed limitation drive axle is shown when the speed is
limited. Raise/retract the boom in order to reduce the load on the
drive axle.
• Dynamic depending on critical error codes
017476
Event menu speed limitation drive axle load

The speed limitation is set using the initiation menu, see menu 8.2
Monitoring 1/XX INITIATE, page 8:222.

8 Control system – Service indicator 8:9
8.2.6 Service indicator

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

Service indicator, changing the service interval

See also Initiation, work instructions, page 8:169 for a general explana-
tion of how settings are made.
2. Navigate to the service menu with or and confirm with .
10:23
CUSTOMER SETTINGS
0
014981
3. Enter diagnostic code 1111 to set with or and confirm with .

10:23
0 WRITE PIN CODE
0 0
015625
4. Select 8. CONTROL SYSTEM by scrolling with or and con-

*SETTINGS & DIAGNOSTICS* firm with .
8.CONTROL SYSTEM
015624

8:10 8 Control system – Load sensors
5. Select 8.2 Monitoring by scrolling with or and confirm with .

* 8.CONTROL SYSTEM *

8.2 Monitoring
8.3 Error codes
8.4 Diagnostics
8.5 Setup
8.6 Software
015629
6. Select INITIATE by scrolling with or and confirm with .
8.2 Monitoring
8.3 Error codes
8.4 Diagnostics
8.5 Setup
8.6 Software
015735
7. Select Service time interval by scrolling with or .

See also 8.2 Monitoring 3/XX INITIATE, page 8:222 for setting the
service interval.
8. Press once for EDIT and adjust the interval time with or .
Press once for SAVE in order to save the set value, or press
to cancel the entry.
9. Select Service time pop up hours by scrolling with or .

See also 8.2 Monitoring 5/XX INITIATE, page 8:223 for setting
how long before the service interval expires that a warning is
shown to the operator.
10. Press once for EDIT and adjust the time with or .
Press once for SAVE in order to save the set value, or press
to cancel the entry.
11. Leave Initiation by scrolling out with .
8.2.11 Load sensors

Load sensors, description
Load sensors use the pressure sensors for the lift cylinders together
with sensors for boom angle and boom length in order to calculate the
load. The weight of the load is calculated as a function of boom angle,
boom length and the pressure in the lift cylinders. This information is
used for several of the machine's subsystems, e.g.:
• Overload system
• Weight indicator
• Load counter
• Load centre limitation
• Height limitation
• Printout of load receipts

8 Control system – Load sensors 8:11
Load sensors, function description
7
D7950
D7902
D7971
D5 2, 4, 6
D5
D1
023389
5 5 1 3

1 Sensor boom length (B7686) sends volt- U = 0.5-4.5 V Sensor, boom length, description, page 8:18.
age signals proportional to the boom D2: Diagnostic menu, see 8.2 Monitoring 16/
length to Control unit KFU (D7971). XX DIAGNOSE, page 8:103.
2 Control unit KFU (D7971) sends boom Checked by control sys- 11.5.3.4 Control unit KFU (D7971), page
length information on the CAN bus. tem, error shown with er- 11:34
ror code.
3 Sensor boom angle (B7241) sends volt- U = 0.5-4.5 V Sensor boom angle, description, page 8:17
age signals proportional to the boom an- D4: Diagnostic menu, see 8.2 Monitoring 16/
gle to Control unit KFU (D7971). XX DIAGNOSE, page 8:103.
4 Control unit KFU (D7971) sends boom Checked by control sys- 11.5.3.4 Control unit KFU (D7971), page
angle information on the CAN bus. tem, error shown with er- 11:34
ror code.
5 Sensor hydraulic pressure lift cylinder pis- U = 0.5-4.5 V Sensor hydraulic pressure lift cylinder, de-
ton side left (B7226-1), Sensor hydraulic scription, page 8:15
pressure lift cylinder rod side left (B7226- D6: Diagnostic menu, see 8.2 Monitoring 17/
3), Sensor hydraulic pressure lift cylinder XX DIAGNOSE, page 8:104 and 8.2 Monitor-
piston side right (B7226-2) and Sensor ing 18/XX DIAGNOSE, page 8:104.
hydraulic pressure lift cylinder rod side
right (B7226-4) send voltage signals pro-
portional to the hydraulic pressure in the
lift cylinders to Control unit KFU (D7971).
6 Control unit KFU (D7971) calculates and Checked by control sys- 11.5.3.4 Control unit KFU (D7971), page
sends the weight on the CAN bus. The tem, error shown with er- 11:34
weight is calculated by a machine-unique ror code.
load curve based on sensor values for
boom angle, boom length and pressure in
the lift cylinders.
NOTE
The load curve is unique for each
machine.
7 Control unit KID (D7950) shows weight in- - 11.5.3.3 Control unit, KID (D7950), page
formation in the display. 11:32

Load sensors, calibration
DANGER
The overload system must be function tested after
calibration.
Extreme danger
Deficient calibration may cause load calculation to be
incorrect. The machine must not be operated without
the overload system having been function tested.
NOTE
the given order.

the cylinders.
10:23
CUSTOMER SETTINGS
0
014981

10:23

0 0
015625
5. Select 8. CONTROL SYSTEM by scrolling with or and con-

*SETTINGS & DIAGNOSTICS* firm with .
8.CONTROL SYSTEM
015624

6. Select 8.2 Monitoring by scrolling with or and confirm with .


8.2 Monitoring
8.3 Error codes
8.4 Diagnostics
8.5 Setup
8.6 Software
015629
8.2 Monitoring
8.3 Error codes
8.4 Diagnostics
8.5 Setup
8.6 Software
015628
8. Lower the boom to the lowest position (0°). Press to save this
value.
9. Select CALIBRATE 6 by scrolling with .
10. Lift the boom to its highest angle. Press to save this value.
12. Retract the boom completely. Press to save this value.


14. Extend the boom completely.

Press to save this value.
a. Retract the boom completely.

b. Lower the boom and inch towards the end until 2-4 cm re-
mains on the lift cylinders.
c. Wait approximately five seconds to stabilise the pressure.
d. Press to save this value.
a. Extend the boom completely.

b. Wait approximately five seconds to stabilise the pressure.
c. Press to save this value.
NOTE
Negative values indicate switched connectors on the pressure
sensors.
Large variations between right and left indicate errors in the sen-
sors' signals.
Checking the calibration

18. Operate the machine without a load, stop the machine and check
that Actual load = 00000 ± 500 kg.
Check lifting/lowering boom in different operating ranges, as well
as extension long in and extension long out. The boom must not
reach the end positions during checking.
If the weight is not correct, repeat the calibration.
NOTE
Check when stationary. (Operating generates dynamic forces.)

20. Check that the function of the overload system disengages the
boom movement at high load.
a. Take a load and lift it so that it just lifts up from the ground.
b. Run out extension and hold the load as close to the ground as
possible.
c. Check that the overload system disengages the boom
movement.


Sensor hydraulic pressure lift cylinder, description
Sensor, hydraulic pressure lift cylinder measures the pressure in the lift
cylinders and is installed on valve block lift cylinder.
The pressure in the cylinders is measured in order to measure the load
as part of the overload system and to determine when regeneration
can be engaged. The pressure sensors are also used to calculate the
weight of the load.
1 2 The sensors are supplied with voltage by, and send a voltage signal
proportional to the hydraulic oil pressure to Control unit KFU (D7971).
The signals can be checked with the diagnostic menu, see 8.2 Monitor-
ing 17/XX DIAGNOSE, page 8:104 and 8.2 Monitoring 18/XX DIAG-
NOSE, page 8:104.
016931
Valve block lift cylinder

1. Sensor, hydraulic pressure lift cylinder, rod side,
left (B7226-3)
Sensor, hydraulic pressure lift cylinder, rod side,
right (B7226-4)
2. Sensor, hydraulic pressure lift cylinder, piston
side, left (B7226-1)
Sensor, hydraulic pressure lift cylinder, piston
side, right (B7226-2)

Sensor, hydraulic pressure lift cylinder, replacement
NOTE
Safety.

NOTE
3. Disconnect the cable harness from the sensor for hydraulic pres-
sure lift cylinder.
4. Remove the sensor for hydraulic pressure lift cylinder.
5. Fit the new sensor.
NOTE
1 2 Change the O-rings. Check that the O-rings are positioned
correctly.
6. Connect the cable harness to the sensor for hydraulic pressure.

7. Clamp the cable harness in the same way as before.
hydraulic system.
NOTE
the lock ring.
016931

Valve block lift cylinder
10. Activate the lift carefully.
1. Sensor, hydraulic pressure lift cylinder, rod side,
left (B7226-3)
Sensor, hydraulic pressure lift cylinder, rod side,
right (B7226-4) CAUTION
2. Sensor, hydraulic pressure lift cylinder, piston
side, left (B7226-1) Air in the hydraulic system may cavitate and result in
Sensor, hydraulic pressure lift cylinder, piston product damage.
side, right (B7226-2)
11. Check that the hydraulic connections of the valve block seal tight
and lift/lower works correctly.
manual.
13. Check the function of the sensor from the diagnostic menu. See
8.2 Monitoring 17/XX DIAGNOSE, page 8:104.
Raise the boom and check that the sensor is sending values. The
value should be approximately the same as from the sensor on the
second lift cylinder.


Sensor boom angle, description
The boom's angle is measured by Sensor, boom angle (B7241), that
detects the boom's angle in relation to the frame. The sensor consists
of a sensor housing, potentiometer and arm. The sensor housing is
mounted on the boom. The arm is connected to the frame and turns the
potentiometer when the boom is angled.
Sensor boom angle (B7241) is supplied with voltage and sends signals
proportional to the angle to Control unit KFU (D7971)
The signal can be checked with the diagnostic menu, see 8.2 Monitor-
016932
Sensor boom angle (B7241)
Sensor, boom angle, replacement

4. Calibrate load sensor, see Load sensors, calibration, page 8:12.
5. Check that the end position damping works in both upper and low-
er end positions.
016932
Sensor boom angle (B7241)


Sensor, boom length, description
Sensor, boom length (B7686) detects the lift boom's extension and is
fitted in the rear edge of the boom.
The sensor is connected to a spring-loaded wire that is connected to a
rotary potentiometer via a gearbox. The wire is connected to the inner
boom. When the boom is extended, the wire acts on the potentiometer
and the signal is changed.
Sensor, boom length (B7686) is supplied with voltage by, and sends a
voltage signal proportional to the length to Control unit KFU (D7971).
The signal can be checked with the diagnostic menu, see 8.2 Monitor-
018508
Sensor, boom length (B7686)
Sensor, boom length, replacement

4. Calibrate the sensor, see Load sensors, calibration, page 8:12.
5. Check that the end-position damping works in both outer and inner
end-positions.
018508
Sensor, boom length (B7686)

8 Control system – Statistics 8:19
8.2.12 Statistics
Trip computer, description
The trip computer shows fuel consumption, speed and load calculator.
1 2
10:23 2
1756 rpm
32.8 l/h 9.5 km/h
3
20.2 km/h
21°
26.1 l/h
74.8 km
120:36 h 14432
016518
1. Fuel consumption
2. Speed
3. Load counter
Statistics menus, description
Data regarding operating time, fuel consumption, mileage and lifting

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

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

8:20 8 Control system – Weight indicator
8.2.13 Weight indicator

Weight indicator, description
The weight indicator shows the weight of the raised load. The weight in-
10:23 2
dicator uses the load sensor's sensor signals in order to calculate the
10 20
0
rpm x 100
30 weight of the lifted load, see Load sensors, description, page 8:10. The
weight is shown in tonnes in the main menu in the display.
21° 1899999
km/h
Load weight is shown in the main menu, more detailed weight informa-
tion is shown in Operating menu scale and the menus for statistics and
operating time. For information on menus and handling, see Operator's
manual.
017471
35.0t
D U
Display of load weight in the main menu
Scales, weighing and load totalling

1. Grab the load.
1 10:23
4 2. Perform a lift movement and then lower the load slowly about 30
CUSTOMER SETTINGS
cm.
2 5
0 3. Select Operating menu, scale / . Confirm with .
3 6 4. Select tarring with / .

Switch between to tare (current weight displayed) and not to tare
0
(0 shown).
Confirm with .
0
016095
5. Select load weight with / .

The value of the load weight can be added to the total weight with
1. Tare symbol .
2. Total symbol 6. Select total weight with /
3. Reset symbol The value of the total weight can be reset by .
4. Tare weight
5. Load weight (net weight) 7. Exit the menu with .
6. Sum weight (gross weight)




8 Control system – Container counter 8:21
8.2.14 Container counter

Container counter, description
The container counter counts the number of lifted containers. The
10:23
counter has two counters that can be reset separately. The container
counter counts in different ways depending on whether the top lift/over-
height-legs (twistlocks) or bottom lift (lift legs) is used.
123 1 23476 pcs a
Top lift
123 2 23476 pcs b
The container counter counts lifting when contact is broken with locked
123
1 23476 pcs c twistlocks and twistlocks are not opened within 8 seconds.
123
2 23476 pcs d Overheight
016384
Operating menu load counter
The container counter counts lifting when contact is broken with locked
a. Counter 1 top lift twistlocks and twistlocks are not opened within 8 seconds.
b. Counter 2 top lift
c. Counter 1 bottom lift/overheight-lift Bottom lift
d. Counter 2 bottom lift/overheight-lift
The container counter counts lifting when the clamp function is acti-
vated and lifting is started and unloading clamping position is not acti-
vated within 20 seconds.
Container counter, function description (product

alternative top lift)
1, 4, 7 D2
11
D7950
10
D7902 D7901
D7911
3, 6, 9
D5
D2
2, 8 5
123
023390

1 The attachment is positioned over a con- - Lifting/lowering, function description, page 7:17
tainer with the functions 7.2 Lifting/lower- Extension, function description, page 7:33
ing, 7.3 Side shift. D1: Diagnostic menu, 7.1 Controls and Instr 5/
2 Sensor, contact left front (B7202-FL), Sensor directly oppo- Sensor, contact, description, page 7:139
Sensor, contact right front (B7202-FR), site indicator plate: U = D2: Diagnostic menu, see 7.9 Load Carrier 4/
Sensor, contact left rear (B7202-RL), 24 V XX DIAGNOSE, page 8:68
send a voltage signal to Control unit KAU
(D7911).

8:22 8 Control system – Container counter

3 Control unit KAU (D7911) sends contact Checked by control 11.5.3.8 Control unit KAU (D7911), page 11:40
on the CAN bus. system, error shown
with error code.
4 Twistlocks are rotated to the locked posi- - Twistlocks, function description, page 7:127
tion and are closed with the 7.9.1 Twist-
locks function.
5 Sensor, locked twistlocks left (B7205-LE) Sensor directly oppo- Sensor, twistlocks, description, page 7:141
and Sensor locked twistlocks right site indicator plate: U = D5: Diagnostic menu, see 7.9 Load Carrier 5/
(B7205-RI) send a voltage signal to Con- 24 V XX DIAGNOSE, page 8:68
trol unit KAU (D7911).
6 Control unit KAU (D7911) sends locked Checked by control 11.5.3.8 Control unit KAU (D7911), page 11:40
twistlocks on the CAN bus. system, error shown
with error code.
7 The container is lifted with the function - Lifting/lowering, function description, page 7:17
7.2 Lifting/lowering.
8 Sensor, contact left front (B7202-FL), U=0V Sensor, contact, description, page 7:139
Sensor, contact right front (B7202-FR), D2: Diagnostic menu, see 7.9 Load Carrier 4/
Sensor, contact left rear (B7202-RL), XX DIAGNOSE, page 8:68
stop sending a voltage signal to Control
unit KAU (D7911).
9 Control unit KAU (D7911) sends no con- Checked by control 11.5.3.8 Control unit KAU (D7911), page 11:40
tact on the CAN bus. system, error shown
with error code.
10 If the twistlocks remain locked for 8 sec- - 11.5.3.1 KCU control unit (D7901), page 11:27
onds then Control unit KCU (D7901)
adds one lift to the container counter.
11 Control unit KID (D7950) updates the Checked by control 11.5.3.3 Control unit, KID (D7950), page 11:32
display in Operating menu load counter. system, error shown
with error code.

alternative bottom lift)

2, 7 1 3 4
D1
D3 D4
11
D7950
D2 10
D7902 D7901
D7912
6, 9
D5
D8
8 5
123
023391

8 Control system – Container counter 8:23

1 The attachment's rear lift legs fold are low- - Raising/lowering rear lift legs, function de-
ered to operating position with the function scription, page 7:148
7.9.2 Lift legs. D1: Diagnostic menu, see 7.9 Load Carrier
2 The attachment is positioned over a con- - Lifting/lowering, function description, page
tainer with the functions 7.2 Lifting/lowering, 7:17
7.3 Side shift. Extension, function description, page 7:33
D2: Diagnostic menu, 7.1 Controls and Instr 5/
3 The front lift legs are lowered with the func- - Raising/lowering front lift legs, function de-
tion 7.9.2 Lift legs. scription, page 7:144
4 The lift legs clamp around the container - Clamping with lift legs, function description,
with the function 7.9.2 Lift legs. page 7:152
5 Sensor clamping position front leg left Sensor directly oppo- Sensor, clamping position, description, page
(B7215-LF), Sensor clamping position rear site indicator plate: U = 7:169
leg left (B7215-LR), Sensor clamping posi- 24 V D5: Diagnostic menu, see 7.9 Load Carrier
tion front leg right (B7215-RF) and Sensor 30/XX DIAGNOSE, page 8:73
clamping position rear leg right (B7215-RR)
send a voltage signal to Control unit KAU2
(D7912).
6 Control unit KAU2 (D7912) sends clamping Checked by control 11.5.3.8 Control unit KAU (D7911), page
position lift legs on the CAN bus. system, error shown 11:40
with error code.
7 The container is lifted with the function 7.2 - Lifting/lowering, function description, page
Lifting/lowering. 7:17
D2: Diagnostic menu, 7.1 Controls and Instr 5/
8 Sensor contact front leg left (B7213-LF), Sensor directly oppo- Sensor, contact, description, page 7:168
Sensor contact rear leg left (B7213-LR), site indicator plate: U = D8: Diagnostic menu, see 7.9 Load Carrier
Sensor contact front leg right (B7213-RF) 24 V 32/XX DIAGNOSE, page 8:74
and Sensor contact rear leg right (B7213-
RR) send a voltage signal to Control unit
KAU2 (D7912).
9 Control unit KAU2 (D7912) sends contact Checked by control 11.5.3.8 Control unit KAU (D7911), page
on the CAN bus. system, error shown 11:40
with error code.
10 If clamping position remains active for 20 - 11.5.3.1 KCU control unit (D7901), page 11:27
seconds then Control unit KCU (D7901)
adds one bottom lift to the container
counter.
11 Control unit KID (D7950) updates the dis- Checked by control 11.5.3.3 Control unit, KID (D7950), page
play in Operating menu load counter. system, error shown 11:32
with error code.

8:24 8 Control system – Container counter

alternative Overheight-legs)

Overheight-legs Lowered Overheight-legs, description, page 7:130
1, 4, 7 D2
11
D7950
10
D7902 D7901
D7911
3, 6, 9
D5
D2
2, 8 5
123
023390
1 The attachment is positioned over a con- - Lifting/lowering, function description, page 7:17
tainer with the functions 7.2 Lifting/lower- Extension, function description, page 7:33
ing, 7.3 Side shift. D1: Diagnostic menu, 7.1 Controls and Instr 5/
2 Sensor, contact left front (B7214-FL), Sensor directly oppo- Sensor, contact, description, page 7:139
Sensor, contact right front (B7214-FR), site indicator plate: U =
Sensor, contact left rear (B7214-RL), 24 V
send a voltage signal to Control unit KAU
(D7911).
3 Control unit KAU (D7911) sends contact Checked by control 11.5.3.8 Control unit KAU (D7911), page 11:40
on the CAN bus. system, error shown
with error code.
4 Twistlocks are rotated to the locked posi- - Twistlocks, function description, page 7:127
tion and are closed with the 7.9.1 Twist-
locks function.
5 Sensor, locked twistlocks left (B7205-LE) Sensor directly oppo- Sensor, twistlocks, description, page 7:141
and Sensor locked twistlocks right site indicator plate: U = D5: Diagnostic menu, see 7.9 Load Carrier 5/
(B7205-RI) send a voltage signal to Con- 24 V XX DIAGNOSE, page 8:68
trol unit KAU (D7911).
6 Control unit KAU (D7911) sends locked Checked by control 11.5.3.8 Control unit KAU (D7911), page 11:40
twistlocks on the CAN bus. system, error shown
with error code.
7 The container is lifted with the function - Lifting/lowering, function description, page 7:17
7.2 Lifting/lowering.
8 Sensor, contact left front (B7214-FL), U=0V Sensor, contact, description, page 7:139
Sensor, contact right front (B7214-FR),
Sensor, contact left rear (B7214-RL),
stop sending a voltage signal to Control
unit KAU (D7911).

8 Control system – Synchronised lift 8:25

9 Control unit KAU (D7911) sends no con- Checked by control 11.5.3.8 Control unit KAU (D7911), page 11:40
tact on the CAN bus. system, error shown
with error code.
10 If the twistlocks remain locked for 8 sec- - 11.5.3.1 KCU control unit (D7901), page 11:27
onds then Control unit KCU (D7901)
adds one lift to the container counter.
11 Control unit KID (D7950) updates the Checked by control 11.5.3.3 Control unit, KID (D7950), page 11:32
display in Operating menu load counter. system, error shown
with error code.
8.2.15 Synchronised lift

Synchronised lift, description
Synchronised lift is when the load is lifted straight up or lowered straight
up or down by means of the control system activating controlled lift and
extension for a straight movement. Synchronous lifting is activated with
the shift button together with the control lever and uses the sensors for
boom angle and extension in order to control the movement. The speed
of lift, lower and extension is controlled synchronously in order to obtain
a straight movement.
Synchronised lift, function description

Height limitation Bypassed or boom height lower Height limitation, description, page 8:7
than height limitation.
1 D1
+ 2
D7902
D7971
5
D4
D3 016867
3 4

1 Switch shift button (S1991) and Con- Shift button: U = 24 V Control lever (Ego), description, page 7:6
trol lever (S8150-R8070-¨1) send a Lower: UR8070-1 = 0.5–2.0 V D1: Diagnostic menu, see 7.1 Controls and
voltage signal to Control unit KPU Zero position: UR8070-1 = 2.0– Instr 5/XX DIAGNOSE, page 8:53 and 7.1
(D7902). 3.0 V Controls and Instr 7/XX DIAGNOSE, page
Lift: UR8070-1 = 3.0–4.5 V 8:53.
2 Control unit KPU (D7902) sends Checked by control system, 11.5.3.2 KPU control unit (D7902), page
synchronised lift on the CAN bus. error shown with error code. 11:30
3 Sensor boom angle (B7241) sends U = 0.5-4.5 V Sensor boom angle, description, page 8:17
voltage signals to Control unit KFU D3: Diagnostic menu, see 8.2 Monitoring 16/
(D7971). XX DIAGNOSE, page 8:103

8:26 8 Control system – Printout of load receipts

4 Sensor boom length (B7686) sends U = 0.5-4.5 V Sensor, boom length, description, page 8:18
voltage signals to Control unit KFU D4: Diagnostic menu, see 8.2 Monitoring 16/
(D7971). XX DIAGNOSE, page 8:103
5 Control unit KFU (D7971) controls Checked by control system, 11.5.3.4 Control unit KFU (D7971), page
the functions 7.2 Lift/lower and 7.3 error shown with error code. 11:34
Extension at the same time so that Lifting/lowering, function description, page
the lifting movement is vertical. 7:17
Extension, function description, page 7:33
8.2.17 Printout of load receipts

Printout of load receipts, general
a Reciept Printing As an option for Insight (see Insight, description, page 11:56), the ma-
chine can be equipped with a function for printout of load receipts. The
WEIGHT function for load receipts uses the load indicator (see Load sensors, de-
b 12345 KG scription, page 8:10) in its most accurate work range (boom angle 10–
LOAD ID 35° and boom extension 0–1.5 m) in order to weigh the load. A key-
c ABCD 123456 7 board is used to add load identification to the receipt, which is con-
nected to the control unit for Insight. Load receipts can be printed out
on a printer or to a file on a USB memory stick, depending on what is
connected to the control unit for Insight.
019911
d e f g When the load is manoeuvred to the correct area, Event menu, load re-
Event menu, load receipt ceipt is shown. Incorrect values are indicated by a red background. The
a. Header row. Shows status and error messages. header row in the event menu shows status and error messages. For
b. Load's weight in kg. When the weight has been example, during printout or when there is no paper left.
stabilised and is approved for the load receipt, a
green background is shown. It is possible to adapt the function for load receipts in the menu for ma-
c. Load identification. When the field has been filled chine settings (see Operator's manual) and the initiation menus (see
in correctly, a green background is shown. If the 8.2 Monitoring 27/XX INITIATE, page 8:226 and 8.2 Monitoring 28/XX
text is entered incorrectly, a red background is INITIATE, page 8:227).
shown.
d. Printout of stored load receipts on a printer or to a
USB memory stick. The icon changes if a USB
memory stick is connected.
e. Display of previously lifted loads, scrolls back in
the history.
f. Prints out or saves a load receipt of the current
values (despite measured load not being green).
g. Deletes current weighing or closes the menu.
8.2.17.1 Printer
Printer, general
See Printer, description, page 11:57.
8.2.17.2 Keyboard
Keyboard, general
See Keyboard, description, page 11:57.

8 Control system – Diagnostics 8:27
8.4 Diagnostics
Diagnostics, general
Diagnostics are performed via menus in the display. Diagnostics is a
tool in order to perform service and troubleshooting.
The machine has built-in functions for troubleshooting called diagnostic
test. The diagnostic test consists of several menus shown on the dis-
play. The menus are grouped for faster access. Diagnostic tests show
how the control units interpret input signals as well as which signals
that the control units send. The diagnostic tests are grouped in accord-
ance with the function groups in the manuals.
Diagnostics are divided into the following groups:
• Engine, 8.4.1 Engine, page 8:29.
• Transmission, 8.4.2 Transmission, page 8:39.
• Brakes, 8.4.4 Brakes, page 8:44.
• Steering, 8.4.5 Steering, page 8:46.
• Suspension, 8.4.6 Suspension, page 8:49
• Load handling, 8.4.7 Load handling, page 8:52.
• Control system, 8.4.8 Control system, page 8:101.
• Frame, body, cab and accessories, 8.4.9 Frame, body, cab and ac-
cessories, page 8:107.
• Common hydraulics, 8.4.10 Common hydraulics, page 8:133.
• Common electrics, 8.4.11 Common electrics, page 8:135.
• Pin diagnostics, 8.4.13 Pin diagnostics, page 8:166.
All diagnostic menus are listed below, except those for pin diagnostics.
The menus for pin diagnosis work in the same way for each input/out-
put, so only the principle is described. Certain menus refer to options
that are only shown on the display if the machine has the option in
question.
Navigation diagnostic menus, work instructions

1. Park the machine.
10:23
CUSTOMER SETTINGS
0
014981
3. Enter diagnostic code 1111 with or and confirm with .

10:23
0 WRITE PIN CODE
0 0
015625

8:28 8 Control system – Diagnostics
4. Select the function with or and confirm with .

2.TRANSMISSION Symbol Function
1. Engine
2. Transmission
3. Driveline/Axle
4. Brakes
015623
5. Steering
6. Suspension
7. Load handling
8. Control system
9. Frame, body, cab and accessories
10. Common Hydraulics
11. Common electrics
Pin diagnosis
5. Select group by scrolling with or and confirm with .

* 2.TRANSMISSION *

2.2 Torque Conv & Clutch Sys
2.3 Mechanical Transmission
2.4 Hydraulic Transmission
2.5 Electrical Transmission
2.6 Lubrication System
2.7 Cooling system
2.8 Transmission Control Sys
015627
6. Select DIAGNOSE with or and confirm with .

* 2.TRANSMISSION *
2.2 Torque Conv & Clutch Sys
2.3 Mechanical Transmission
2.4 Hydraulic Transmission
2.5 Electrical Transmission
2.6 Lubrication System
2.7 Cooling system
2.8 Transmission Control Sys
016048
7. Each menu group consists of a sequence of menus. The first menu

for the selected group opens in the display. Use the arrow keys
or to move to the desired menu.
8. Use the function key MAN to manually control the output shown
in the menu. For a description of the menu screen, see Menu ex-
ample, description, page 8:29.
All signal values in the menu figures are examples and may
differ from the values shown in an actual machine.
NOTE
Example of first menu in group Current values can only be adjusted within specific limits.

8 Control system – Engine 8:29
Menu example, description

All diagnostic menu, except for the pin diagnostics, are explained
1 2 3 separately.
2.8 Control System 2 XX DIAGNOSE
– Menu group, enter the group, 2.8 Control System, whose signals
Current gear position 0 provides a basis for diagnosis. The menus are subdivided into the
Operating mode 0
same function groups as the manuals.
Fault present 0
– Sequence number, 2/XX, enter the page number and total number
8 of menus in the menu loop. As the number of menus is dependent
Converter pump
(impeller) torque
0 Nm 4 on how the machine is equipped, state the number of menus here
Converter turbine
torque
0 Nm with XX.
Active config ID 0 – Diagnose indicates in the menu example that diagnosis is the se-
015873
MAN LEAVE
lected setting function. Other settings functions are Initiate for set-
ting and Calibrate for calibration.
7 5 – Variables, such as row 1 Current gear position, describe the func-
6
tion/component that the signal/measurement comes from. Each
1. Menu group menu can contain 1-6 rows, where each row describes a variable
2. Sequence number with an associated signal value.
3. Selected setting function – Signal value, 0, is the current value for Current gear position.
4. Signal values All signal values in the menu figures in this manual are exam-
ples and may differ from the values in a real machine.
5. Function key LEAVE/Cancel
The following icons are used to explain further the signal values:
6. Arrow keys
7. Function key Manual mode/Edit mode denotes a saved value.
8. Variables denotes an output value from an output from a control unit.
denotes an input value which is measured by a control unit.
Explanation of pin status codes
Variables of the pin status type can have the following values:
Code Explanation
OK There is no error
O.C Open circuit
S.C Short circuit
O.C/S.C Open or short circuit
Other Other error
CfgErr Configuration error
8.4.1 Engine
8.4.1.1 Diagnostic menus Controls and
instruments engine
1.1 Controls & Instr 1/XX DIAGNOSE
Row 1 shows signal A from the pedal (R6900).
Row 2 shows the value on row 1 converted into % of the total possible
value.
Row 3 shows signal B from the pedal (R6900).
Row 4 shows the value on row 3 converted into % of the total possible
value.
Row 5 shows the requested pedal outcome in %.
Row 6 shows the requested speed to the engine via the pedal.

8:30 8 Control system – Engine

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

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

Row 1 shows the current fuel consumption.
Row 2 shows the average fuel consumption since the engine was
started.
This value is reset every time the engine is started.
Row 3 shows the average fuel consumption.
Row 4 shows resetting of the value for average fuel consumption.
It is possible to reset average fuel consumption. Change to 0 in row 4,
Reset average fuel consumption. See Navigation of menus, de-
scription, page 8:4 for an explanation how settings are made.
8.4.1.3 Diagnostic menus Exhaust cleaning

1.3 Aux Exhaust Clean 1/XX Diagnose
Row 1 shows the signal from sensor, exhaust back pressure (B7572).
Row 2 shows current exhaust back pressure as a percentage of permit-
ted maximum pressure.
Row 3 shows highest measured exhaust back pressure as a percent-
age of permitted maximum pressure.
Row 4 shows engine speed limitation due to exhaust back pressure.

8.4.1.6 Diagnostic menus Air intake and exhaust

outlet
1.6 Intake Exhaust 2/XX DIAGNOSE
Row 1 shows input Switch prevent regeneration of engine's after-treat-
ment system (S1049).
0 = Not activated.
1 = Activated.
Row 2 shows that request for prevent regeneration is sent on the CAN
bus to the engine.

Row 1 describes signals for the emission control system.
Row 2 shows level in DEF tank in %.
Row 3 shows temperature in DEF tank.
Row 4 shows the status for the exhaust cleaning system.
3 = Reduced engine power.
4 = Advance warning of serious error for DEF additive.
5 = Serious error for DEF additive.
6 = Temporary disengagement of DEF additive.
Row 5 shows setting for fixed warning for low DEF level.
0 = No flashing.
1 = Fixed warning.
Row 6 shows setting for flashing warning for low DEF level.
0 = No flashing.
1 = Flashing warning (1 Hz).

Applies to Volvo Stage V.
The machine must be in safe mode with manual regeneration of DPF.
Row 1 shows the status to initiate manual regeneration of DPF.
It is possible to initiate burn-off. Change to 1 in Row 1, DPF init manual
regen (CM1). See Navigation of menus, description, page 8:4 for
Row 2 shows the lamp for the switch prevent regeneration of the en-
gine DPF.
Row 3 shows DPF status from CAN.
0 = OK.
1 = regeneration needed, lowest level.
2 = regeneration needed, moderate level.
3 = regeneration needed, highest level.
Row 4 shows DPF lamp from CAN.
Solid glow (solid) = regeneration needed, moderate level.
Flashing (flashing) = regeneration needed, highest level.
Row 5 shows exhaust gas temperature in °C from CAN.


Applies to Volvo Stage V.
Row 1 shows status for regeneration of DPF.
Row 2 shows cancelled regeneration of DPF from CAN.
Row 3 shows cancelled regeneration of DPF due to released parking
brake.
Row 4 shows % soot amount in DPF from CAN.
Row 5 shows % ash amount in DPF from CAN. Soot that is burned be-
comes ash, and at 100% ash level it is time for filter change.
8.4.1.7 Diagnostic menus Cooling system

1.7 Cooling system 4/XX DIAGNOSE
Row 1 describes cooling fan Visco clutch (M6580).
Row 2 shows the requested pulse length.
It is possible to set the pulse length on row 2, Requested duty cycle.
See Navigation of menus, description, page 8:4 for an explanation
how settings are made.
Row 3 shows the required voltage in relation to the battery voltage.
Row 4 shows the true current.
Row 5 shows the pin status. See Explanation of pin status codes, page
8:29 for an explanation of pin status.
Row 6 shows the calculated impedance.

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

Row 1 describes Cooling fan, intercooler (M6590).


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

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

Row 1 describes cooling fan intercooler.
Row 2 shows fan reversing request.
It is possible to activate fan reversing on row 2, Fan reversing request.
0 = normal, anticlockwise as seen from the rear of the truck.
1 = reverse.
Row 3 shows whether the fan reversing procedure is activated
0 = Not activated.
1 = fan turning activated.
Row 4 shows requested pulse length for Cooling fan, intercooler
(M6590).
Row 5 shows the cooling fan's calculated rpm based on pulse length.
Positive value indicates rpm in normal direction, negative value indi-
cates rpm with turned direction

Row 1 shows outside temperature (sensor for engine).
Row 2 shows the engine's coolant temperature.
Row3 shows the transmission's oil temperature.
Row 4 shows charge air temperature after the intercooler.
Row 5 shows the intake temperature.
Row 6 shows the engine's turbo pressure.


Row 1 shows need of drive for the engine cooling fan from the
transmission.
It is possible to set the drive need in Row 1, Cooling required from
transmission (1–100%). See Navigation of menus, description,
page 8:4 for an explanation how settings are made.
Row 2 shows temperature in transmission oil sump.
Row 3 shows temperature in transmission torque converter.
8.4.1.8 Diagnostic menus Lubrication system

1.8 Lubrication 1/XX DIAGNOSE
Row 1 shows the oil pressure.
Row2 shows the oil temperature.
8.4.1.9 Diagnostic menus, Control system, engine

1.9 Control System 1/XX DIAGNOSE
Row 2 shows the true engine speed.
Row 3 shows the true torque in % from the engine (EEC1).
Row 4 shows % load at the current speed (EEC2).
Row 5 shows the nominal friction torque in % from the engine (EEC3).
Row 6 shows the engine's maximum reference torque at a specific
speed (EC1).

Row 1 shows the engine's total operating time in hours.
Row 2 shows the battery voltage in the engine's control computer.
Row 3 shows the alternator's charging status.
0 = not charging
1 = charging


Row 1 shows pedal position.
Row 2 shows requested engine speed limitation.
Row 3 shows actual engine speed limitation.
Row 4 shows requested torque limitation.

Row 1 shows pedal position.
Row 2 shows requested engine speed limitation.
Row 3 shows actual engine speed limitation.
Row 4 shows requested torque limitation.

Row 1 shows CAN-bus message TSC1 to the engine.
Row 2 shows status for steering request to Control unit, engine.
0 = No control.
1 = Rotation speed control.
2 = Torque control.
3 = Rotation speed and torque limitation.
Row 3 shows conditions for steering request to Control unit, engine.
0 = Response mode, optimised for neutral position and drive without
lock-up.
1 = Stability mode, optimised for neutral position and drive without lock-
up.
2 = Stability mode, optimised for drive with/without lock-up operating
mode 1.
mode 2.
Row 4 shows degree of priority for steering request to Control unit,
engine.
0 = Top priority.
1 = High priority.
2 = Intermediate priority.
3 = Low priority.
Row 5 shows requested rotation speed limit.
Row 6 shows requested torque limit.


Row 1 shows CAN-bus message TSC2 to the engine.
Row 2 shows status for steering request to Control unit, engine.
0 = No control.
1 = Rotation speed control.
2 = Torque control.
3 = Rotation speed and torque limitation.
Row 3 shows conditions for steering request to Control unit, engine.
0 = Response mode, optimised for neutral position and drive without
lock-up.
1 = Stability mode, optimised for neutral position and drive without lock-
up.
mode 1.
mode 2.
Row 4 shows degree of priority for steering request to Control unit,
engine.
0 = Top priority.
1 = High priority.
2 = Intermediate priority.
3 = Low priority.
Row 5 shows requested rotation speed limit.
Row 6 shows requested torque limit.

Row 1 shows max. available torque in % (EEC2).
Row 2 shows part of available torque that is used in % (EEC1).

8.4.1.11 Diagnostic menus Start and stop

1.11 Start & Stop 1/XX DIAGNOSE
Row 1 shows the input for the start button (S1051).
0 = start button not active.
1 = start button active.
Row 2 shows output signal to starter relay (K3600).
It is possible to set the output signal for the starter relay on row 2, Start-
er relay output K3600 C1p43 D7971. See Navigation of menus,
description, page 8:4 for an explanation of how the settings are
made.
0 = starter motor not active.
1 = starter motor active.
Row 3 shows the true current to the relay.
Row 5 shows the input start immobiliser (K3300).
0 = start immobiliser active, engine will not start.
1 = start immobiliser not active.

Row 1 shows the input for the start button (S1051).
0 = start button not activated.
1 = start button activated.
Row 2 shows VP status (applies to Volvo engines)
It is possible to set the output signal to the starter relay on row 2, Start
request on CAN message VP Status. See Navigation of menus,
description, page 8:4 for an explanation how settings are made.
0 = Not activated.
1 = request to start.
Row 3 shows the request to stop the engine.
0 = not stop the starter motor.
1 = stop starter motor.
Row 4 shows the input start immobiliser (K3300).
0 = start immobiliser active, engine will not start
1 = start immobiliser not active


Row 1 shows automatic start and stop function.
Row 2 shows whether automatic start and stop function is available on
the machine.
It is possible to set activate automatic start and stop function in row 2,
Function available. See Navigation of menus, description, page
8:4 for an explanation how settings are made.
0 = Automatic start and stop function not available.
1 = Automatic start and stop function available.
Row 3 shows whether the conditions for auto-stop are fulfilled (pre-
pared to auto-start).
0 = Engine not auto-stopped.
1 = Engine auto-stopped.
Row 4 shows status for temperature of engine, transmission, hydraulics
and in the cab.
0 = Temperatures too low for automatic start and stop function.
1 = Temperatures for automatic start and stop function reached.
Row 5 shows status for charge level of batteries.
0 = Charge level too low for automatic start and stop function.
1 = Charge level for automatic start and stop function reached.

Row 1 shows automatic start and stop function.
Row 2 shows whether the engine is running.
0 = Engine stopped.
1 = Engine running.
Row 3 shows whether the parking brake is applied.
0 = Parking brake not applied.
1 = Parking brake applied.
Row 4 shows whether the parking brake is released.
0 = Parking brake not released.
1 = Parking brake released.
Row 5 shows countdown timer to auto-stop. How quick the countdown
is depends on the set time for the auto-stop timer. Long time means
that the counter is counting slowly.

8 Control system – Transmission 8:39

Row 1 shows whether the automatic stop function is available on the
machine. (Automatic stop function means that the engine is switched
off automatically, starting must take place manually.) Automatic stop
function is always active in ECO mode.
It is possible to set activate the automatic stop function in row 2, Func-
tion available. See Navigation of menus, description, page 8:4 for
0 = Automatic stop function not available.
1 = Automatic stop function available.
Row 2 shows whether the conditions for auto-stop are fulfilled.
0 = Engine not auto-stopped.
1 = Engine auto-stopped.
Row 3 shows status for temperature of engine, transmission, hydraulics
and in the cab.
0 = Temperatures too low for auto-stop.
1 = Temperatures for auto-stop reached.
Row 4 shows status for charge level of batteries.
0 = Charge level too low for auto-stop.
1 = Charge level for auto-stop reached.
Row 5 shows whether the engine has been auto-stopped by means of
the parking brake being applied.
0 = Not auto-stopped by applied parking brake.
1 = Auto-stopped because the parking brake has been applied.
Row 6 shows countdown timer to auto-stop. How quick the countdown
is depends on the set time for the auto-stop timer. Long time means
that the counter is counting slowly.
8.4.2 Transmission
instruments transmission
Row 1 describes the input signals from the travel direction selector
(S1310).
Row 2 shows the input parking brake.
Row 3 shows the input forward.
Row 4 shows the input neutral.
Row 5 shows the input centre.
Row 6 shows the input reverse.

8:40 8 Control system – Transmission
Machine with joystick control or mini-wheel

Row 1 describes the input signals forward/backward from the mini-
wheel (S1310-3).

Row 1 describes the control system's request to the transmission.
Row 2 shows the request forward.
Row 3 shows the request neutral.
Row 4 shows the request reverse.

Row 1 shows the shifting position.
0 = manual.
1 = automatic.
Row 2 shows the input signal from Switch, automatic/manual shifting
(S1790).
0 = Not activated.
1 = Activated.
Row 3 shows the input signal from Switch, manual shifting down
(S1350-1).
0 = Not activated.
1 = Activated.
Row 4 shows the input signal from Switch, manual shifting up (S1350-
2).
0 = Not activated.
1 = Activated.
Row 5 shows the requested gear, +/- 125.
Row 6 shows the current gear +/- 125.


Row 1 describes the input signals from the travel direction selector
mini-switch (S1310-1)
8.4.2.6 Diagnostic menus Lubrication system

2.6 Lubrication Sys 1/XX DIAGNOSE
Row 1 shows the oil temperature in the transmission.
2.6 Lubrication Sys 2/XX DIAGNOSE

Row 1 shows the oil level in the transmission.
8.4.2.8 Diagnostic menus Control system,

transmission
Drive-train alternative ECO efficient
Row 1 shows voltage feed measured by Control unit transmission
(D7930).
Row 2 shows battery voltage measured by Control unit transmission
(D7930).
Row 3 shows the voltage for PWM-controlled outputs measured by
Control unit transmission (D7930).
Row 4 facilitates replacement of outputs for transmitting from Control

8:42 8 Control system – Transmission

Row 1 shows current shifting range, -3 – 3.
Row 2 shows rotation speed from Sensor, engine speed (on the
transmission).
Row 3 shows rotation speed from Sensor, rotation speed output shaft.
Row 4 shows gear ratio.
Row 5 shows machine speed in km/h.

Row 1 shows current shifting range, -3 – 3.
Row 2 shows status for the drive:
0 = neutral
1 = engaged
Row 3 shows current operating mode:
0 = Initiation
2 = Limp home
5 = Emergency mode off
7 = Normal
8 = Heating
11 = Calibration
Row 4 shows current error:
0 = No error.
1 = there is one active error.
Row 4 shows the torque transmitted from the engine to the
transmission.
Row 5 shows the torque transmitted by the transmission to the drive
axle.

Row 1 shows the hydraulic pressure to hydrostatic circuit A in bar.
Row 2 shows the hydraulic pressure to hydrostatic circuit B in bar.
Row 3 shows the pressure difference between hydrostatic circuit A and
B in bar.
Row 4 shows status for the pressure switch for the transmission's oil
filter:
0 = Normal pressure.
1= Pressure too high, change oil filter.
Row 5 shows the oil temperature in the transmission's oil sump.
Row 6 shows the oil temperature, draining temperature.


Row 1 shows hydraulic pressure for clutch C1 in bar.
Row 4 shows hydraulic pressure for clutch CR in bar.

Row 1 shows shifting speed from speed sensor 1.

Row 1 shows main version for the software in Control unit transmission
(D7930):
0 = Baseline A
1 = Baseline B
2 = Baseline C
3 = Baseline D.
Row 1 shows underlying version for the software in Control unit trans-
mission (D7930).
Row 3 shows revision for the software in Control unit transmission
(D7930).
Row 4 shows program ID for the software in Control unit transmission
(D7930).
Row 5 shows type for the transmission.
Row 6 shows version for the transmission.

8:44 8 Control system – Brakes
8.4.4 Brakes
instruments brakes
Row 1 shows signal A from Sensor brake pedal (R8092).

Row 2 shows pedal position read from signal A in percentage of cali-
brated maximum position.
Row 3 shows signal B from Sensor brake pedal (R8092).
Row 4 shows pedal position read from signal B in percentage of cali-
brated maximum position.
Row 5 shows pedal aggregate position from signal A and B in percent-
age of calibrated maximum position.
Row 6 shows measured brake pressure.
8.4.4.3 Diagnostic menus Power-assisted brake

system
4.3 Power Assisted 3/XX DIAGNOSE
Row 1 shows the signal from the brake pressure sensor (B7681).
Row 2 shows the brake pressure.
Row 3 shows the signal from accumulator pressure sensor (B7683).
Row 4 shows the accumulator pressure.

Row 1 shows the signal from the accumulator pressure sensor (B7683).
Row 3 shows the requested speed limitation.
Row 4 shows the requested gear limitation.

8 Control system – Brakes 8:45
8.4.4.5 Diagnostic menus Parking brake system

4.5 Park Brake Sys 1/XX DIAGNOSE
Row 1 describes the parking brake system.
Row 2 shows whether the standard travel direction selector (S1310) is
in the parking brake position.
0 = not in position.
1 = in parking brake position.
Row 3 shows whether the travel direction selector (S1310) is in the
centre position.
1 = in centre position.
Row 4 shows whether the brake pressure is OK, when the pressure is
so high that the parking brake may be released.
0 = not OK.
1 = OK.
It is possible to release the parking brake on row 4, Parking brake re-
leased. See Navigation of menus, description, page 8:4 for an ex-
planation how settings are made.
0 = not released.
1 = released.

Row 1 shows status for the output to Solenoid valve parking brake
(Y6420).
It is possible to set the signal for the output on row 1, Output Y6420
C1p17 D7971. See Navigation of menus, description, page 8:4 for
an explanation of how the settings are made.
0 = no signal.
1 = signal.
Row 2 shows analogue output actual current.
Row 3 shows the pin status for the output. See Explanation of pin sta-
tus codes, page 8:29 for an explanation of pin status.
Row 4 shows the signal from the parking brake sensor (B7682).
Row 4 shows the pressure for parking brake caliper.
0 = not released.
1 = released.

Row 1 describes the parking brake system.
0 = not released.
1 = released.

8:46 8 Control system – Steering
8.4.4.8 Diagnostic menus Temperature control,

cleaning and oil brake system
4.8 Oil Temp/Clean 1/XX DIAGNOSE
Row 1 shows the signal from Sensor, temperature brake system
(B7720).
Row 2 shows temperature of oil for brake system.
Row 3 shows requested speed limitation depending on the temperature
Row 4 shows requested gear limitation depending on the temperature

Row 1 describes cooling fan brake system (M6740).
8.4.5 Steering
8.4.5.2 Diagnostic menus Power assisted system
Row 1 describes joystick control without feedback of the steering wheel

position.
Row 2 shows the on/off button for joystick control.
0 = off.
1 = on.
Row 3 shows whether the left arm rest is in position.
1 = in position.
Row 4 shows the signal from the joystick (R8250-1).

8 Control system – Steering 8:47
Row 1 describes mini-steering wheel.

Row 2 shows the status for the on/off button for mini-wheel steering.
0 = off.
1 = on.
Row 3 shows whether the left arm rest is in position.
1 = in position (lowered).
Row 4 shows the signal from the mini-wheel's sensor channel 1
(R8250-1).
Row 5 shows the signal from the mini-wheel's sensor channel 2
(R8250-2).
Row 1 shows status for voltage feed to the controls in the arm rest.
0 = no voltage feed.
1 = voltage feed.
Row 4 shows status for indicator lamp mini-wheel steering (H5992).
0 = off.
1 = on.
Row 5 shows actual current to indicator lamp mini-wheel steering
(H5992).
Row 1 shows status for voltage feed to Electric steering module

(Y6150).
0 = no voltage feed.
1 = voltage feed (joystick control or mini-wheel active).
Row 4 shows the value of the return signal from the coil for Electric
steering module (Y6150). The return signal shows how much pressure
and in which direction the steering module actuates out to the steering
cylinder, 50% corresponds to no steering angle (neutral position).
It is possible to manually set the steering angle on row 4. See Naviga-
tion of menus, description, page 8:4 for an explanation of how the
settings are made.
Row 5 shows actual voltage from Electric steering module (Y6150).

Row 1 shows error signal for Electric steering module (Y6150).

Row 1 describes sensor, steering wheel angle.
Row 2 shows sensor 1, B7700-1.
0 = off.
1 = on.
Row 3 shows sensor 1, B7700-2.
0 = off.
1 = on.
Row 4 shows whether steering is activated
0 = not activated.
1 = activated.

Row 1 describes sensor, steering axle.
Row 2 shows sensor, steering axle (B7245-LE).
Row 3 shows sensor, steering axle (B7245-RI).
Row 4 shows the current steering angle, -100% to 100%.

Row 1 describes sensor, steering axle.
Row 2 shows sensor, steering axle (B7245-LE).
Row 3 shows the current steering angle, -100% to 100%.

8 Control system – Suspension 8:49
8.4.6 Suspension
8.4.6.3 Diagnostic menus Tyres and rims
6.3 Tyres and Rims 1/XX Diagnose
Row 1 describes Sensor tyre pressure left front outer (B9130-1).

Row 2 shows tyre pressure in bar.
Row 3 shows 99 as fixed value, this is not an actual tyre temperature.
Row 4 shows the status for the sensor.
0 = No contact with the control unit.
1 = Data sent.
Row 5 shows the status for the tyre.
0 = OK.
1 = Air leak detected.
2 = Error.
Row 6 shows combined status for tyre and sensor.
0 = OK.
1 = Low battery voltage (replace sensor).
2 = Error.
Row 1 describes Sensor tyre pressure left front inner (B9130-2).

1 = Data sent.
0 = OK.
2 = Error.
0 = OK.
2 = Error.

8:50 8 Control system – Suspension
Row 1 describes Sensor tyre pressure right front inner (B9130-3).

1 = Data sent.
0 = OK.
2 = Error.
0 = OK.
2 = Error.
Row 1 describes Sensor tyre pressure right front outer (B9130-4).

1 = Data sent.
0 = OK.
2 = Error.
0 = OK.
2 = Error.

8 Control system – Suspension 8:51
Row 1 describes Sensor tyre pressure left rear (B9130-5).

1 = Data sent.
0 = OK.
2 = Error.
0 = OK.
2 = Error.
Row 1 describes Sensor tyre pressure right rear (B9130-6).

1 = Data sent.
0 = OK.
2 = Error.
0 = OK.
2 = Error.
Row 1 describes serial number of sensors for tyre pressure monitoring

on front wheels.
Row 2 shows serial number for Sensor, tyre pressure left front outer
(B9130-1).
Row 3 shows serial number for Sensor, tyre pressure left front inner
(B9130-2).
Row 4 shows serial number for Sensor, tyre pressure right front inner
(B9130-3).
Row 5 shows serial number for Sensor, tyre pressure right front outer
(B9130-4).

8:52 8 Control system – Load handling
Row 1 describes serial number of sensors for tyre pressure monitoring

on rear wheels.
Row 2 shows serial number for Sensor, tyre pressure left rear (B9130-
5).
Row 3 shows serial number for Sensor, tyre pressure right rear
(B9130-6).
Row 1 shows number of connected sensors for tyre pressure

monitoring.
Row 2 shows message from Control unit tyre pressure monitoring
(A9130).
8.4.7 Load handling

instruments
7.1 Controls and Instr 4/XX DIAGNOSE
Row 1 shows whether the hydraulic functions are activated.
0 = not active.
1 = active.
Row 2 shows the signal from the control breaker (S2500).
0 = not activated.
1 = activated.
Row 3 shows the driver in seat sensor (B2300).
0 = driver not in seat.
1 = driver in seat.
Row 4 shows the signal from the bypass switch (S1005).
0 = not bypassed.
1 = bypassed.
Row 5 shows whether the hydraulic functions are reduced.
0 = not reduced.
1 = reduced.
Reduced hydraulic function means that the value of the levers is
restricted to 50% movement speed.
It is possible to use the reduced hydraulic functions when row 3=0
and row 4=1.

8 Control system – Load handling 8:53

Row 1 describes Control lever (S8150).
Row 2 shows the position on the X-axis with the help of signals from
potentiometer (R8070-2).
Row 3 shows control lever actuation as a percentage.
Row 4 shows the position on the Y-axis with the help of signals from po-
tentiometer (R8070-1).
Row 5 shows control lever actuation as a percentage.

Row 1 describes the thumb control on Control lever (S8150).
Row 2 shows the position on the X-axis with the help of signals from
potentiometer (R8070-3).
Row 3 shows thumb lever actuation as a percentage.
Row 4 shows the position on the Y-axis with the help of signals from po-
tentiometer (R8070-4).
Row 5 shows thumb lever actuation as a percentage.

Row 1 describes the buttons on Control lever (S8150).
Row 2 shows signal from Switch shift button (S1991) (alternative
function).
0 = not activated.
1 = activated.
Row 3 shows the signal from Switch, horn (S1490).
0 = not activated
1 = activated
Row 4 shows signal from Switch open twistlocks (S1020) or Switch
open/clamp function (S1020).
0 = not activated.
1 = activated.
Row 5 shows the signal from Switch, levelling lock (S1037).
0 = not activated.
1 = activated.
Row 6 shows the signal from Switch, tilt lock.
0 = not activated.
1 = activated.

Row 1 describes the buttons on Remote control (D9001).

Row 2 shows the signal from Switch, radio control function (S9001) (in
the cab).
0 = not activated.
1 = activated.
Row 3 shows status for TX messages from the remote control.
0 = no contact.
1 = communication OK.
Row 4 shows status for the switch to activate radio communication (re-
mote control).
0 = not activated.
1 = activated.
Row 5 shows status for parking brake and disengagement of control
lever.
0 = not activated.
1 = parking brake activated, control lever disengaged.
Row 1 shows status for the switch on the remote control for radio
control.
0 = not activated.
1 = activated.
Row 2 shows status for the switch for alternative function, forwards.
0 = not activated.
1 = activated.
Row 3 shows status for the switch for alternative function, backwards.
0 = not activated.
1 = activated.
Row 4 shows status for the switch for clamping position, clamp load.
0 = not activated.
1 = activated.
Row 5 shows status for the switch for clamping position, release load.
0 = not activated.
1 = activated.

Row 1 shows status for the switch for front legs up on the remote con-
trol for radio control.
0 = not activated.
1 = activated.
Row 2 shows status for Switch, front legs down.
0 = not activated.
1 = activated.
Row 3 shows status for Switch, rear legs up.
0 = not activated.
1 = activated.
Row 4 shows status for Switch, rear legs down.
0 = not activated.
1 = activated.
Row 5 shows status for the switch for side shift left.
0 = not activated.
1 = activated.
Row 6 shows status for the switch for side shift right.
0 = not activated.
1 = activated.
Row 1 describes left control lever on the remote control for radio
control.
Row 2 shows lever deflection to right in %.
Row 3 shows lever deflection to left in %.
Row 4 shows lever deflection forward (upward) in %.
Row 4 shows lever deflection backward (downward) in %.
Row 1 describes right control lever on the remote control for radio
control.
Row 2 shows lever deflection to right in %.
Row 3 shows lever deflection to left in %.
Row 4 shows lever deflection forward (upward) in %.
Row 4 shows lever deflection backward (downward) in %.


Row 1 shows signals from control lever on the remote control for radio
control.
Row 2 shows the position for raised idle (0–3) that has been selected
using the remote control.
Row 3 shows current request for raised idle.
8.4.7.2 Diagnostic menus Lifting/lowering

7.2 Lifting Lowering 6/XX DIAGNOSE
Row 1 shows the output to the lift solenoid valve (Y6005). Output actual
current in % of max. current that is set in Initiation, see 7.2 Lifting Low-
ering 12/XX INITIATE, page 8:190.
Row 2 shows the requested current.
It is possible to set the current on row 2 manually, Requested current.
Row 6 shows the pulse length. Pulse length in % of the battery voltage
is another measure of how much the valve is operated.

Row 1 shows the output to the lower solenoid valve (Y6004). Output
actual current in % of max. current that is set in Initiation, see 7.2 Lifting
Lowering 14/XX INITIATE, page 8:191.


Row 1 describes controlling blocking valves for the lift cylinders.
Row 2 shows status for activation
0 = blocking valves not activated (lift cylinders blocked).
1 = blocking valves activated (lowering possible).
Row 3 shows actual current to Solenoid valve blocking left (Y6045-LE).
Row 4 shows pin status for the output to Solenoid valve blocking left
(Y6045-LE). See Explanation of pin status codes, page 8:29 for an ex-
planation of pin status.
Row 5 shows actual current to Solenoid valve, blocking right (Y6045-
RI).
Row 6 shows pin status for the output to Solenoid valve blocking right
(Y6045-RI). See Explanation of pin status codes, page 8:29 for an ex-
planation of pin status.

Row 1 describes controlling the regeneration valves for the lift cylinders.
0 = regeneration valves not activated.
1 = regeneration valves activated (regeneration engaged).
Row 3 shows actual current to Solenoid valve regeneration left (Y6051-
LE).
Row 4 shows pin status for the output to Solenoid valve regeneration
left (Y6051-LE). See Explanation of pin status codes, page 8:29 for an
explanation of pin status.
Row 5 shows actual current to Solenoid valve regeneration right
(Y6051-RI).
Row 6 shows pin status for the output to Solenoid valve regeneration
right (Y6051-RI). See Explanation of pin status codes, page 8:29 for an
explanation of pin status.
8.4.7.3 Diagnostic menus Extension

7.3 Extension 1/XX DIAGNOSE
Row 1 shows the output to Solenoid valve boom out (Y6006). Output
actual current in % of max. current that is set in Initiation, see 7.3 Ex-
tension 2/XX INITIATE, page 8:194.


Row 1 shows the output to Solenoid valve boom in (Y6007). Output ac-
tual current in % of max. current that is set in Initiation, see 7.3 Exten-
sion 4/XX INITIATE, page 8:194.

Row 1 describes controlling Solenoid valve blocking extension (Y6050).
0 = blocking valve not activated (extension cylinder blocked).
1 = blocking valve activated (boom in possible).
Row 4 shows pin status for the output. See Explanation of pin status
codes, page 8:29 for an explanation of pin status.

Row 1 describes controlling Solenoid valve regeneration (Y6051-1).
0 = regeneration valve not activated.
1 = regeneration valve activated (regeneration engaged).

Row 1 describes controlling Solenoid valve pump unloading (Y6093).
It is possible to manually activate the solenoid valve on row 2, Re-
quested output. See Navigation of menus, description, page 8:4
for an explanation how settings are made.
0 = Solenoid valve not activated (pump engaged).
1 = Solenoid valve activated (pump disengaged).

8.4.7.4 Diagnostic menus Side shift

7.4 Side Shift 3/XX DIAGNOSE
Row 1 shows the output to Solenoid valve, side shift right (Y6021). Out-
put actual current in % of max. current that is set in Initiation, see 7.4
Side Shift 6/XX INITIATE, page 8:195.
Row 6 shows the pulse length.

Row 1 shows the output to Solenoid valve, side shift left (Y6020). Out-
Side Shift 8/XX INITIATE, page 8:196.

Row 1 Describes sensor for side shift.
Row 2 shows the signal from Sensor, side shift limit (B7687).
0 = Activated.
1 = Not activated.

8.4.7.5 Diagnostic menus Spreading

7.5 Spreading 7/XX DIAGNOSE
Row 1 describes switch for the spreading function.
Row 2 shows the signal from Switch, extra stop spreading (S1004).
0 = Not activated.
1 = Activated.
Row 3 shows the signal from Switch automatic spreading 20'-40'
(S1012-2).
0 = Not activated.
1 = Activated.

Row 1 describes position sensor for the spreading function.
Row 2 shows the signal from Sensor end position 20'-40' (B7690).
0 = Not activated.
1 = Activated.
Row 3 shows the signal from Sensor, extra stop spreading (B7770).
0 = Not activated.
1 = Activated.

Row 1 describes position sensor for the spreading function.
Row 2 shows the signal from Sensor, end position 20'–40' left (B7690-
LE), which controls damping end position and stop extra position .
0 = Not activated.
1 = Activated.
Row 3 shows the signal from Sensor, extra stop spreading left (B7770-
LE), which controls stop end position and damping extra position .
0 = Not activated.
1 = Activated.
Row 4 shows the signal from Sensor, end position 20'–40' right
(B7690-RI), which controls damping end position and stop extra posi-
tion .
0 = Not activated.
1 = Activated.
Row 5 shows the signal from Sensor, extra stop spreading right
(B7770-RI), which controls stop end position and damping extra posi-
tion .
0 = Not activated.
1 = Activated.


Menu for chain spreading.
Row 1 shows the output to Solenoid valve, spreading out (Y6018). Out-
Spreading 14/XX INITIATE, page 8:197.

Row 1 shows the output to Solenoid valve, spreading in (Y6019). Out-
Spreading 17/XX INITIATE, page 8:198.

Menu for cylinder spreading.
Row 1 shows the output to Solenoid valve, spreading left out (Y6018-
LE).Output actual current in % of max. current that is set in Initiation,
see 7.5 Spreading 20/XX INITIATE, page 8:199.


Row 1 shows the output to Solenoid valve, spreading left in (Y6019-LE).
Output actual current in % of max. current that is set in Initiation, see
7.5 Spreading 23/XX INITIATE, page 8:200.

Row 1 shows the output to Solenoid valve, spreading right out (Y6018-
RI). Output actual current in % of max. current that is set in Initiation,

Row 1 shows the output to Solenoid valve, spreading right in (Y6019-
RI). Output actual current in % of max. current that is set in Initiation,


Row 1 describes buzzer for automatic spreading 20'–40'.
Row 2 shows the requested output signal.
It is possible to manually activate the buzzer on row 2, Requested out-
put. See Navigation of menus, description, page 8:4 for an explan-
ation how settings are made.
0 = Not activated.
1 = activated, buzzer active.
Row 3 shows actual current to Buzzer automatic spreading 20'–40'
(H9003).
8.4.7.6 Diagnostic menus Rotation

7.6 Rotation 1/XX DIAGNOSE
Row 1 shows output to Solenoid valve rotation clockwise (Y6008). Out-
Rotation 2/XX INITIATE, page 8:203.

Row 1 shows output to Solenoid valve rotation anticlockwise (Y6009).
7.6 Rotation 4/XX INITIATE, page 8:204.

Row 1 describes position sensors.

Row 2 shows the signal from Sensor, rotation stop (B7225).
0 = Not activated.
1 = Activated.
Row 1 describes disengagement of brake on rotation motors. For ma-

chines with tool changer prepared for Bönnhoff pliers.
0 = Not activated.
1 = activated, rotation disengaged.
8.4.7.7 Diagnostic menus Tilt

7.7 Tilt 4/XX DIAGNOSE
Row 1 shows the output to Solenoid valve, tilt out (Y6010). Output ac-
tual current in % of max. current that is set in Initiation, see 7.7 Tilt 8/XX


Row 1 shows the output to Solenoid valve, tilt in (Y6011). Output actual
current in % of max. current that is set in Initiation, see 7.7 Tilt 10/XX

Row 1 describes tilt lock.
Row 2 shows the status for tilt lock.
It is possible to manually activate tilt lock on row 2, Requested output.
0 = lock position
1 = float position (solenoid valves activated)
Row 3 shows actual current to Solenoid valve tilt lock (Y6012-1).
Row 5 shows actual current to Solenoid valve tilt lock (Y6012-2).
Row 1 shows the signal from Sensor, tilt angle (B7253).

Row 2 shows the current tilt angle of the attachment in relation to the
boom.
Row 3 shows the current tilt angle of the attachment, compensated for
the angle of the boom (0° is horizontal).

Row 1 shows the function for parallel tilt angle attachment.

0 = deactivated
1 = activated
Row 2 shows the current tilt angle of the attachment in relation to the
boom.
Row 3 shows the current tilt angle of the attachment, compensated for
Row 4 shows the desired tilt angle of the attachment, compensated for
Row 5 shows output tilt out. Output actual current in % of max. current
that is set in Initiation, see 7.7 Tilt 10/XX INITIATE, page 8:206.
Row 6 shows output tilt in. Output actual current in % of max. current
that is set in Initiation, see 7.7 Tilt 10/XX INITIATE, page 8:206.
8.4.7.8 Diagnostic menus Levelling

7.8 Levelling 3/XX DIAGNOSE
Row 1 shows output to Solenoid valve levelling clockwise (Y6035).

7.8 Levelling 6/XX INITIATE, page 8:207.
Row 1 shows output to Solenoid valve levelling anticlockwise (Y6036).

7.8 Levelling 8/XX INITIATE, page 8:208.

Row 1 describes disengagement of levelling lock.

Row 2 shows the status for levelling lock.
It is possible to manually control the levelling lock in row 2, Requested
output. See Navigation of menus, description, page 8:4 for an ex-
0 = lock position
1 = float position (solenoid valves activated)
Row 3 shows actual current to Solenoid valve levelling lock (Y6034-1).
Row 5 shows actual current to Solenoid valve levelling lock (Y6034-2).
Row 1 shows the signal from Sensor, tilt angle (B7253).

Row 2 shows the current tilt angle of the attachment.
8.4.7.9 Diagnostic menus Load carrier

7.9 Load Carrier 3/XX DIAGNOSE
Row 1 describes twistlocks.
Row 2 shows the signal from Switch, lock twistlocks (S1003).
0 = Not activated.
1 = Activated.
Row 3 shows signal from Switch open twistlocks (S1002) or Switch
open/clamp function (S1020).
0 = Not activated.
1 = Activated.


Row 1 describes position sensor for contact twistlocks.
Row 2 shows the signal from Sensor contact left front (B7202-FL).
0 = Not activated.
1 = Activated.
Row 3 shows the signal from Sensor contact right front (B7202-FR).
0 = Not activated.
1 = Activated.
Row 4 shows the signal from Sensor contact left rear (B7202-RL).
0 = Not activated.
1 = Activated.
Row 5 shows the signal from Sensor contact right rear (B7202-RR).
0 = Not activated.
1 = Activated.

Row 1 describes position sensor for twistlocks.
Row 2 shows the signal from Sensor, locked twistlocks left (B7205-LE).
0 = Not activated.
1 = Activated.
Row 3 shows the signal from Sensor, unlocked twistlocks left (B7204-
LE).
0 = Not activated.
1 = Activated.
Row 4 shows the signal from Sensor, locked twistlocks right (B7205-
RI).
0 = Not activated.
1 = Activated.
Row 5 shows the signal from Sensor, unlocked twistlocks right (B7204-
RI).
0 = Not activated.
1 = Activated.

Row 1 describes Solenoid valve lock twistlocks (Y6040).
Row 2 shows status for the output.
0 = Not activated.
1 = activated (open twistlocks).


Row 1 describes Solenoid valve open twistlocks (Y6039).
0 = Not activated.
1 = activated (lock twistlocks).

Row 1 describes Indicator light, locked twistlocks (H5630-1).
It is possible to manually activate the indicator light in row 2, Requested
0 = Not activated.
1 = activated (lamp illuminated).

Row 1 describes Indicator light, open twistlocks (H5620-1).
0 = Not activated.

Row 1 describes Indicator light, contact twistlocks (H5640-1).
0 = Not activated.


Row 1 describes the ground signal to the indicator lights on the boom.
The ground signal pulse length is controlled in order to increase and
decrease the brightness of the indicator lights.
It is possible to manually set the pulse length on row 2, Requested duty
cycle C2p35 D7911. See Navigation of menus, description, page
8:4 for an explanation of how the settings are made.
Row 3 shows the requested voltage.

Row 1 describes Indicator light, locked twistlocks (H5630-2).
0 = Not activated.

Row 1 describes Indicator light, open twistlocks (H5620-2).
0 = Not activated.

Row 1 describes Indicator light, contact twistlocks (H5640-2).
0 = Not activated.

Row 1 describes status for switches for lift legs.

Row 2 shows status for Switch front leg (S1006-FR) up.
0 = Not activated.
1 = Activated.
Row 3 shows status for Switch front leg (S1006-FR) down.
0 = Not activated.
1 = Activated.
Row 4 shows status for Switch rear leg (S1006-RE) up.
0 = Not activated.
1 = Activated.
Row 5 shows status for Switch rear leg (S1006-RE) down.
0 = Not activated.
1 = Activated.
Row 1 describes status for switches for clamp/release lift legs.

Row 2 shows status for Switch clamp legs (S1008).
0 = Not activated.
1 = Activated.
Row 3 shows status for Switch release legs (S1008).
0 = Not activated.
1 = Activated.

Row 1 describes stages in the raising/lowering sequence for the corre-

sponding lift leg for bottom lift.
Row 2 shows status for lift leg left front.
0 = Sequence error.
1 = Leg up, knee in.
2 = Leg up, knee moving.
3 = Leg up, knee out.
4 = Leg moving, knee out.
5 = Leg down, knee out.
Row 3 shows status for lift leg right front.
0 = Sequence error.
Row 4 shows status for lift leg left rear.
0 = Sequence error.
Row 5 shows status for lift leg right rear.
0 = Sequence error.
Row 1 describes status for position sensor knee for lift legs.
Row 2 shows status for Sensor front knee left front (B7217-LF).
0 = Not activated.
1 = Activated.
Row 3 shows status for Sensor front knee right front (B7217-RF).
0 = Not activated.
1 = Activated.
Row 4 shows status for Sensor front knee left rear (B7217-LR).
0 = Not activated.
1 = Activated.
Row 5 shows status for Sensor front knee right rear (B7217-RR).
0 = Not activated.
1 = Activated.

Row 1 describes status for position sensor leg for lift legs.
Row 2 shows status for Sensor front leg left front (B7219-LF).
0 = Not activated.
1 = Activated.
Row 3 shows status for Sensor front leg right front (B7219-RF).
0 = Not activated.
1 = Activated.
Row 4 shows status for Sensor front leg left rear (B7219-LR).
0 = Not activated.
1 = Activated.
Row 5 shows status for Sensor front leg right rear (B7219-RR).
0 = Not activated.
1 = Activated.
Row 1 describes status for position sensor clamping position for lift
legs.
Row 2 shows status for Sensor clamping position left front (B7215-LF).
0 = Not activated.
1 = Activated.
Row 3 shows status for Sensor clamping position right front (B7215-
RF).
0 = Not activated.
1 = Activated.
Row 4 shows status for Sensor clamping position left rear (B7215-LR).
0 = Not activated.
1 = Activated.
Row 5 shows status for Sensor clamping position right rear (B7215-
RR).
0 = Not activated.
1 = Activated.
Row 1 describes status for position sensor operating position for lift
legs.
Row 2 shows status for Sensor operating position left (B7212-LE).
0 = Not activated.
1 = Activated.
Row 3 shows status for Sensor operating position right (B7212-RI).
0 = Not activated.
1 = Activated.

Row 1 describes status for position sensor contact for lift legs.
Row 2 shows status for Sensor contact left front (B7213-LF).
0 = Not activated.
1 = Activated.
Row 3 shows status for Sensor contact right front (B7213-RF).
0 = Not activated.
1 = Activated.
Row 4 shows status for Sensor contact left rear (B7213-LR).
0 = Not activated.
1 = Activated.
Row 5 shows status for Sensor contact right rear (B7213-RR).
0 = Not activated.
1 = Activated.
Row 1 shows output to Solenoid valve knee out left front (Y6057-LF).
7.9 Load carrier 15/XX INITIATE, page 8:210.
Row 1 shows output to Solenoid valve leg down left front (Y6059-LF).

Row 1 shows output to Solenoid valve leg up left front (Y6058-LF). Out-
Row 1 shows output to Solenoid valve knee in left front (Y6056-LF).

Row 1 shows output to Solenoid valve knee out right front (Y6057-RF).

Row 1 shows output to Solenoid valve leg down right front (Y6059-RF).
Row 1 shows output to Solenoid valve leg up right front (Y6058-RF).

Row 1 shows output to Solenoid valve knee in right front (Y6056-RF).


Row 1 shows output to Solenoid valve knee out left rear (Y6057-LR).
Row 1 shows output to Solenoid valve leg down left rear (Y6059-LR).
Row 1 shows output to Solenoid valve leg up left rear (Y6058-LR). Out-

Row 1 shows output to Solenoid valve knee in left rear (Y6056-LR).

Row 1 shows output to Solenoid valve knee out right rear (Y6057-RR).
Row 1 shows output to Solenoid valve leg down right rear (Y6059-RR).

Row 1 shows output to Solenoid valve leg up right rear (Y6058-RR).

Row 1 shows output to Solenoid valve knee in right rear (Y6056-RR).

Row 1 shows output to Solenoid valve clamp close left (Y6054-LE).

0 = Not activated.
1 = Activated.

Row 1 shows output to Solenoid valve clamp open left (Y6055-LE).

0 = Not activated.
1 = Activated.
Row 1 shows output to Solenoid valve clamp close right (Y6054-RI).

0 = Not activated.
1 = Activated.
Row 1 shows output to Solenoid valve clamp open right (Y6055-RI).

0 = Not activated.
1 = Activated.
Row 1 shows output to Solenoid valve operating position left (Y6053-

LE).
0 = Not activated.
1 = Activated.

Row 1 shows output to Solenoid valve operating position right (Y6053-

RI).
0 = Not activated.
1 = Activated.
Row 1 describes Indicator light contact lift leg left front (H5760-LF).
0 = Not activated.
Row 1 describes Indicator light contact lift leg right front (H5760-RF).
0 = Not activated.
Row 1 describes Indicator light contact lift leg left rear (H5760-LR).
0 = Not activated.

Row 1 describes Indicator light contact lift leg right rear (H5760-RR).
0 = Not activated.
Row 1 describes Indicator light lift legs front up (H5800-UP).

0 = Not activated.
Row 1 describes Indicator light lift legs front down (H5800-LO).

0 = Not activated.
Row 1 describes Indicator light clamping position front leg (H5780-FR).

0 = Not activated.

Row 1 describes Indicator light clamping position rear leg (H5780-RE).

0 = Not activated.
Row 1 describes the ground signal to the indicator lights for bottom lift
on the boom. The ground signal's pulse length is controlled in order to
increase and decrease the brightness of the indicator lights.
cycle. See Navigation of menus, description, page 8:4 for an ex-
Row 1 describes status for switch lift legs, for external lifting tool ELME.
Row 2 shows status for front leg up (S1006-FR).
0 = Not activated.
1 = activated
Row 3 shows status for front leg down (S1006-FR).
0 = Not activated.
1 = activated

Row 1 describes 24V voltage feed to external lifting tool ELME.

It is possible to manually activate the output on row 2, Requested out-
0 = Not activated.
1 = activated
Row 5 shows feedback attachment engaged.
0 = Not activated.
1 = activated
Row 1 describes input signal from sensor on external lifting tool ELME.
Row 2 shows left leg pair clamp (B7215-LE).
0 = Not activated.
1 = activated
Row 3 shows right leg pair clamp (B7215-RI).
0 = Not activated.
1 = activated
Row 4 shows contact first leg (B7213-1).
0 = Not activated.
1 = activated
Row 5 shows contact all legs (B7213-4)
0 = Not activated.
1 = activated
Row 1 describes Solenoid valve lift legs down front (Y6059-FR) for ex-
ternal lifting tool ELME.
0 = Not activated.
1 = activated

Row 1 describes Solenoid valve lift legs up front (Y6058-FR) for exter-
nal lifting tool ELME.
0 = Not activated.
1 = activated
Row 1 describes Solenoid valve lift legs down rear (Y6059-RE) for ex-
0 = Not activated.
1 = activated
Row 1 describes control of Solenoid valve lift legs up rear (Y6058-RE)

for external lifting tool ELME.
0 = Not activated.
1 = activated

Row 1 describes control of Solenoid valve clamp close (Y6054) for ex-
0 = Not activated.
1 = activated
Row 1 describes control of Solenoid valve clamp open (Y6055) for ex-
Row 2 shows status for the output
0 = Not activated.
1 = activated.
Row 1 describes 24V voltage feed to external lifting tool Bönnhoff pliers.
0 = Not activated.
1 = Activated.
Row 5 shows feedback attachment engaged.
0 = Not activated.
1 = Activated.

Row 1 describes input signals from Sensor clamping pressure for ex-
ternal lifting tool Bönnhoff pliers.
Row 2 shows signal voltage from Sensor clamping pressure left
(B7680-LE) in mV.
Row 3 shows recalculated pressure from Sensor, clamping pressure
left (B7680-LE) in bar.
Row 4 shows signal voltage from Sensor clamping pressure right
(B7680-RI) in mV.
Row 5 shows recalculated pressure from Sensor clamping pressure
right (B7680-RI) in bar
Row 1 shows output to Solenoid valve clamp close (Y6019) for external
lifting tool Bönnhoff pliers. The output's existing current in % of the max-
imum current, which is set in Initiation, see 7.9 Load carrier 25/XX INI-
TIATE, page 8:213.
Row 1 shows output to Solenoid valve clamp open (Y6018) for external
lifting tool Bönnhoff pliers. The output's existing current in % of the max-
imum current, which is set in Initiation, see 7.9 Load carrier 25/XX INI-
TIATE, page 8:213.

Row 1 describes setting the speed limitation at clamping position for

external lifting tool Bönnhoff pliers.
Row 3 shows the machine's speed.
Row 1 describes Sensor damping attachment (B7230).

Row 2 shows the input signal from Sensor, damping attachment
(B7230) in mV.
Row 3 shows recalculated distance to container in mm.
Row 4 shows status for damping of lower function.
0 = No damping.
1 = Damping active.
Row 1 describes overheight-legs.

Row 2 shows the input signal from Switch, overheight-legs (S1031)
down.
0 = Not activated.
1 = Activated.
Row 3 shows the input signal from Switch, overheight-legs (S1031) up.
0 = Not activated.
1 = Activated.
Row 1 describes status for overheight-legs.

Row 2 shows status for Sensor, overheight-legs up left (B7231-LE):
0 = Not activated.
1 = Activated.
Row 3 shows status for Sensor, overheight-legs up right (B7231-RI):
0 = Not activated.
1 = Activated.
Row 4 shows status for Sensor, overheight-legs down left (B7256-LE):
0 = Not activated.
1 = Activated.
Row 5 shows status for Sensor, overheight-legs down right (B7256-RI):
0 = Not activated.
1 = Activated.

Row 1 describes status for Sensor, contact for overheight-legs.

Row 2 shows status for Sensor, contact left front (B7214-FL):
0 = Not activated.
1 = Activated.
Row 3 shows status for Sensor, contact right front (B7214-FR):
0 = Not activated.
1 = Activated.
Row 4 shows status for Sensor, contact left rear (B7214-RL):
0 = Not activated.
1 = Activated.
Row 5 shows status for Sensor contact right rear (B7214-RR):
0 = Not activated.
1 = Activated.
Row 1 shows output to Solenoid valve overheight-legs down (Y6071).

Row 1 shows output to Solenoid valve overheight-legs up (Y6070).


Row 1 describes Indicator light overheight-legs up (H5001-UP).

0 = Not activated.

Row 1 describes status for Sensor, lifting tool connected.
Row 2 shows status for Sensor, lifting tool connected (Bxxxx-x):
0 = Not activated.
1 = Activated.
Row 3 shows status for blocking release of twistlocks on connected lift-
ing tool:
0 = Normal function of twistlocks.
1 = Twistlocks blocked, can only be released by activating by-pass.

Row 1 describes status for Sensor, eccentric load.
Row 2 shows signal voltage from Sensor, eccentric load left front
(B7235-LF).
Row 2 shows signal voltage from Sensor, eccentric load left rear
(B7235-LR).
Row 2 shows signal voltage from Sensor, eccentric load right front
(B7235-RF).
Row 2 shows signal voltage from Sensor, eccentric load right rear
(B7235-RR).

Row 2 shows load left front in kg.
Row 2 shows load left rear in kg.
Row 2 shows load right front in kg.
Row 2 shows load right rear in kg.


Row 2 shows status for distribution of the load on the left-hand side of
the attachment.
Row 3 shows status for distribution of the load on the right-hand side of
the attachment.

Row 1 describes status for Sensor, side shift position. Minus value
means side shift to left; plus value means side shift to right.
Row 2 shows status for side shift position measured by Sensor, side
shift position (B7770).

Row 1 describes Indicator light, centre of gravity left (H5990-LE).
0 = Not activated.

Row 1 describes Indicator light, centre of gravity right (H5990-RI).
0 = Not activated.


Row 1 describes Indicator light, centre of gravity centred (H5990).
0 = Not activated.

Row 1 describes status for position of twistlock.
Row 2 shows status for Switch for standard twistlock.
0 = Not activated.
1 = Activated.
Row 3 shows status for Switch for WTP position.
0 = Not activated.
1 = Activated.

Row 1 describes status for WTP position sensor, inner position.
Row 2 shows status for Sensor, left front inner position (B7694-LF).
0 = Not activated.
1 = Activated.
Row 3 shows status for Sensor, left rear inner position (B7694-LR).
0 = Not activated.
1 = Activated.
Row 4 shows status for Sensor, right front inner position (B7694-RF).
0 = Not activated.
1 = Activated.
Row 5 shows status for Sensor, right rear inner position (B7694-RR).
0 = Not activated.
1 = Activated.


Row 1 describes status for WTP position sensor.
Row 2 shows status for Sensor, left front outer position (B7693-LF).
0 = Not activated.
1 = Activated.
Row 3 shows status for Sensor, left rear outer position (B7693-LR).
0 = Not activated.
1 = Activated.
Row 4 shows status for Sensor, right front outer position (B7693-RF).
0 = Not activated.
1 = Activated.
Row 5 shows status for Sensor, right rear outer position (B7693-RR).
0 = Not activated.
1 = Activated.

Row 2 shows the signal from Sensor, unlocked twistlocks left front
(B7204-LF).
0 = Not activated.
1 = Activated.
Row 3 shows the signal from Sensor, unlocked twistlocks left rear
(B7204-LR).
0 = Not activated.
1 = Activated.
Row 4 shows the signal from Sensor, unlocked twistlocks right front
(B7204-RF).
0 = Not activated.
1 = Activated.
Row 5 shows the signal from Sensor, unlocked twistlocks right rear
(B7204-RR).
0 = Not activated.
1 = Activated.


Row 2 shows the signal from Sensor, locked twistlocks left front
(B7205-LF).
0 = Not activated.
1 = Activated.
Row 3 shows the signal from Sensor, locked twistlocks left rear
(B7205-LR).
0 = Not activated.
1 = Activated.
Row 4 shows the signal from Sensor, locked twistlocks right front
(B7205-RF).
0 = Not activated.
1 = Activated.
Row 5 shows the signal from Sensor, locked twistlocks right rear
(B7205-RR).
0 = Not activated.
1 = Activated.

Row 1 describes Solenoid valve, WTP out (Y6046-1).
0 = Not activated.
1 = activated (WTP out).

Row 1 describes Solenoid valve, WTP in (Y6046-2).
0 = Not activated.
1 = activated (WTP in).


Row 1 describes reference ground WTP valves.
0 = Not activated.
1 = activated.

Row 1 describes Indicator light WTP outer position (H1753-1).
0 = Not activated.

Row 1 describes Indicator light WTP outer position (H1753-2), in cab.
0 = Not activated.

Row 1 describes voltage feed to WTP sensor.
Row 2 shows output for 24 V sensor voltage feed to WTP.
It is possible to manually set the signal in Row 2, 24V sensor power
supply C2p10 KEM-3 A7993. See Navigation of menus, descrip-
tion, page 8:4 for an explanation of how the settings are made.
0 = no signal.
1 = voltage feed.


Row 1 describes the status for opening the container door.
Row 2 shows the status for Switch for open container door (S1754).
0 = Not activated.
1 = Activated.
Row 3 shows status for Switch for close container door (S1754).
0 = Not activated.
1 = Activated.
Row 4 shows status for Switch select container door (S1755).
0 = Not activated.
1 = Activated.

Row 1 describes status for WTP position sensor container door.
Row 2 shows the status for Sensor, container door front closed
(B7692-FR).
0 = Not activated.
1 = Activated.
Row 3 shows the status for Sensor, container door rear closed (B7692-
RE).
0 = Not activated.
1 = Activated.

Row 1 describes status for WTP position sensor container door.
Row 2 shows the status for Sensor, container door open (B7691).
0 = Not activated.
1 = Activated.

Row 1 shows the output to Solenoid valve, container door open
(Y6022). Output actual current in % of max. current that is set in Initia-
tion, see 7.9 Load carrier 46/XX INITIATE, page 8:216.


Row 1 shows the output to Solenoid valve, container door close
(Y6023). Output actual current in % of max. current that is set in Initia-
tion, see 7.9 Load carrier 47/XX INITIATE, page 8:216.

Row 1 describes Solenoid valve, select container door (Y6085).
0 = Not activated.
1 = activated.

Row 1 describes Sensor, attachment clamp.
Row 2 shows status for left leg.
0 = not activated
1 = activated
Row 3 shows status for right leg.
0 = not activated
1 = activated


Row 1 describes Sensor, attachment "seated".
Row 2 shows contact front leg left, all legs (B7213–LF).
0 = not activated
1 = activated
Row 3 shows contact front leg right, first leg (B7213-RF).
0 = not activated
1 = activated
Row 4 shows contact rear leg left (B7213–LR).
0 = not activated
1 = activated
Row 5 shows contact rear leg right (B7213–RR).
0 = not activated
1 = activated

Row 1 describes front legs down.
Row 2 shows the status for the output (Y6059-FR).
0 = not activated
1 = activated
Row 4 shows the pin status. See Explanation of pin status codes in the
Workshop Manual, Chapter 8.

Row 1 describes front legs up.
Row 2 shows the status for the output (Y6058-FR).
0 = not activated
1 = activated

Row 1 describes rear legs down.
Row 2 shows the status for the output (Y6059-RE).
0 = not activated
1 = activated


Row 1 describes rear legs up.
Row 2 shows the status for the output (Y6058-RE).
0 = not activated
1 = activated

Row 1 describes clamp in.
Row 2 shows status for the output (Y6054).
0 = not activated
1 = activated

Row 1 describes clamp out.
Row 2 shows status for the output (Y6055).
0 = not activated
1 = activated
8.4.7.10 Diagnostic menus Other functions

7.10 Other Functions 5/XX DIAGNOSE
Row 1 Describes Switch support jacks (S1013).
Row 2 shows signal from Switch support jacks (S1013) up.
0 = Not activated.
1 = Activated.
Row 3 shows signal from Switch support jacks (S1013) down.
0 = Not activated.
1 = Activated.


Row 1 Describes sensor for support jacks.
Row 2 shows the signal from Sensor support jacks up left (B7222-LE).
0 = Not activated.
1 = Activated.
Row 3 shows the signal from Sensor support jacks up right (B7222-RI).
0 = Not activated.
1 = Activated.
Row 4 shows the signal from Sensor support jacks down left (B7223-
LE).
0 = Not activated.
1 = Activated.
Row 5 shows the signal from Sensor support jacks down right (B7223-
RI).
0 = Not activated.
1 = Activated.

Row 1 shows output to Solenoid valve support jacks up (Y6063). Out-
Other functions 13/XX INITIATE, page 8:219.
See 7.10 Other functions 11/XX INITIATE, page 8:218 for an ex-

Row 1 shows output to Solenoid valve support jacks down (Y6064).
7.10 Other functions 12/XX INITIATE, page 8:218.
See 7.10 Other functions 11/XX INITIATE, page 8:218 for an ex-


Row 1 shows output to Indicator light support jacks down (H5740).
0 = Not activated.
1 = activated (support jacks in lower end position).

Row 1 Describes signals for shaking the attachment.
Row 2 shows the signal from Switch, shake attachment (S1064).
0 = Not activated.
1 = Activated.
Row 3 shows the output of Solenoid valve, shake attachment (Y6111).
It is possible to manually control the output of Solenoid valve, shake at-
tachment in Row 3, Requested output Y6111 C2p36 D7911. See
Navigation of menus, description, page 8:4 for an explanation of
8.4.8 Control system

instruments
Row 1 describes control of the searchlights in the panels.
Row 2 describes Sensor, ambient brightness (B7252).
Row 3 shows the input signal from Sensor, ambient brightness (B7252).
Row 4 describes the drive-train/wiper control panel (A3700-02).
It is possible to manually control the pulse length (brightness) on row 5,
Requested duty. See Navigation of menus, description, page 8:4

8:102 8 Control system – Control system

Row 1 describes control of the function lights in the panels.
Row 4 describes the drive-train/wiper control panel (A3700-02).

Row 1 describes control of the searchlight on the switch.
Row 4 describes output signal to searchlight in switch.
8.4.8.2 Diagnostic menus, monitoring

8.2 Monitoring 1/XX DIAGNOSE
Row 1 shows the speed limitation request. The value 99.9 kph means
that there is no speed limitation.
Row 2 shows the gear limitation request.
Row 3 shows the speed limitation request.
Row 4 shows whether speed limitation is activated.
0 = Not activated.
1 = Activated.
Row 4 shows the torque limitation request.
Row 5 shows whether torque limitation is activated.
0 = Not activated.
1 = Activated.


Row 1 shows settings for ECO Drive Mode.
Row 2 shows set ECO mode.
It is possible to manually set ECO mode on row 2 Mode selected. See
Navigation of menus, description, page 8:4 for an explanation how
settings are made.
1 = Maximum output.
2 = Normal.
3 = ECO mode.
Row 3 shows the speed limitation request. It is possible to manually ac-
tivate speed limitation only on row 3, Vehicle speed limit request. See
Navigation of menus, description, page 8:4 for an explanation how set-
tings are made.
Row 4 shows the speed limitation request. It is possible to manually ac-
tivate engine speed limitation only in row 4, Engine speed limit re-
quest. See Navigation of menus, description, page 8:4 for an
explanation how settings are made.
Row 5 shows the torque limitation request. It is possible to manually ac-
tivate torque limitation only in Row 5, Engine torque limit request.
See Navigation of menus, description, page 8:4 for an explanation how
settings are made.
Row 6 shows whether working temperature has been reached to
achieve torque limitation, Operating temperatures reached (To get
trq lim). See Navigation of menus, description, page 8:4 for an explan-

Row 1 shows the number of hours remaining to the next service
interval.
Row 2 shows the number of hours when restoring a new service
interval.

Row 1 describes hydraulic load sensor.
Row 2 shows the signal from Sensor, boom angle (B7241).
Row 3 shows recalculated boom angle.
Row 4 shows the signal from Sensor, boom length (B7686).
Row 5 shows recalculated boom length.


Row 2 describes pressure sensors.
Row 3 shows the signal from Sensor lift cylinder piston side left
(B7226-1).
Row 4 shows the signal from Sensor lift cylinder rod side left (B7226-3).
Row 5 shows the signal from Sensor lift cylinder piston side right
(B7226-2).
Row 6 shows the signal from Sensor lift cylinder rod side right (B7226-
4).

Row 2 describes pressure sensors.
Row 3 shows the recalculated signal from Sensor lift cylinder piston
side left (B7226-1).
Row 4 shows the recalculated signal from Sensor lift cylinder rod side
left (B7226-3).
Row 5 shows the recalculated signal from Sensor lift cylinder piston
side right (B7226-2).
Row 6 shows the recalculated signal from Sensor lift cylinder rod side
right (B7226-4).

Row 2 shows the permitted load at current load position.
Row 3 shows the measured load at current load positions.
Row 4 shows calculated axle weight on the steering axle at current load
position.
Row 5 shows calculated axle weight on the drive axle at current load
position.
Row 6 shows distance from the drive axle's centre point to the load's
centre point.

Row 2 shows the machine's total height.
Row 3 shows the height from the ground to the attachment's mounting
in the boom.
Row 4 shows the height from the ground to the lower edge of the
attachment.
Row 5 shows distance from the front wheel's front edge to the load's
centre point.
Row 6 shows distance from the drive axle's centre point to the load's
centre point.

Row 1 shows fire warning from external fire extinguishing system.

Row 2 shows input signal from Control unit fire extinguishing system
(A9160).
0 = not active.
1 = active.
Row 3 shows output signal for fire warning in the machine.
It is possible to manually activate the warning for fire in row 3, Function
output Fire detected. See Navigation of menus, description, page
0 = not active.
1 = active.
Row 1 shows status for speed limitation for the engine at cold start.
0 = not active.
1 = active.
Row 2 shows the engine speed to which the engine is limited based on
the current coolant temperature.
the current transmission oil temperature.
the current hydraulic oil temperature.
Row 5 shows the maximum permissible engine speed for the current
temperatures.
Row 1 shows speed limitation depending on load position.

Row 2 shows how much the vertical position of the load limits the
speed in the current zone.
Row 3 shows how much the longitudinal position of the load limits the
speed in the current zone.
Row 4 shows the limitation zone used to limit machine speed.
Row 5 shows the maximum permissible speed for the current load
position.
Row 1 shows error code for printer for load receipt.

0 = No error.
1 = Incorrect length of printout message.
2 = No response from the printer within valid time interval.
3 = No printer connected.
4= Not used.
5 = Paper out.
6 = Incorrect format.
7 = Cover lid open

Row 1 describes the indicator light to indicate that the load is within the
scales range for load receipt.
Row 2 shows status for the output (Indicator light option boom nose
(H5004)).
0 = Not activated.
1 = activated (load within scales range for load receipt).
Row 1 describes speed limitation depending on drive axle load.

Row 2 shows maximum permitted load for speed limit 1 in kg.
Row 3 shows maximum permitted load for speed limit 2 in kg.
Row 4 shows setting for speed limit 1 in km/h.
Row 5 shows setting for speed limit 2 in km/h.
Row 6 shows current speed limit for the machine (the speed can be
limited by other functions in the machine).
Row 1 describes External Scale System (ESS).

Row 2 shows the weight of the previous lifting container.
Row 3 shows the number of lifts.
Row 4 shows the weight of the current lifting container.
Row 5 shows the accumulated weight.

Row 2 shows the weight of the previous lifting container.
Row 3 shows the number of lifts.
Row 4 shows the weight of the current lifting container.
Row 5 shows the weight on pin 0.
Row 6 shows the weight on pin 1.

8 Control system – Frame, body, cab and accessories 8:107

Row 2 shows the weight displacement too far to the left.
Row 3 shows the weight displacement too far to the right.
Row 4 shows the current eccentricity.
Row 5 shows the eccentricity limit.
8.4.9 Frame, body, cab and accessories

instruments
Row 1 shows the signal from the bypass switch (S1005).
0 = Not activated.
1 = Activated.
Row 2 shows bypass active.
It is possible to manually set bypass active on row 2, Override active.
0 = Not activated.
1 = activated, bypassed.

Row 1 describes the switch to adjust the steering panel.
Row 2 shows the input for the steering panel up adjustment switch
(S1058-1).
Row 3 shows the input for the steering panel down adjustment switch
(S1058-2).

8:108 8 Control system – Frame, body, cab and accessories

Row 1 describes the adjustment of the steering panel.
Row 2 shows the steering motor output, steering panel up/down
(M6943).
0 = not active.
1 = active.
Row 3 shows the direction H-bridge.
It is possible to manually set the H-bridge direction on row 3, H-bridge
direction. See Navigation of menus, description, page 8:4 for an
0 = down.
1 = up.
Row 6 shows the feedback signal for steering panel position.

Row 1 describes the adjustment forward/back of the right arm rest.
Row 2 shows the input for right arm rest forward adjustment switch
(S1056-1).
0 = Not activated.
1 = Activated.
Row 3 shows the input for right arm rest back adjustment switch
(S1056-2).
0 =not activated.
1 = Activated.

Row 1 describes the adjustment forward/back of the right arm rest.
Row 2 shows the output for the control motor steering panel forwards/
back (M6941).
0 = not active.
1 = active.
0 = back.
1 = forward.
Row 6 shows the feedback signal for the arm rest length position.


Row 1 describes the height adjustment of the right arm rest.
Row 2 shows the input for right arm rest up adjustment switch (S1057-
1).
Row 3 shows the input for right arm rest down adjustment switch
(S1057-2).

Row 1 describes the height adjustment of the right arm rest.
Row 2 shows the steering motor output, panel up/down (M6942).
0 = not active.
1 = active.
0 = downward.
1 = upward.
Row 6 shows the feedback signal for the arm rest height position.
Row 1 describes key lock for the bypass function.

Row 2 shows the signal from the bypass key switch (S1005-2).
0 = not active.
1 = active.

8.4.9.3 Diagnostic menus Driver's seat

9.3 Seat 1/XX DIAGNOSE
Row 1 shows the input for seatbelt contact (B2250).
0 = seatbelt not fastened.
1 = seatbelt fastened.
Row 2 shows the input for driver in seat contact (B2300).
0 = no driver in seat.
1 = driver in seat.
Row 3 shows an indication that the seatbelt is not fastened.
0 = seatbelt fastened.
1 = seatbelt not fastened.
8.4.9.4 Diagnostic menus Air conditioning unit

9.4 Climate System 1/XX DIAGNOSE
Row 1 describes the air conditioning control panel.
Row 2 shows the input for the defroster switch (S1390).
0 = not active.
1 = active.
Row 3 shows the input for the recirculation switch (S1910).
0 = not active.
1 = active.
Row 4 shows the input for the residual heat switch (S1019).
0 = not active.
1 = active.
Row 5 shows the input for the auto air conditioning switch (S1054).
0 = not active.
1 = active.

Row 2 shows the input for the increase fan speed switch (S1180-1).
0 = not active.
1 = increases fan speed.
Row 3 shows the input for the decrease fan speed switch (S1180-2).
0 = not active.
1 = reduce fan speed.
Row 4 shows the input for the increase temperature switch (S1052-1).
0 = not active.
1 = increases temperature.
Row 5 shows the input for the decrease temperature switch (S1052-2).
0 = not active.
1 = lower temperature.


Row 2 shows the input for the roof air distribution switch (S1053-1).
0 = not active.
1 = active.
Row 3 shows the input for the central air distribution switch (S1053-2).
0 = not active.
1 = active.
Row 4 shows the input for the floor air distribution switch (S1053-3).
0 = not active.
1 = active.
Row 5 shows the input for the air conditioning switch (S1120).
0 = not active.
1 = active.

Row 1 describes the temperature sensor.
Row 2 shows input Sensor, ambient temperature (B7740).
Row 3 shows input Sensor, deicing temperature (B7753).
Row 4 shows the input for Sensor, fan temperature (B7752).
Row 5 shows input Sensor, inside temperature (B7751).

Row 1 describes the temperature sensor.
Row 2 shows recalculated signal from Sensor, ambient temperature
(B7740).
Row 3 shows recalculated signal from Sensor, deicing temperature
(B7753).
Row 4 shows recalculated signal from Sensor, fan temperature
(B7752).
Row 5 shows recalculated signal from Sensor, inside temperature
(B7751).


Row 1 describes sensors.
Row 2 shows status for signal from Pressure switch refrigerant (B2460)
within normal interval.
0 = not within the interval.
1 = within the interval.
Row 3 shows status for high-pressure signal from Pressure switch re-
frigerant (B2460).
0 = low AC pressure, which results in low fan speed.
1 = AC pressure > 16 bar, which results in max. fan speed.
Row 4 shows air filter contact input (B2190).
0 = no signal.
1 = signal, which may indicate a clogged filter.

Row 1 describes temperature control.
Row 2 shows the requested temperature.
Row 3 shows the true temperature from the inside temperature sensor
(B7751).
Row 4 shows the feedback signal for position from Water valve
(Y6730).
Row 5 shows recalculated value for position of Water valve (Y6730).

Row 1 describes air distribution control.
Row 2 shows the requested air distribution position 0–6
0= Auto position.
1= Windscreen.
2= Windscreen-Panel.
3= Panel.
4= Panel-Floor.
5= Floor.
6= Floor-Windscreen.
Row 3 shows the true air distribution position.
0= Auto position.
1= Windscreen.
2= Windscreen-Panel.
3= Panel.
4= Panel-Floor.
5= Floor.
6= Floor-Windscreen.
Row 4 shows the feedback signal for position on Damper motor, air dis-
tribution (Y6720).


Row 1 describes signals relating to fan motor (M6570) in the cab.

Row 1 describes Actuator motor, recirculation (Y6120).
It is possible to manually set the output signal on row 2, Requested out-
put (0=recirculate). See Navigation of menus, description, page
0 = Recirculated air.
1 = Fresh air.

Row 1 describes Actuator motor, recirculation (Y6120).

Row 1 describes Magnetic clutch, AC compressor (Y6450).
It is possible to manually set the signal on row 2, Requested output.
0 = Not activated.
1 = Activated.


Row 1 describes opening of Water valve (Y6730).

Row 1 describes closing of Water valve (Y6730).

Row 1 describes opening the Damper motor, air distribution (Y6720).

Row 1 describes closing the Damper motor, air distribution (Y6720).


Row 1 shows the signal from the residual heat switch (S1019).
Row 2 shows whether the function is activated.
It is possible to manually activate the function on row 2, Function Acti-
vated. See Navigation of menus, description, page 8:4 for an ex-
0 = Not activated.
1 = Activated.
Row 1 shows the signals from the external heater unit for the cab and
engine heater (E6690).
Row 2 shows whether the function is activated
It is possible to manually activate the function on row 2, Function Acti-
vated. See Navigation of menus, description, page 8:4 for an ex-
0 = Not activated.
1 = Activated.
Row 1 describes the heating system circulation pump (M6670).

0 = Not activated.
1 = Activated.

8.4.9.5 Diagnostic menus Windscreen wipers

9.5 Wiper Washer Sys 1/XX DIAGNOSE
Row 1 describes the switch for continuous wiper.
Row 2 shows the input for the continuous front windscreen wiper switch
(S1190-FR).
Row 3 shows the input for the continuous roof windscreen wiper switch
(S1190-UP).
Row 4 describes the switch for the interval wiper.
Row 5 shows the input for the front intermittent wiper switch (S1520-
FR).
Row 6 shows the switch for the roof intermittent wiper switch (S1520-
UP).
For all row it applies:
0 = no signal.
1 = switch activated.
9.5 Wiper & Washer Sys 2/XX DIAGNOSE

Row 1 describes the combined Wiper motor, front/roof (M6503).
Row 2 shows status for the output to Wiper motor front/roof (M6503).
It is possible to manually activate the output on row 1, Output M6503
0 = no signal.
1 = signal active.
Row 5 describes the feedback signal from Wiper motor front/roof
(M6503).
Row 6 shows the feedback signal from Wiper motor front/roof (M6503).
0 = no signal.
1 = signal active.

Row 1 describes the combined windscreen washer front/roof.
Row 2 shows the input for the windscreen washer switch (S1200).
0 = no signal.
1 = signal, switch activated.
Row 3 shows the status for the output washer motor front/roof (M6513).
It is possible to manually activate the signal on row 3, Front roof wash-
er motor out M6513 C2p15 D7901. See Navigation of menus, de-
scription, page 8:4 for an explanation of how the settings are made.
0 = no signal.
1 = signal active.
Row 6 shows status for signal from Contact level, washer fluid (B2991).
0 = no signal.
1 = fluid level OK.


Row 1 describes the rear windscreen wiper switch.
Row 2 shows the input for the continuous rear windscreen wiper switch
(S1190-RE).
0 = no signal.
Row 3 shows the input for the intermittent rear windscreen wiper switch
(S1520-RE).
0 = no signal.

Row 1 describes Wiper motor rear (M6502).
Row 2 shows output Wiper motor rear (M6502).
It is possible to manually activate the signal on row 2, Output M6502
0 = no signal.
1 = signal.
Row 5 describes rear windscreen wiper motor feedback.
Row 6 shows the feedback signal from Wiper motor rear (M6502).
0 = no signal.
1 = signal.

Row 1 describes signals for rear windscreen wiper.
Row 2 shows the input for the washer switch (S1200).
Row 3 shows output Washer motor rear (M6512).
It is possible to manually activate the signal on row 3, Rear washer mo-
tor Out M6512 C2p16 D7901. See Navigation of menus, descrip-
0 = no signal.
1 = signal.
Row 6 shows status for signal from Contact level, washer fluid (B2991).
0 = no signal.
1 = fluid level OK.


Row 1 describes the front windscreen wiper switch.
Row 2 shows the input for the front windscreen wiper switch (S1190-
FR).
0 = no signal.
Row 3 shows the intermittent front windscreen wiper switch input
(S1520-FR).
0 = no signal.
Row 1 describes Wiper motor left front (M6501-LE).

Row 2 shows output Wiper motor left front (M6501-LE).
It is possible to manually activate the signal in Row 2, Output C2p06
D7901. See Navigation of menus, description, page 8:4 for an ex-
planation of how the settings are made.
0 = no signal.
1 = signal.
Row 5 describes feedback Wiper motor left front (M6501-LE).
Row 6 shows feedback signal from Wiper motor left front (M6501-LE).
0 = no signal.
1 = signal.
Row 1 describes Wiper motor right front (M6501-RI).

Row 2 shows output Wiper motor right front (M6501-RI).
It is possible to manually activate the signal in Row 2, Output C2p09
0 = no signal.
1 = signal.
Row 5 describes feedback Wiper motor right front (M6501-RI).
Row 6 shows feedback signal from Wiper motor right front (M6501-RI).
0 = no signal.
1 = signal.


Row 1 describes the front windscreen washer (S1200).
Row 2 shows the input for the washer switch.
Row 3 shows the output of the front windscreen washer motor (M6511).
It is possible to manually activate the signal on row 3, Front washer
motor rel. out K6511 C2p10 D7901. See Navigation of menus,
description, page 8:4 for an explanation of how the settings are
made.
0 = no signal.
1 = signal.
Row 6 shows the washer fluid level sensor input (B2991).
0 = no signal.
1 = fluid level OK.

Row 1 describes signals from the roof windscreen wiper switch.
Row 2 shows the input for the continuous roof windscreen wiper switch
(S1190-UP).
Row 3 shows the input for the intermittent roof windscreen wiper switch
(S1520-UP).

Row 1 describes the roof windscreen wiper motor.
Row 2 shows the output of the roof windscreen wiper motor (M6503).
It is possible to manually activate row 2, Output M6503 C2p19 D7901.
of how the settings are made.
0 = no signal.
1 = signal, motor running.
Row 5 describes feedback from roof windscreen wiper motor (M6503).
Row 6 shows input feedback from roof windscreen wiper motor
(M6503).
0 = no signal.
1 = signal.


Row 1 describes roof washer.
Row 2 shows the roof washer switch input (S1200).
0 = no signal.
Row 3 shows the output of the roof washer motor (M6513).
It is possible to manually activate row 3, Roof washer motor out
M6513 C2p15 D7901. See Navigation of menus, description, page
0 = no signal.
1 = signal.
Row 6 shows the washer fluid level sensor input (B2991).
0 = no signal.
1 = fluid level OK.
8.4.9.6 Diagnostic menus Lighting

9.6 Lighting Sys 1/XX DIAGNOSE
Row 1 shows the headlights switch input (S1000).
Row 2 describes high beam
Row 3 shows the input for Switch, high beam (S1600).
Row 4 shows the input for Switch, high beam on the arm rest for joy-
stick/mini-wheel (S1992).
0 = no signal.
Row 1 describes high beam.

0 = no signal.
1 = high beam lamp should be lit.
Row 3 shows the actual current in the left high beam lamp (E4020-LE).
Row 5 shows the actual current in the right high beam lamp (E4020-RI).


Row 1 describes front lights or low beam .
0 = no signal.
1 = low beam lamp should be lit.
Row 3 shows the true current in the left low beam lamp (E4000-LE).
Row 5 shows the true current in the right low beam lamp (E4000-RI).

Row 1 describes tail lights.
0 = no signal.
1 = tail light lamp should be lit.
Row 3 shows the true current in the tail light lamp (H4120-LE/RI).

Row 1 describes brake lights.
0 = no signal.
1 = brake light lamp should be lit.
Row 3 shows the true current in the brake light lamp (H4110-LE/RI).


Row 1 describes the direction indicators.
Row 2 shows the multi-function lever right direction indicator input
(S1600:R).
Row 3 shows the multi-function lever left direction indicator input
(S1600:L).
Row 4 shows the input for the direction indicator switch (S1470) on the
arm rest right mini-wheel/joystick control (S1470:1)
Row 5 shows the input for the direction indicator switch (S1470) on the
arm rest left mini-wheel/joystick control (S1470:3).
0 = no signal.

Row 1 describes the direction indicators.
Row 2 shows the requested left output signal.
It is possible to manually set the signal on row 2, Requested output
left. See Navigation of menus, description, page 8:4 for an explan-
0 = no signal.
1 = left direction indicator lamp should be lit.
Row 3 shows the true current for the left direction indicator lamp
(H4220-FL/RL).

Row 1 describes the direction indicators
Row 2 shows requested output right.
It is possible to manually set the signal on row 2, Requested output
right. See Navigation of menus, description, page 8:4 for an ex-
0 = no signal.
1 = right direction indicator lamp should be lit.
Row 3 shows the true current for the right direction indicator lamp
(H4220-FR/RR).

Row 1 describes position lights.
Row 2 shows requested output signal for position lights.
0 = no signal.
1 = position light lamp should be lit.
Row 3 shows actual current in the position light lamp.


Row 1 shows signals for rear work light switch (S1032).
It is possible to set the signal on row 1, Requested output. See Naviga-
tings are made.
0 = no signal.
1 = rear work light lamp should be lit.
Row 3 shows true current for left rear work light lamp (E4050-LE).
Row 5 shows true current for right rear work light lamp (E4050-RI).

Row 1 shows signals for cab work light switch (S1050-1).
It is possible to set the signal on row 1, Requested output. See Naviga-
tings are made.
0 = no signal.
1 = work light lamp should be lit.
Row 3 shows the true current for left cab work light lamp (E4042-LE).
Row 5 shows the true current for right cab work light lamp (E4042-RI).

Row 1 shows signals for cab work light switch extra S1050-4.
0 = no signal.
1 = cab work light lamp should be lit.
Row 3 shows the true current for cab work light lamp extra (E4042-1).


Row 1 shows signals for cab work light switch extra S1050-4.
0 = no signal.
1 = cab work light lamp should be lit.
Row 3 shows the true current for cab work light lamp (E4042-2).

Row 1 shows signals for mast/boom work light switch (S1050-2).
0 = no signal.
1 = the mast/boom work light lamp should be lit.
Row 3 shows the true current for left mast/boom work light lamp
(E4043-LE).
Row 5 shows the true current for right mast/boom work light lamp
(E4043-RI).

Row 1 shows signals for frame work light switch (S1050-4).
0 = no signal
1 = frame work light lamp should be lit
Row 3 shows the true current for frame work light lamp (E4041-1).
Row 5 shows the true current for frame work light lamp (E4041-2).


Row 1 describes cab lighting
Row 2 shows the input for the interior lighting switch (S1160).
Row 3 shows the input for the step lighting switch (S1410).
Row 4 shows the input for the right cab door contact switch (B2660-RI).
Row 5 shows the input for the left cab door contact switch (B2660-LE).
0 = no signal.

Row 1 describes signals for interior lighting lamp (E4340)

Row 1 shows the signals from Switch, work light attachment (S1050-3).
0 = no signal.
1 = working lights attachment illuminated.
Row 3 shows actual current to Working lights on attachment left
(E4044-LE).
Row 5 shows actual current to Working lights on attachment right
(E4044-RI).

0 = no signal.
Row 3 shows actual current to Working lights on attachment left
(E4044-LF).
Row 5 shows actual current to Working lights on attachment right
(E4044-RF).
0 = no signal.
Row 3 shows actual current to Work lights on lift leg left rear (E4045-
LR).
Row 5 shows actual current to Work lights on lift leg right rear (E4045-
RR).

0 = no signal.
Row 3 shows actual current to Work lights on lift leg left front (E4045-
LF).
Row 5 shows actual current to Work lights on lift leg right front (E4045-
RF).
8.4.9.7 Diagnostic menus Signal system

9.7 Signalling Sys 1/XX DIAGNOSE
Row 1 describes the horn.
Row 2 shows the multi-function lever horn (S1600:31b).
0 = no signal.
Row 3 shows the input for the right panel horn switch (S8500-2).
0 = no signal.
Row 4 shows the horn output (H8500).
It is possible to manually set the signal on row 4, Output M8500 C2p12
0 = no signal.
1 = horn sounds.

Row 1 describes the revolving beacon cab and boom.
Row 2 shows the input for Switch, revolving beacon (S1100).
0 = no signal.
Row 3 shows the output for Revolving beacon (H4282).
It is possible to manually set the signal on row 3, Output H4282 C2p13.
0 = no signal.
1 = revolving beacon switched on.

Row 1 describes the revolving beacon on the frame.

Row 2 shows the input for the revolving beacon switch (S1100).
0 = no signal.
It is possible to set the signal on row 3, Output H4281 C1p45 D7971.
0 = no signal.
1 = revolving beacon frame switched on.
Row 1 describes the revolving beacon on the attachment.

Row 2 shows the input for Switch, revolving beacon.
0 = no signal.
0 = no signal.
1 = warning beacon attachment illuminates.

Row 1 describes the reversing alarm.
Row 2 shows the request for reversing (H9650).
0 = no signal.
1 = reversing.
Row 3 shows the reversing alarm output (H9650).
0 = no signal.
1 = reversing alarm.


Row 1 describes hazard warning lights.
Row 2 shows the input for the hazard warning lights switch (S1090).
0 = no signal.
Row 3 shows requested output.
It is possible to set the signal on row 3, Output request. See Navigation
of menus, description, page 8:4 for an explanation how settings
are made.
0 = no signal.
1 = hazard flashers flash.
8.4.9.9 Diagnostic menus, Glass/windows/mirrors

9.9 Glass Wind Mirr 1/XX DIAGNOSE
Row 1 describes the heating of mirrors.

Row 1 shows the input from electrically heated rear view mirror/screen
switch (S1046).
0 = no signal.
Rows 2 shows the electrically heated rear view mirror/screen output
(E8020).
It is possible to manually set the signal on row 2, Output E8020 C2p22
0 = no signal.
1 = heating of the rear view mirror/screen.
9.9 Glass Wind Mirr 2/XX DIAGNOSE
Row 1 describes the heating of rear screen.

Row 2 shows the input from electrically heated rear screen switch
(S1046).
0 = no signal.
Row 3 show the output for the electrically heated screen relay (K8881).
It is possible to set the signal on row 3, Output K8881 C2p06 D7901.
0 = no signal.
1 = electrically heated screen.

8.4.9.10 Diagnostic menus Structure and

suspension of cab
9.10 Cab suspension 1/XX DIAGNOSE
Row 1 describes the switch.

Row 2 shows the signal from Switch cab (S1751) forward.
0 = Not activated.
1 = Activated.
Row 3 shows the signal from Switch cab (S1751) backward.
0 = Not activated.
1 = Activated.
Row 4 shows the signal from Sensor damping end position (B7248).
0 = Not activated.
1 = Activated.
Row 5 shows voltage signal from Sensor cab position (B7254).
Row 6 shows cab position measured from rearmost position.
Row 1 shows output to Solenoid valve cab forward/up (Y6016). Output

actual current in % of max. current that is set in Initiation, see 9.10 Cab
Suspension 2/XX INITIATE, page 8:239.
Row 1 shows output to Solenoid valve backward/down (Y6017). Output

actual current in % of max. current that is set in Initiation, see 9.10 Cab
Suspension 5/XX INITIATE, page 8:240.

Row 1 describes the switch.

Row 2 shows the signal from Switch cab (S1750) upward.
0 = Not activated.
1 = Activated.
Row 3 shows the signal from Switch cab (S1750) downward.
0 = Not activated.
1 = Activated.
Row 4 shows voltage signal from Sensor cab position (B7254).
Row 5 shows cab position measured from lowest position.
Row 6 shows status for the cab's position.
0 = Cab not in lowest position.
1 = Cab in lowest position.
Row 1 shows output to Solenoid valve cab up (Y6016). Output actual

current in % of max. current that is set in Initiation, see 9.10 Cab Sus-
pension 9/XX INITIATE, page 8:241.
Row 1 shows output to Solenoid valve down (Y6017). Output actual

current in % of max. current that is set in Initiation, see 9.10 Cab Sus-
pension 12/XX INITIATE, page 8:242.

Row 1 shows speed limitation during raising the cab which is set from
the factory.
Row 2 shows the set speed limit.
Row 3 shows actual machine speed.
8.4.9.14 Diagnostic menus Central lubrication

9.14 Central Lubr 1/XX DIAGNOSE
Row 1 describes central lubrication frame.

Row 2 shows remaining pause time (time until next lubrication cycle).
Row 3 shows the feedback signal from Sensor, central lubrication
(B7242).
0 = not active.
1 = active (lubrication system pressurised).
Row 4 shows the number of performed lubrication cycles.
Row 5 shows the timeout status.
0 = OK.
1 = timeout, central lubrication interrupted.
Row 1 describes central lubrication frame.

Row 2 shows the status for Lubrication motor (M6930).
It is possible to manually start the motor on row 2, Motor on/off M6930
0 = off.
1 = on.
(B7242).
0 = not active.

8 Control system – Common hydraulics 8:133
Row 1 describes central lubrication attachment.

Row 2 shows remaining pause time (time until next lubrication cycle).
(B7242).
0 = not active.
Row 4 shows the number of performed lubrication cycles.
Row 5 shows the timeout status.
0 = OK.
1 = timeout, central lubrication interrupted.
Row 1 describes central lubrication attachment.

Row 2 shows the status for Lubrication motor (M6930).
It is possible to manually start the motor in Row 2, Motor on/off M6930
0 = off.
1 = on.
(B7242).
0 = not active.
8.4.10 Common hydraulics

8.4.10.4 Diagnostic menus Pumps
10.4 Pumps 1/XX DIAGNOSE
Row 1 describes activation of hydraulic pressure to attachment.
Row 2 shows status for Solenoid valve engagement of hydraulic pres-
sure to top lift (Y6003).
quested output Y6003 C1p15 D7971 KFU. See Navigation of me-
nus, description, page 8:4 for an explanation of how the settings
are made.
0 = off.
1 = on (attachment pressurised).

8:134 8 Control system – Common hydraulics

Row 1 describes disengagement of hydraulic pump 2 at boom in.
Row 2 shows status for Solenoid valve pump unloading (Y6003).
0 = off.
1 = on (hydraulic oil pump 2 disengaged).

Row 1 shows output to Servo valve, load signal attachment (Y6002).
10.4 Pumps 11/XX INITIATE, page 8:245.
Row 1 shows the signal from Sensor, servo pressure attachment

(B7688).
Row 2 shows servo pressure attachment.
Row 3 shows the present control current to Servo valve, load signal at-
tachment (Y6002).

Row 1 describes signals regarding genset pump.
Row 2 shows the output for Control unit KFU (D7971).
It is possible to manually set the signal for genset pump in Row 2, Out-
put C1p44 D7971 KFU. See Navigation of menus, description,
page 8:4 for an explanation of how the settings are made.
0 = Not activated
1 = Activated

8 Control system – Common electrics 8:135
8.4.10.6 Diagnostic menus, temperature control,

cleaning and hydraulic oil
Row 1 shows the input for hydraulic oil temperature sensor (B7760).
Row 2 shows the hydraulic oil temperature.
Row 4 shows the requested gear limitation.

Row 1 shows signals relating to hydraulic oil cooling fan (M6680).
0 = no signal.
1 = signal.
8.4.11 Common electrics

instruments
Row 1 describes signals relating to driving forward.
Row 2 shows the output for Control unit KCU (D7901).
It is possible to manually set the signal on row 2 Output C2p31 D7901
KCU. See Navigation of menus, description, page 8:4 for an ex-
0 = no signal.
1 = driving forward.

8:136 8 Control system – Common electrics

Row 1 describes signals relating to driving backward.
Row 2 shows the output for Control unit KCU (D7901).
It is possible to manually set the signal on row 2 Output C2p32 D7901
KCU. See Navigation of menus, description, page 8:4 for an ex-
0 = no signal.
1 = driving backward.

Row 1 describes signals relating to driving forward.
Row 2 shows the output for Control unit KFU (D7971).
It is possible to manually set the signal on row 2, Output C1p22 D7971
KFU. See Navigation of menus, description, page 8:4 for an ex-
0 = no signal.
1 = driving forward.

Row 1 describes signals relating to driving backward.
Row 2 shows the signal from Control unit KFU (D7971).
It is possible to manually set the signal on row 2, Output C1p23 D7971
KFU. See Navigation of menus, description, page 8:4 for an ex-
0 = no signal.
1 = driving backward.
8.4.11.4 Diagnostic menus Alternator

11.4 Alternator 1/XX DIAGNOSE
Row 1 shows status for alternator charging voltage (D+).
0 = not charging.
1 = charging.
Row 2 shows the battery voltage.

8.4.11.5 Diagnostic menus Distribution of electricity

11.5 Distr of Electr 1/XX DIAGNOSE
Row 1 describes the voltage feed to and from Control unit KCU
(D7901).
Row 2 shows the battery voltage input (F9968-RD:2).
Row 3 shows the ignition current input.
Row 4 shows the input for the ignition key lock switch (S1500).
0 = no signal.
Row 5 shows the output for voltage feed to sensors and transducers.

Row 1 describes redundant voltage feed (CPU Power) from Control
unit KCU (D7901).
Row 2 shows output redundant voltage feed (CPU Power).
It is possible to manually set the signal for redundant voltage feed (CPU
Power) on row 2, CPU power supply system output C2p35. See
how the settings are made.
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed from Control unit KCU (D7901).
Row 2 shows output for 24 V sensor and voltage feed to controls for
mini-wheel/joystick control, pressure switch cab filter, pressure switch
refrigerant, level switch washer fluid, feedback wiper motors.
It is possible to manually set the signal on row 2, 24V sensor power
supply cabin, output C2p05. See Navigation of menus, descrip-
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed to and from Control unit KFU
(D7971).
Row 2 shows input redundant voltage feed (CPU Power).
Row 3 shows input voltage feed ignition voltage (voltage bolt).
Row 4 shows output for 5 V voltage feed to sensors.


Row 1 describes the voltage feed from Control unit KFU (D7971).
Row 2 shows output for 24 V sensor voltage feed to sensors for central
lubrication and electric heater.
It is possible to manually set Row 2, 24V sensor power supply, output
C2p32. See Navigation of menus, description, page 8:4 for an ex-
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed from Control unit KFU (D7971).
Row 2 shows output for 24 V voltage feed to sensors and switches
mast/boom.
It is possible to manually set on row 2, 24V sensor power supply
mast/boom, output C2p33. See Navigation of menus, description,
0 = no signal.
1 = voltage feed.

Row 1 and 2 describe safe voltage feed (Control breaker voltage)
group 1/1 in Control unit KFU (D7971), output C1p27-29, C1p33.
0 = no signal.
1 = voltage feed.
Row 4 shows PWM ready.
Row 5 shows voltage on output C1p27-29, 33.

group 1/2 in Control unit KFU (D7971), output C1p34-37.
0 = no signal.
1 = voltage feed.
Row 5 shows voltage on output C1p34-37.


0 = no signal.
1 = voltage feed.

Rows 1 and 2 describe safe voltage feed (Control breaker voltage)
group 1/4 in Control unit KFU (D7971), output C1p47-48, C2p50.
0 = no signal.
1 = voltage feed.
Row 5 shows voltage on output C1p47-48, C2p50.

group 1/5 in Control unit KFU (D7971), output C2p35, C2p37.
0 = no signal.
1 = voltage feed.
Row 5 shows voltage on output C2p35, 37.

0 = no signal.
1 = voltage feed.
Row 4 shows Digout ready.


group 2/2 in Control unit KFU (D7971), output C1p01, C1p43, C2p01–
02.
0 = no signal.
1 = voltage feed.

group 2/3 in Control unit KFU (D7971), output C1p11, C1p44, C2p03-
04.
0 = no signal.
1 = voltage feed.

group 2/4 in Control unit KFU (D7971), output C1p12, C1p45, C1p49,
C2p05.
0 = no signal.
1 = voltage feed.

group 2/5 in Control unit KFU (D7971), output C1p13-15, C1p21-22,
C2p06, C2p27.
0 = no signal.
1 = voltage feed.


group 2/6 in Control unit KFU (D7971), output C1p17-18, C2p36,
C2p38.
0 = no signal.
1 = voltage feed.

group 2/7 in Control unit KFU (D7971), output C1p23-24, C2p22,
C2p34.
0 = no signal.
1 = voltage feed.

group 2/8 in Control unit KFU (D7971), output C1p16, C1p19-20,
C1p26, C1p42, C1p46, C2p26, C2p32-33.
0 = no signal.
1 = voltage feed.

Row 1 describes safe voltage feed (Control breaker voltage) ground 1
in Control unit KFU (D7971), output C1p10.
It is possible to manually set the voltage feed in Row 2, Requested out-
0 = not grounding.
1 = grounding.


in Control unit KFU (D7971), output C1p30.
It is possible to manually set the voltage feed in Row 2, Requested out-
0 = not grounding.
1 = grounding.

Row 1 describes the voltage feed to Control unit KFU-2 (D7972).
Row 3 shows input voltage feed ignition voltage.
Row 4 shows the output for voltage feed to sensors.

Row 1 describes the voltage feed from Control unit KFU-2 (D7972).
Row 2 shows output for 24 V voltage feed to sensors and switches.
It is possible to manually set the 24V sensor power supply TDS etc.
output C2p32. See Navigation of menus, description, page 8:4 for
0 = no signal.
1 = voltage feed.

It is possible to manually set the signal on row 2, 24V sensor power
supply Output C2p33. See Navigation of menus, description,
0 = no signal.
1 = voltage feed.


supply Output C2p22 Attachment, support jacks, etc.. See
0 = no signal.
1 = voltage feed.

group 1/1 in Control unit KFU-2 (D7972), output C1p27-29, C1p33.
0 = no signal.
1 = voltage feed.

group 1/2 in Control unit KFU-2 (D7972), output C1p34-37.
0 = no signal.
1 = voltage feed.

0 = no signal.
1 = voltage feed.


group 1/4 in Control unit KFU-2 (D7972), output C1p47-48, C1p50.
0 = no signal.
1 = voltage feed.

group 1/5 in Control unit KFU-2 (D7972), output C1p35, C1p37.
0 = no signal.
1 = voltage feed.
Row 5 shows voltage on output C2p35, 37.

0 = no signal.
1 = voltage feed.

group 2/2 in Control unit KFU-2 (D7972), output C1p01, C1p43,
C2p01–02.
0 = no signal.
1 = voltage feed.


group 2/3 in Control unit KFU-2 (D7972) output C1p11, C1p44, C2p03-
04.
0 = no signal.
1 = voltage feed.

group 2/4 in Control unit KFU-2 (D7972), output C1p12, C1p45, C1p49,
C2p05.
0 = no signal.
1 = voltage feed.

group 2/5 in Control unit KFU-2 (D7972), output C1p13-15, C1p21-22,
C2p06, C2p27.
It is possible to manually set the signal in Row 3, Requested output.
0 = no signal.
1 = voltage feed.

group 2/6 in Control unit KFU-2 (D7972), output C1p17-18, C2p36,
C2p38.
0 = no signal.
1 = voltage feed.


group 2/7 in Control unit KFU-2 (D7972), output C1p23-24, C2p22,
C2p34.
0 = no signal.
1 = voltage feed.

group 2/8 in Control unit KFU-2 (D7972), output C1p16, C1p19–20,
C1p26, C1p42, C1p46, C2p26, C2p32–33.
0 = no signal.
1 = voltage feed.

in Control unit KFU-2 (D7972), output C1p10.
0 = not grounding.
1 = grounding.

in Control unit KFU-2 (D7972), output C1p30.
0 = not grounding.
1 = grounding.


Row 1 describes the voltage feed to Control unit KAU-2 (D7912).
Row 4 shows output for 5V voltage feed to sensors.

Row 1 describes the voltage feed to Control unit KAU-2 (D7912).
supply output C2p32. See Navigation of menus, description,
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed from Control unit KAU-2 (D7912).
supply output C2p33. See Navigation of menus, description,
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed from Control unit KAU-2 (D7912).
It is possible to manually set the signal on row 2, 24V external attach-
ment Output C2p34. See Navigation of menus, description, page
0 = no signal.
1 = voltage feed.


group 1/1 in Control unit KAU-2 (D7912), output C1p27-29, C1p33.
0 = no signal.
1 = voltage feed.

group 1/2 in Control unit KAU-2 (D7912), output C1p34-37.
0 = no signal.
1 = voltage feed.

0 = no signal.
1 = voltage feed.

group 1/4 in Control unit KAU-2 (D7912), output C1p47-48, C1p50.
0 = no signal.
1 = voltage feed.


group 1/5 in Control unit KAU-2 (D7912), output C2p35, C2p37.
0 = no signal.
1 = voltage feed.
Row 5 shows voltage on output C2p35, C2p37.

0 = no signal.
1 = voltage feed.

group 2/2 in Control unit KAU-2 (D7912), output C1p01, C1p43,
C2p01-02.
0 = no signal.
1 = voltage feed.

group 2/3 in Control unit KAU-2 (D7912), output C1p11, C1p44,
C2p03-04.
0 = no signal.
1 = voltage feed.


group 2/4 in Control unit KAU-2 (D7912), output C1p12, C1p45, C1p49,
C2p05.
0 = no signal.
1 = voltage feed.

group 2/5 in Control unit KAU-2 (D7912), output C1p13-15, C1p21-22,
C2p06, C2p27.
0 = no signal.
1 = voltage feed.

group 2/6 in Control unit KAU-2 (D7912), output C1p17-18, C2p36,
C2p38.
0 = no signal.
1 = voltage feed.

group 2/7 in Control unit KAU-2 (D7912), output C1p23-24, C2p22,
C2p34.
0 = no signal.
1 = voltage feed.


group 2/8 in Control unit KAU-2 (D7912), output C1p16, C1p19-20,
C1p26, C1p42, C1p46, C2p26, C2p32-33.
0 = no signal.
1 = voltage feed.

in Control unit KAU-2 (D7912), output C1p10.
0 = not grounding.
1 = grounding.

in Control unit KAU-2 (D7912), output C1p30.
0 = not grounding.
1 = grounding.

Row 1 describes the voltage feed to and from Control unit KAU
(D7911).
Row 4 shows output for 5 V voltage feed to sensors.


Row 1 describes the voltage feed from Control unit KAU (D7911).
Row 2 shows output for 24 V sensor voltage feed to sensors and
switches.
left C2p32. See Navigation of menus, description, page 8:4 for an
explanation of how the settings are made.
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed from Control unit KAU (D7911).
Row 2 shows output for 24 V sensor voltage feed to sensors and
switches.
right C2p33. See Navigation of menus, description, page 8:4 for
0 = no signal.
1 = voltage feed.

Row 1 describes voltage feed from Control unit KAU (D7911) to extra
lifting tool.
It is possible to manually set the signal on row 2, 24V external attach-
ment Output C2p34. See Navigation of menus, description, page
0 = No signal.
1 = Voltage feed.

Row 1 describes voltage feed from Control unit KAU (D7911) to extra
lifting tool.
It is possible to manually set the signal in Row 2, 24V external attach-
ment Output C2p37 15A. See Navigation of menus, description,
0 = No signal.
1 = Voltage feed.


group 1/1 in Control unit KAU (D7911), output C1p27-29, C1p33.
0 = no signal.
1 = voltage feed.

group 1/2 in Control unit KAU (D7911), output C1p34-37.
0 = no signal.
1 = voltage feed.

0 = no signal.
1 = voltage feed.

group 1/4 in Control unit KAU (D7911), output C1p47-48, C1p50.
0 = no signal.
1 = voltage feed.


group 1/5 in Control unit KAU (D7911), output C2p35, C2p37.
0 = no signal.
1 = voltage feed.
Row 5 shows voltage on output C2p35, C2p37

0 = no signal.
1 = voltage feed.

group 2/2 in Control unit KAU (D7911), output C1p01, C1p43, C2p01-
02.
0 = no signal.
1 = voltage feed.

group 2/3 in Control unit KAU (D7911), output C1p11, C1p44, C2p03-
04.
0 = no signal.
1 = voltage feed.


group 2/4 in Control unit KAU (D7911), output C1p12, C1p45, C1p49,
C2p05.
0 = no signal.
1 = voltage feed.

group 2/5 in Control unit KAU (D7911), output C1p13-15, C1p21-22,
C2p06, C2p27.
0 = no signal.
1 = voltage feed.

group 2/6 in Control unit KAU (D7911), output C1p17-18, C2p36,
C2p38.
0 = no signal.
1 = voltage feed.

group 2/7 in Control unit KAU (D7911), output C1p23-24, C2p22,
C2p34.
0 = no signal.
1 = voltage feed.


group 2/8 in Control unit KAU (D7911), output C1p16, C1p19-20,
C1p26, C1p42, C1p46, C2p26, C2p32-33.
0 = no signal.
1 = voltage feed.

in Control unit KAU (D7911), output C1p10.
0 = not grounding.
1 = grounding.

in Control unit KAU (D7911), output C1p30.
0 = not grounding.
1 = grounding.

Row 1 describes the voltage feed to Control unit KPU (D7902).


Row 1 describes the voltage feed from Control unit KPU (D7902).
Row 2 shows output for 5 V voltage feed to analogue controls and feed-
back signals (internally connected to C3p01 and C8p04).
It is possible to manually set the voltage feed to sensors on row 2, 5V
ref. power supply output C2p01 (internally connected to
C3p01 and C8p04). See Navigation of menus, description, page
0 = no signal.
1 = voltage feed.
Row 3 shows the output voltage.

Row 2 shows output for 5 V voltage feed to the steering panel, silicone
panel, right-hand dashboard panel front section (climate controls) and
silicone panel, right-hand dashboard panel rear section (lighting con-
trols), (internally connected to C7p01 and C9p01).
It is possible to manually set the voltage feed to sensors on row 2, 5V
ref. power supply Output C6p01 (internally connected to
C7p01 and C9p01). See Navigation of menus, description, page
0 = no signal.
1 = voltage feed.
Row 3 shows the output voltage.

Row 2 shows output for 24 V sensor voltage feed to Switch, control lev-
er (off/on buttons), output C3p09.
It is possible to manually set the voltage feed on row 2, 24 sensor
power supply (switches, joystick, etc.) Output C3p09. See
0 = no signal.
1 = voltage feed.

Row 2 shows output for 24 V sensor voltage feed to Switch, output
C4p01.
It is possible to manually set the voltage feed on row 2, 24 sensor
power supply Output C4p01. See Navigation of menus, descrip-
0 = no signal.
1 = voltage feed.


Row 2 shows output for 24 V voltage feed to travel direction selector
and parking brake, sensor steering wheel angle and multi-function lev-
er, output C5p01.
It is possible to manually set the voltage feed on Row 2, 24 sensor
power supply (steering column, etc.) Output C5p01. See Navi-
gation of menus, description, page 8:4 for an explanation of how
the settings are made.
0 = no signal.
1 = voltage feed.

Row 2 shows output for 24 V voltage feed to Switch control breaker
(S2500), output C8p01.
It is possible to manually set the voltage feed on Row 2, 24 sensor
power supply Output C8p01. See Navigation of menus, descrip-
0 = no signal.
1 = voltage feed.

Row 1 shows input from Switch control breaker (S2500)
0 = no signal (control breaker depressed).
1 = breaker activated.

Row 1 describes the voltage feed to Control unit KID (D7950).


Row 1 describes the voltage feed to KEM (A7991).
Row 2 shows input voltage feed.
Row 3 shows Address Voltage. It identifies KEM on the CAN bus. Must
be a value > 4500 mV in order for KEM to work.

Row 1 describes the voltage feed to KEM-2 (A7992).
Row 3 shows Address Voltage. It identifies KEM-2 on the CAN bus.
Must be a value > 4500 mV in order for KEM-2 to work.

Row 1 describes the voltage feed to KEM-3 (A7993).
Row 3 shows Address Voltage. It identifies KEM-3 on the CAN bus.
Must be a value > 4500 mV in order for KEM-3 to work.

8.4.11.6 Diagnostic menus Communication

11.6 Communication 1/XX DIAGNOSE
Row 1 describes the RedCAN system.
Row 2 shows the expected number of nodes.
Row 3 shows the true number of nodes.
Row 4 shows discovered cable errors on the CAN bus.
Row 5 shows the communication mode.
0 = normal.
1 = scanning.
2 = RedCAN locked.
3 = Program downloading.
Row 6 shows scanning of the RedCAN system.
It is possible to manually activate scanning on row 5, Scan RedCAN
system. See Navigation of menus, description, page 8:4 for an ex-
0 = no scanning.
1 = scanning.

Row 1 describes the expected RedCAN system.
Row 2 shows the 1st node number.
Row 3 shows the 2nd node number.
Row 4 shows the 3rd node number.
Row 5 shows the 4th node number.
The 1st node number is the first node in the loop, the 2nd node number
is the second node in the loop, etc. For a description of node number-
ing, see 11.6.2 Redundant CAN bus, page 11:50.

Row 1 describes the expected RedCAN system.
The 6th node number is the sixth node in the loop, the 7th node number
is the seventh node in the loop, etc. For a description of node number-
ing, see 11.6.2 Redundant CAN bus, page 11:50.


Row 1 describes which nodes actually communicate in the RedCAN
system.
Row 2 shows the 1st node number.
Row 3 shows the 2nd node number.
For a description of node numbering, see 11.6.2 Redundant CAN bus,
page 11:50.

Row 1 describes which nodes actually communicate in the RedCAN
system.
page 11:50.

Row 1 describes the RedCAN system.
Row 2 shows the node number for the node that has detected a cable
error on its normal side.
Row 3 shows the node number for the node that has detected a cable
error on its redundant side.
page 11:50.

Row 1 describes RedCAN nodes, which are not found during start-up
of the CAN bus. For a more detailed explanation, see Redundant CAN
bus, start-up, page 11:52.
Row 2 shows 1st node not found.
Row 3 shows 2nd node not found.
Row 4 shows 3rd node not found.
Row 5 shows 4th node not found.
Row 6 shows 5th node not found.
0 = OK
1= node not found
page 11:50.


Row 1 describes RedCAN, which nodes disappear (unresponsive) after
start-up of the CAN bus. For a more detailed explanation, see Redun-
dant CAN bus, start-up, page 11:52.
Row 2 shows 1st node disappeared.
Row 3 shows 2nd node disappeared.
Row 4 shows 3rd node disappeared.
Row 5 shows 4th node disappeared.
Row 6 shows 5th node disappeared.
0 = OK.
1 = node disappeared.
page 11:50.

Row 1 describes the RedCAN statistics.
Row 2 shows the number of system scans since start-up. Scanning is
performed in the event of problems delivering messages, a high num-
ber of scans may be due to intermittent faults in the cable harness or
faulty termination resistors.
Row 3 shows the last scan time. A short scanning time means that the
CAN bus is working well.
Row 4 shows scanning of the RedCAN system.
It is possible to manually activate scanning on row 4, Scan RedCAN
system. See Navigation of menus, description, page 8:4 for an ex-
0 = no scanning.
1 = scanning in progress.

Row 1 describes status for the communication for CAN bus drive-train.
Row 2 shows status for Control unit engine (D7940-1).
0 = no contact.
Row 3 shows status for Control unit ACM (D7940-2).
0 = no contact.
Row 4 shows status for Control unit transmission (D7930).
0 = no contact.


Row 1 shows identification of operator.
Row 2 shows whether the ID for the operator is supported.
0 = ID not supported.
1 = ID supported.
Row 3 shows ID number.

Row 1 shows signal strength (CSQ). (CSQ is a GSM standard for sig-
nal strength.)
Row 2 shows whether GSM is registered on the GSM network.
0 = not registered.
1 = registered.
Row 3 shows whether OTA, communication with "back-office", is OK.
0 = OTA not OK.
1 = OTA OK.
Row 4 shows whether GPS is OK.
0 = GPS not OK.
1 = GPS OK. Position fixed.
Row 5 shows whether MTU Tx OK is OK.
0 = MTU Tx OK, not OK.
1 = GPS MTU Tx OK, OK.

Telematics unit
Row 1 shows type of unit.
Row 2 shows version.

Telematics unit
Row 1 shows serial number.


Row 1 describes communication on CAN bus drive-train.
Row 2 shows status for Control unit engine (D7940-1).
0 = no contact.
Row 3 shows status for Control unit transmission (D7930).
0 = no contact.

Row 1 describes communication between I/O module KEM-2 (A7992)
and Control unit KAU (D7911).
Row 2 shows the status for the communication.
0 = no contact.

Row 1 describes communication between I/O module KEM-3 (A7993)
and Control unit KAU (D7911).
0 = no contact.

Row 1 describes the communication between External Scale System
(ESS) and Control Unit KCU (D7901).
0 = no contact.


Row 1 shows internal error External Scale System (ESS).
Row 2 shows lost communication with the attachment.
Row 3 shows lost communication pin 0.
0 = no contact.

Row 1 describes the serial number of External Scale System (ESS).
Row 2 shows the serial number of the main unit.
Row 3 shows the serial number of the attachment unit.
Row 4 shows the serial number of pin 0.
Row 5 shows the serial number of pin 1.

Row 1 describes the version of External Scale System (ESS).
Row 2 shows the version of the main unit.
Row 3 shows the version of the attachment unit.
Row 4 shows the version of pin 0.
Row 5 shows the version of pin 1.

Row 1 describes the checksum of External Scale System (ESS).
Row 2 shows the checksum of the main unit.
Row 3 shows the checksum of the attachment unit.
Row 4 shows the checksum of pin 0.
Row 5 shows the checksum of pin 1.

8:166 8 Control system – Pin diagnostics
8.4.13 Pin diagnostics

Pin diagnostics, description
The menus for pin diagnostics have the same structure as other diag-
nostic menus. See Navigation of menus, description, page 8:4 for an
explanation of how to navigate to and through the menus.
The pin diagnostics are used to quickly diagnose all functions in the
control system. Input signal values from e.g. a lever are shown in the
diagnostic menus. A control unit's output signal current to a corre-
sponding valve can be shown and with that it is possible to check
whether the software sends a correct signal to control the valve. It can
be quickly determined whether the problem is on the input or output
side and if the control unit is working properly without connecting to oth-
er instruments.
Outputs and inputs are described with respect to the contact and pin,
for example C2p01, which denotes contact 2, pin 1.
Outputs can also be controlled with the right permissions in the diag-
nostic system. The variable Request can be activated manually.
Example 1:
It is discovered that there is no input signal from the lift lever, but to be
able to move the machine to the workshop the attachment must be
lifted from the ground. In this situation the lifting can be "force operated"
from the display using service code and wiring diagram.
Example 2:
It is established that everything seems to be OK for lifting, and input
and output signals are as they should be. Despite this lifting does not
work. If the "forced operation" function does not work despite stronger
current than normal to the solenoid valve, then the fault probably lies in
the valve or cables.
The following terms are used in pin diagnostic menus.
1
Actual current indicates the true current.
11.7 I/O D7901 KCU 10 XX DIAGNOSE
Digital input indicates digital input.
2 C2p01 digital input 0 Digital output indicates digital output.
C2p01 digital output
4 Direction indicates the direction.
Request 1
5 Duty cycle indicates the pulse length of an analogue PWM output.
3 Actual current 800.0 mA
6 Frequency input indicates the frequency input.
Pin status OK H bridge indicates H-bridge for engine control.
016092
Impedance indicates impedance.

MAN LEAVE
Pin status indicates status for input or output, see Explanation of pin
1. Example Menu group status codes, page 8:29.
2. Signal from digital input, contact 2 pin 1 PWM output indicates pulse width modulated output
3. Signals from digital output, contact 2 pin 1 PVE output indicates PVE output of the Sauer Danfoss type.
4. Request for signal to the digital output Request indicates the ability to manually set the signal value.
5. True current Requested current indicates the requested current.
6. Pin status Requested duty cycle indicates the requested pulse length.
Requested voltage indicates the requested voltage.
Resistance input indicates the resistance measurement input.
Voltage input indicates the voltage input.
11.7 I/O D7901 KCU 1-48/XX DIAGNOSE

Contains diagnostic menu 1-48 for Control unit KCU (D7901).
11.8 I/O D7902 KPU 1–41/XX DIAGNOSE

Contains diagnostic menu 1-41 for Control unit KPU (D7902).

8 Control system – Pin diagnostics 8:167
11.9 I/O D7971 KFU 1–75/XX DIAGNOSE

Contains diagnostic menu 1-75 for Control unit KFU (D7971).
11.10 I/O D7950 KID 1–4/XX DIAGNOSE

Contains diagnostic menu 1-4 for Control unit KID (D7950).
11.11 I/O D7911 KAU 1–75/XX DIAGNOSE

Contains diagnostic menu 1-75 for Control unit KAU (D7911).
11.12 I/O D7912 KAU2 1–75/XX DIAGNOSE

Contains diagnostic menu 1-75 for Control unit KAU-2 (D7912).
11.13 I/O D7972 KFU2 1–75/XX DIAGNOSE

Contains diagnostic menu 1-75 for Control unit KFU-2 (D7972).
11.15 I/O A7991 KEM 1–12/XX DIAGNOSE

Contains diagnostic menu 1–12 for I/O module KEM (A7991).
11.16 I/O A7992 KEM-2 1–12/XX DIAGNOSE

Contains diagnostic menu 1–12 for I/O module KEM-2 (A7992).
11.17 I/O A7993 KEM-3 1–12/XX DIAGNOSE

Contains diagnostic menu 1–12 for I/O module KEM-3 (A7993).

8:168 8 Control system – Setup
8.5 Setup
Initiation, general
Initiation is performed before using the machine for work and means to
set e.g., start and stop currents, deadband, sensitivity, minimum and
maximum values for the control of different functions.
DANGER
The settings influence the functions. Adjustments may
impair the function.
If uncertain, contact Cargotec Service.
NOTE
The machine must be stationary with parking brake applied in order
to enable access to the menus.
After changes have been made, the ignition must be switched off
and then on for the changes to be saved and start to apply.
NOTE
Initiation does not need to be performed in one process but each step
can be performed separately, independently of other steps.
Initiation is available for the following groups:

• Engine, 8.5.1 Engine, page 8:171
8.5.1.1 Initiation menus Controls and instruments engine, page
8:171
8.5.1.2 Initiation menus Fuel system, page 8:172
8.5.1.7 Initiation menus Cooling system engine, page 8:173
8.5.1.9 Initiation menus Control system, engine, page 8:174
8.5.1.11 Initiation menus Start and stop, page 8:176
• Transmission, 8.5.2 Transmission, page 8:177
8.5.2.1 Initiation menus Controls and instruments transmission,
page 8:178
• Brakes, 8.5.4 Brakes, page 8:178
8.5.4.1 Initiation menus Controls and instruments brakes, page
8:178
8.5.4.5 Initiation menus Parking brake system, page 8:179
• Steering, 8.5.5 Steering, page 8:179
8.5.5.2 Initiation menus, Power assisted system, page 8:179
• Suspension, 8.5.6 Suspension, page 8:188
8.5.6.3 Initiation menus Tyres and rims, page 8:188
• Load handling, 8.5.7 Load handling, page 8:189
8.5.7.1 Initiation menus Controls and instruments load handling,
page 8:189
8.5.7.2 Initiation menus Lifting/lowering, page 8:190
8.5.7.3 Initiation menus, Extension, page 8:193
8.5.7.4 Initiation menus, Side shift, page 8:195
8.5.7.5 Initiation menus, Spreading, page 8:197
8.5.7.6 Initiation menus, Rotation, page 8:203
8.5.7.7 Initiation menus, Tilt, page 8:205
8.5.7.8 Initiation menus, Levelling, page 8:207
8.5.7.9 Initiation menus, Load securing, page 8:210
8.5.7.10 Initiation menus, Other functions, page 8:218

8 Control system – Setup 8:169
• Control system, 8.5.8 Control system, page 8:220

8.5.8.1 Initiation menus Controls and instruments, page 8:220
8.5.8.2 Initiation menus, Monitoring, page 8:222
• Frame, body, cab and accessories, 8.5.9 Frame, body, cab and ac-
cessories, page 8:231
8.5.9.4 Initiation menus, Climate system, page 8:233
8.5.9.5 Initiation menus, Windscreen wipers, page 8:233
8.5.9.6 Initiation menus, Lighting, page 8:234
8.5.9.7 Initiation menus, Signal system, page 8:236
8.5.9.9 Initiation menus, Glass/windows/mirrors,, page 8:238
8.5.9.10 Cab frame and suspension, page 8:238
8.5.9.14 Initiation menus, Central lubrication, page 8:245
• Common electrics, 8.5.11 Common electrics, page 8:246
8.5.11.5 Initiation menus, Voltage feed, page 8:246
Initiation, work instructions

Navigation to a menu, work instruction
To navigate to a menu for setup or calibration, do as follows:
NOTE
The machine must be stationary with parking brake applied in or-
der to enable access to the menus.

10:23
CUSTOMER SETTINGS
0
014981
2. Enter service code with or and confirm with .

10:23

0 0
015625
3. Select the function with or and confirm with .

8.CONTROL SYSTEM
015624

8:170 8 Control system – Setup
4. Select group by scrolling with or and confirm with .


8.2 Monitoring
8.3 Error codes
8.4 Diagnostics
8.5 Setup
8.6 Software
015629
5. Select INITIATE with or and confirm with
8.2 Monitoring
8.3 Error codes
8.4 Diagnostics
8.5 Setup
8.6 Software
015735
6. Each menu group consists of a sequence of a number of menus.

The first menu for the selected group opens in the display. Use the
arrow keys or to move to the desired menu.
All signal values in the menu figures are examples and may
differ from the values shown in an actual machine.
7. Use the function key EDIT to select adjustment mode for the
menu (the function for the arrow keys is changed from navigating
between the menus to adjusting values).
8. Set the new value in the upper row using or .
Example of first menu in group NOTE

Current values can only be adjusted within specific limits.
9. Use the function key SAVE to store the set value.

Menu example, description

All menus for initiation and calibration are explained separately.
1 2 3
– The menu group, indicates the group, 1.7 Cooling System, whose
signals need to be initiated.
– Sequence number, 1/XX, enter the page number and total number
8 of menus in the menu loop. As the number of menus is dependent
4
on how the machine is equipped, state the number of menus here
with XX.
– Initiate indicates in the menu example that initiation is the selected
setting function. The other setup function is Calibrate for calibration.
– Variables, such as row 1 Cooling fan start current, describe the
015883
function/component that the signal/measurement comes from.
Each menu can contain 1-6 rows, where each row describes a vari-
7 5 able with an associated signal value.
6
– Signal value, 450.0 mA, is the saved value for Cooling fan start
1. Menu group current.
2. Sequence number All signal values in the menu figures in this manual are exam-
3. Selected setting function ples and may differ from the values in a real machine.
4. Signal values The following icons are used to explain further the signal values:
5. Function key LEAVE/Cancel
denotes a saved value.
6. Arrow keys
denotes a value from an output from a control unit.
7. Function key Manual mode/Edit mode
denotes an input value which is measured by a control unit.
8. Variables
8.5.1 Engine
8.5.1.1 Initiation menus Controls and instruments
engine
1.1 Controls & Instr 1/XX INITIATE
1. Read the explanation of initiation menus before making any
changes, see Initiation, general, page 8:168.
For a description of navigation to this menu, see Navigation to a
menu, work instruction, page 8:169
2. Row 1 shows the setting value of the pedal's deadband when the
pedal is released.
Row 2 shows the stored value of the pedal's deadband when the
pedal is released.
Row 3 shows the true position of the pedal.
3. Set the deadband for the pedal's zero position in Row 1, Throttle
pedal start deadband. Change the value with / and store
the value with Save .

2. Row 1 shows the setting value of the pedal's deadband at full throt-
tle in the setup position.
Row 2 shows the stored value of the pedal's deadband at full throt-
tle position.
Row 3 shows the true position of the pedal.
3. Set the deadband for the pedal's full throttle position in Row 1,
Throttle pedal end deadband. Change the value with / and
store the value with Save .

8.5.1.1 Calibration menus Controls and

instruments engine
Calibration of pedal
Stop the machine on level ground. Apply the parking brake and leave
the ignition turned on.
1.1 Controls & Instr 1/XX CALIBRATE

NOTE
Depress the pedal firmly at least once before starting calibration.
1. Navigate to 1.1 Controls & Instr 1/XX CALIBRATE, menu 1 with

/ .
2. Row 1 shows the pedal's top position.
Row 2 shows the pedal's current value for signal A.
Row 3 shows the pedal's stored value for signal A.
Row 4 shows the pedal's current value for signal B.
Row 5 shows the pedal's stored value for signal B.
The picture shows an example of the value in mV and 3. Release the pedal SLOWLY all the way and save the value using
may differ depending on model. the function key .
1.1 Controls & Instr 2/XX CALIBRATE

1. Navigate to 1.1 Controls & Instr 1/XX CALIBRATE, menu 2 with
/ .
2. Row 1 shows the pedal's bottom position.
Row 2 shows the pedal's current value for signal A.
Row 3 shows the pedal's stored value for signal A.
Row 4 shows the pedal's current value for signal B.
Row 5 shows the pedal's stored value for signal B.
3. Fully depress the pedal and save the value using the function key
.
The picture shows an example of the value in mV and

may differ depending on model.
8.5.1.2 Initiation menus Fuel system

2. Row 1 shows the setting value for warning in the event of low fuel
level.
Row 2 shows the stored value for warning in the event of low fuel
level.
3. Set the warning in row 1, Alarm Low fuel level. Change the value
with / and store the value with Save .

8.5.1.7 Initiation menus Cooling system engine

1.7 Cooling System 3/XX INITIATE
menu, work instruction, page 8:169.
2. Row 1 shows the setup value for the time between rotation change
of intercooler cooling fans.
Row 2 shows the stored value for the time between rotation
change of intercooler cooling fans.
3. Set the setting value for time between rotation change of inter-
cooler cooling fans in row 1, Time between cooling fan reversing.
Change the value with / and store the value with Save .

2. Row 1 shows the setting value for lock cooling fan at 70% of max.
capacity.
Row 2 shows whether the cooling fan is locked at 70% of max.
capacity.
3. Activate lock cooling fan at 70% in row 1, Lock cooling fan at
70%. Change the value with / and store the value with Save
.
0 = off
1 = on

2. Row 1 shows the setting value for locking of the engine's cooling
fan to a certain rpm in % of the engine's rpm.
Row 2 shows current operating mode for the engine's cooling fan.
0.00 % = Automatic fan control
0.01 — 100.00 % = Locked rpm.
-1.00 % = Locked to the engine speed.
Row 3 shows fan speed.
3. Activate change of lock value for cooling fan row 1, Lock cooling
fan at speed (0–100%) with .


2. Row 1 shows the setting value for locking the speed of the inter-
cooler cooling fans to a certain rpm in % of max. rpm.
Row 2 shows current operating mode for the cooling fan.
0.01 – 100.00 % = Locked rpm in % of max. rotation speed.
Row 3 shows calculated fan speed.
3. Activate change of lock value for cooling fans in row 1, Lock cool-
ing fan charge air at speed (0–100%) with .

2. Row 1 shows the setting value for locking the speed of the trans-
mission cooling fans to a certain rpm in % of max. rpm.
Row 2 shows current operating mode for the cooling fan.
0.01 – 100.00 % = Locked rpm in % of max. rpm.
Row 3 shows calculated fan speed.
3. Activate change of lock value for the cooling fans in row 1, Lock
cooling fan Trans. oil at speed (0–100%) with .
8.5.1.9 Initiation menus Control system, engine

1.9 Control System 1/XX INITIATE
2. Row 1 shows the setting value for the lowest engine speed (idling
speed).
Row 2 shows the saved value for the lowest engine speed.
3. Set lowest engine speed in row 1, Engine min rpm. Change the
value with / and store the value with Save .


2. Row 1 shows the setting value for the highest permitted engine
speed (speed inhibitor).
Row 2 shows the saved value for the highest permitted engine
speed.
3. Set highest permitted engine speed in row 1, Engine max rpm.

2. Row 1 shows the setting value for the engine's ramp time down
(how fast the engine speed is allowed go down to idle). Too short a
time may result in engine stop.
Row 2 shows the saved value for the engine's ramp down time.
3. Set the engine's ramp down time in row 1, Engine request speed
decrease time. Change the value with / and store the value
with Save .

2. Row 1 shows the setting value for the engine's ramp up time (throt-
tle response).
Row 2 shows the saved value for the engine's ramp up time.
3. Set the engine's ramp up time in row 1, Engine request speed in-
crease time. Change the value with / and store the value
with Save .

2. Row 1 shows the setting value for the engine's max. speed in neu-
tral position for the transmission.
Row 2 shows the stored value for the engine's max. speed in neu-
tral position for the transmission.
3. Set the engine's max. speed in row 1, Engine max rpm at neutral.


2. Row 1 shows the setting value for request for limitation of the en-
gine's torque in % of the engine's maximum torque.
Row 2 shows stored value for request for limitation of the engine's
torque.
3. Set the engine torque limitation as % of the engine's maximum tor-
que in Row 1, Engine request torque limit. Change the value with
/ and store the value with Save .
1.9 Start & Stop 7/XX INITIATE

2. Row 1 shows the setting value for stall test.
Row 2 shows the saved value for stall test.
3. Engage a gear with the parking brake activated and the service
brake pedal fully depressed. Value is shown in Engine stall test.
8.5.1.11 Initiation menus Start and stop

2. Row 1 shows the setting value for the delay before the engine is
auto-stopped by the automatic start and stop function in seconds.
Row 2 shows the stored value for the delay before the engine is
auto-stopped in seconds.
3. Set the time in row 1, Auto Start & Stop. Change the value with

2. Row 1 shows the setting value for how the automatic start and stop
function should work on the machine.
Row 2 shows stored value for how the automatic start and stop
function should work on the machine.
1 = Off, only automatic stop function in ECO mode (this cannot
be deselected).
2 = On, automatic start and stop function activated.
3 = Adjustable by the operator. Activates the option to change the
setting via customer settings in the menus, see Operator's manual.
3. Set the setting in row 1, Auto Start & Stop and Auto Start & Stop,
light. Change the value with / and store the value with Save
.


2. Row 1 shows the setting value for the delay before the engine is
auto-stopped by the automatic stop function in seconds.
Row 2 shows the stored value for the delay before the engine is
auto-stopped in seconds.
3. Set the setting in row 1, Auto Start & Stop, light. Change the val-
ue with / and store the value with Save .

2. Row 1 shows the setting value for the drive mode in which the en-
gine should be auto-stopped by the automatic stop function.
Row 2 shows the stored value for the drive mode in which the en-
gine should be auto-stopped by the automatic stop function.
3. Set the setting in row 1, Auto Start & Stop, light Available in
mode. Change the value with / and store the value with Save
.

2. Row 1 shows the setting value for preventing start if the operator is
not wearing the seat belt.
Row 2 shows the stored value for preventing start if the operator is
not wearing the seat belt.
3. Enter the setting in row 1, Disable start when no seat belt.
8.5.2 Transmission
Initiation transmission, general
NOTE
The machine must be stationary with parking brake applied in order
to enable access to the menus.

8:178 8 Control system – Brakes

transmission
2. Row 1 shows the setting value to prevent travel direction selection
if the cab is not locked in rear position on machines with manual
cab movement.
Row 2 shows the stored value to prevent travel direction selection
if the cab is not locked in rear position on machines with manual
cab movement.
3. Set engine speed in Row 1, Interlock gear if cab not locked in
rear position. Change the value with / and store the value
with Save .
8.5.4 Brakes
brakes

2. Row 1 shows setting value for the brake pedal's deadband in re-
leased position.
Row 2 shows stored value for the brake pedal's deadband in re-
leased position.
Row 3 shows the current pedal position.
3. Set the value for the brake pedal's deadband in released position
in row 1, Brake pedal start deadband. Change the value with /
and store the value with Save .

2. Row 1 shows setting value for the brake pedal's deadband in fully
depressed position.
Row 2 shows stored value for the brake pedal's deadband in fully
depressed position.
Row 3 shows the current pedal position.
3. Set the value for the brake pedal's deadband in fully depressed po-
sition in row 1, Brake pedal end deadband. Change the value

8.5.4.5 Initiation menus Parking brake system

4.5 Park brake sys 1/XX INITIATE

2. Row 1 shows the setting value for whether the parking brake
should be applied automatically for idle operation.
Row 2 shows the stored value for whether the parking brake
should be applied automatically for idle operation.
0 = Not activated
1 = Automatic activation when idling
3. Set the function in Row 1, P-brake self setting when idling.
4.5 Park brake sys 2/XX INITIATE

2. Row 1 shows the setting value for the time with idle operation be-
fore the parking brake is applied automatically.
Row 2 shows the stored value for the time with idle operation be-
fore the parking brake is applied automatically.
3. Set the value for the parking brake in Row 1, P-brake self setting
when idling activation time. Change the value with / and
8.5.5 Steering
8.5.5.2 Initiation menus, Power assisted system
5.2 Power Assisted 1/XX INITIATE
2. Row 1 shows the sensitivity of the joystick or the mini-wheel.
Row 2 shows the stored value for joystick or mini-wheel sensitivity.
3. Set joystick or mini-wheel sensitivity on Row 1, Comfort steering
sensitivity. 0 = no deflection and 10 = max. valve deflection.


2. Row 1 shows the max. value for the output signal to Electric steer-
ing module (Y6150) for steering right.
Row 2 shows the stored value for output signal to Electric steering
module (Y6150).
3. Set the value on row 1, Comfort steering duty max right valve
output. Values for steering right are from 50.00 to 0 where 50.00 is
neutral position. Change the value with / and store the value
with Save .

2. Row 1 shows the start value for the output signal to Electric steer-
ing module (Y6150) for steering right.
module (Y6150).
3. Set the value on row 1, Comfort steering duty start right valve
output. Value for steering right is from 50.00 to 0 where 50.00 is
neutral position. Change the value with / and store the value
with Save .

2. Row 1 shows the start value for the output signal to Electric steer-
ing module (Y6150) for steering left.
module (Y6150).
3. Set the value on row 1, Comfort steering duty start left valve
output. Value for steering left is from 50.00 to 100.00 where 50.00
is neutral position. Change the value with / and store the val-
ue with Save .

2. Row 1 shows the max. value for the output signal to Electric steer-
ing module (Y6150) for steering left.
module (Y6150).
3. Set the value on row 1, Comfort steering duty max left valve
output. Value for steering left is 50.00 - 100.00 where 50.00 is neu-
tral position. Change the value with / and store the value with
Save .


2. Row 1 shows the setting of % control current at break point profile
for steering angle at 0 km/h (BP0).
Row 2 shows the stored break point profile for steering deflection
at 0 km/h (BP0).
3. Set break point profile for steering deflection at 0 km/h (BP0) on

Y row 1, Comfort steering stpt profile at 0 kph. Change the value
BP0 with / and store the value with Save .
BP5
BP10
BP15
BP20
BP25
V
016935
0 5 10 15 20 25
Y = Output signal to Electric steering module (Y6150).
V = machine speed in km/h.
BP0-PB25 = Break point profile for 0-25 km/h.


at 5 km/h (BP5).

BP5
BP10
BP15
BP20
BP25
V
016935
0 5 10 15 20 25


at 10 km/h (BP10).

BP5
BP10
BP15
BP20
BP25
V
016935
0 5 10 15 20 25


at 15 km/h (BP15).

BP5
BP10
BP15
BP20
BP25
V
016935
0 5 10 15 20 25


at 20 km/h (BP20).

BP5
BP10
BP15
BP20
BP25
V
016935
0 5 10 15 20 25


at 25 km/h (BP25).

BP5
BP10
BP15
BP20
BP25
V
016935
0 5 10 15 20 25

2. Row 1 shows the setup of the joystick profile for steering deflection.
Row 2 shows the saved profile.
3. Set profile on Row 1, Comfort steering lever stpt linear profile.

Y 0 0 = linear profile, 10 = max. exponential profile. Change the value
10
016934
X
X = Lever movement.
0-10 = Profile.


2. Row 1 shows the joystick's deadband at the end positions.
Row 2 shows the saved value for deadband.
3. Set deadband on row 1, Comfort steering lever high/low dead-
band. Change the value with / and store the value with Save
.

2. Row 1 shows the joystick's deadband at the centre position.
Row 2 shows the saved value for deadband.
3. Set deadband on row 1, Comfort steering lever mid deadband.
8.5.5.2 Steering calibration menu 7-9

5.2 Steering axle, calibration
NOTE
Calibration does not need to be performed in one process but each
step can be performed separately, independently of other steps.
5.2 POWER ASSISTED 7/XX CALIBRATE

Row 1 shows steering axle position.
Row 2 shows the saved value for steering axle position.
3. Set the steering wheel straight ahead, for example, by driving
straight ahead, set the centre position of the steering axle.
The value in Row 1, Steering axle middle position, is saved in
Row 2.

8:188 8 Control system – Suspension

with / .
3. Turn the steering wheel fully left to set the steering axle's left
position.
The value in Row 1, Steering axle left position, is saved in Row 2.

with / .
3. Turn the steering wheel fully right to set the steering axle's right
position.
The value in Row 1, Steering axle right position, is saved in Row
2.
8.5.6 Suspension
8.5.6.3 Initiation menus Tyres and rims
6.3 Tyres & Rims 1/XX INITIATE

2. Row 1 shows setting value for the tyre pressure monitoring func-
tion in the machine.
Row 2 shows the stored value for the tyre pressure monitoring
function.
0 = Tyre pressure monitoring deactivated.
1 = Tyre pressure monitoring with pressure indication in operating
menu.
menu as well as event menus in the event of incorrect tyre
pressure.
menu as well as event menus and speed limitation in the event
of incorrect tyre pressure.
3. Set the tyre pressure monitoring function in row 1, Tyre Pressure
Monitoring mode. Change the value with / and store the val-
ue with Save .

8.5.7 Load handling

load handling
2. Row 1 shows the setting value for Control lever (S8150) deadband
in centre position.
Row 2 shows the stored value for Control lever (S8150) deadband
in centre position.
3. Set Control lever (S8150) deadband on row 1, Joystick middle
deadband. Change the value with / and store the value with
Save .

2. Row 1 shows the setting value for Control lever (S8150) deadband
in end position.
Row 2 shows the stored value for Control lever (S8150) deadband
in end position.
3. Set Control lever (S8150) deadband on row 1, Joystick high/low
deadband. Change the value with / and store the value with
Save .

2. Row 1 shows the setting value for the thumb control on Control lev-
er (S8150) deadband in centre position.
Row 2 shows the stored value for the thumb control on Control lev-
er (S8150) deadband in centre position.
3. Set the thumb control on Control lever (S8150) deadband on row 1,
Thumb joystick middle deadband. Change the value with /

2. Row 1 shows the setting value for the thumb control on Control lev-
er (S8150) deadband in end position.
Row 2 shows the stored value for the thumb control on Control lev-
er (S8150) deadband in end position.
3. Set the thumb control on Control lever (S8150) deadband on row 1,
Thumb joystick high/low deadband. Change the value with /


2. Row 1 shows setting value for attendance switch.
Row 2 shows saved value for attendance switch.
0 = attendance switch activated.
1 = attendance switch not activated.
3. Set whether or not attendance switch should be activated in Row 1,
Disable Dead Man Grip. Change the value with / and store
8.5.7.2 Initiation menus Lifting/lowering

7.2 Lifting Lowering 11/XX INITIATE
2. Row 1 shows the setting value for start current for Solenoid valve
lift (Y6005).
Row 2 shows the saved value for start current.
3. Set start current for Solenoid valve lift (Y6005) in row 1, Start cur-
rent lift boom. Change the value with / and store the value
with Save .
The start current is the lowest current that can be actuated. In prac-
tice, it controls how slowly a function can be operated. On functions
with analogue control/activation (controllable), e.g. lift, this is the
current which is triggered when the lever leaves the zero position
(deadband).

2. Row 1 shows the setting value for end current for Solenoid valve lift
(Y6005).
Row 2 shows the saved value for end current.
3. Set end current for Solenoid valve lift (Y6005) in row 1, End cur-
rent lift boom. Change the value with / and store the value
with Save .
The end current is the highest current that can be actuated. In
practice, it controls how quickly a function can be operated. On
functions with analogue control/activation (controllable), e.g. lift,
this is the current which is triggered when the lever is in the end po-
sition (deadband).


lower (Y6004).
3. Set start current for Solenoid valve lower (Y6004) in row 1, Start
current lower boom. Change the value with / and store the
value with Save .
(deadband).

2. Row 1 shows the setting value for end current for Solenoid valve
lower (Y6004).
3. Set end current for Solenoid valve lower (Y6004) in row 1, End
current lower boom. Change the value with / and store the
value with Save .
sition (deadband).

2. Row 1 shows the setting value for limitation of lifting speed when
the gear is selected. Lifting speed is limited when the machine can
be operated in order to reduce centre of gravity changes.
Row 2 shows the stored value for limitation of lifting speed.
3. Set limitation of lifting speed in % in Row 1, Lift boom max output
when drivetrain is engaged. Change the value with / and
sition (deadband).


2. Row 1 shows the setting value for engine speed at minimum de-
flection of the control lever for lifting without load. The rotation
speed is the lower level for rotation speed increase for the lifting
function for lifting without load. Engine speed affects lifting speed.
Row 2 shows the saved value for the engine speed.
3. Set the engine speed on row 1, Boom engine speed request un-
loaded, min. Change the value with / and store the value
with Save .
sition (deadband).

2. Row 1 shows the setting value for engine speed at maximum de-
flection of the control lever for lifting without load. The rotation
speed is the upper level for rotation speed increase for the lifting
function for lifting without load. Engine speed affects lifting speed.
3. Set the engine speed on row 1, Boom engine speed request un-
loaded, max. Change the value with / and store the value
with Save .
sition (deadband).

2. Row 1 shows the setting value for engine speed at minimum de-
flection of the control lever for lifting with load. The rotation speed
is the lower level for rotation speed increase for the lifting function
for lifting with load. Engine speed affects lifting speed
3. Set the engine speed on row 1, Boom engine speed request
loaded, min. Change the value with / and store the value
with Save .
sition (deadband).


2. Row 1 shows the setting value for engine speed at maximum de-
flection of the control lever for lifting with load. The rotation speed
is the upper level for rotation speed increase for the lifting function
for lifting with load. Engine speed affects lifting speed.
3. Set the engine speed on row 1, Boom engine speed request
loaded, max. Change the value with / and store the value
with Save .
sition (deadband).

1. Row 1 shows the setting value for whether regeneration should be
on for open twistlock.
Row 2 shows the stored value.
2. Set required function in Row 1, Lift boom regeneration auto on
at lift request > 0 when unloaded. Change the value with /
0 = Regeneration is deactivated.
1 = Regeneration is automatically on for open twistlock.
8.5.7.3 Initiation menus, Extension

7.3 Extension 1/XX INITIATE
boom out (Y6006).
3. Set start current for Solenoid valve boom out (Y6006) in row 1,
Start current extend boom. Change the value with / and
(deadband).


boom out (Y6006).
3. Set end current for Solenoid valve boom out (Y6006) in row 1, End
current extend boom. Change the value with / and store the
value with Save .
sition (deadband).

boom in (Y6007).
3. Set start current for Solenoid valve boom in (Y6007) in Row 1,
Start current retract boom. Change the value with / and
(deadband).

boom in (Y6007).
3. Set end current for Solenoid valve boom in (Y6007) in Row 1, End
current retract boom. Change the value with / and store the
value with Save .
sition (deadband).


1. Row 1 shows the setting value for whether regeneration should be
on for open twistlock.
Row 2 shows the stored value.
2. Set required function in Row 1, Ext. boom regeneration auto on
at extension request > 0 when unloaded. Change the value with
0 = Regeneration is deactivated.
1 = Regeneration is automatically on for open twistlock.
8.5.7.4 Initiation menus, Side shift

7.4 Side Shift 5/XX INITIATE
2. Row 1 shows the setting value for start current to Solenoid valve
side shift right (Y6021).
3. Set start current for Solenoid valve side shift right (Y6021) in row 1,
Start current side shift right. Change the value with / and
current which is triggered when the lever leaves the zero position.

2. Row 1 shows the setting value for end current to Solenoid valve
side shift right (Y6021).
3. Set end current for Solenoid valve side shift right (Y6021) in row 1,
End current side shift right. Change the value with / and
functions with analogue control activation (controllable), e.g. lift,
this is the current which is triggered when the lever is in the end
position.


side shift left (Y6020).
3. Set start current for Solenoid valve side shift left (Y6020), on row 1,
Start current side shift left. Change the value with / and

side shift left (Y6020).
3. Set end current for Solenoid valve side shift left (Y6020), on row 1,
End current side shift left. Change the value with / and
position.

8.5.7.5 Initiation menus, Spreading

7.5 Spreading 13/XX INITIATE
spreading out (Y6018).
3. Set start current for Solenoid valve spreading out (Y6018) in row 1,
Start current spreading out. Change the value with / and

spreading out (Y6018).
3. Set end current for Solenoid valve spreading out (Y6018) in row 1,
End current spreading out. Change the value with / and
position.

2. Row 1 shows the setting value for damping of spreading out.
Row 2 shows the saved value for damping.
3. Set value for damping of spreading out in row 1, Damp value
spreading out. Change the value with / and store the value
with Save .
Damping is the percentage by which the control current to the sole-
noid valve is reduced approaching the end position. Damping is
used to increase accuracy and reduce mechanical stress on the
machine.


spreading in (Y6019).
3. Set start current for Solenoid valve spreading in (Y6019) in row 1,
Start current spreading in. Change the value with / and

spreading in (Y6019).
3. Set end current for Solenoid valve spreading in (Y6019) in row 1,
End current spreading in. Change the value with / and
position.

2. Row 1 shows the setting value for damping spreading in.
3. Set value for damping of spreading in in row 1, Damp value
spreading in. Change the value with / and store the value
with Save .
machine.


spreading out left (Y6018-LE).
3. Set start current for Solenoid valve spreading out left (Y6018-LE)
in row 1, Start current spreading out left. Change the value with

spreading out left (Y6018-LE).
3. Set end current for Solenoid valve spreading out left (Y6018-LE) in
row 1, End current spreading out left. Change the value with /
position.

2. Row 1 shows the setting value for damping of spreading out left.
spreading out left. Change the value with / and store the
value with Save .
machine.


spreading in left (Y6019-LE).
3. Set start current for Solenoid valve spreading in left (Y6019-LE) in
row 1, Start current spreading in left. Change the value with /

spreading in left (Y6019-LE).
3. Set end current for Solenoid valve spreading in left (Y6019-LE) in
row 1, End current spreading in left. Change the value with /
position.

2. Row 1 shows the setting value for damping of spreading in left.
3. Set value for damping of spreading in, in row 1, Damp value
spreading in left. Change the value with / and store the val-
ue with Save .
machine.


spreading out right (Y6018-RI).
3. Set start current for Solenoid valve spreading out right (Y6018-RI)
in row 1, Start current spreading out right. Change the value

spreading out right (Y6018-RI).
3. Set end current for Solenoid valve spreading out right (Y6018-RI)
in Row 1, End current spreading out right. Change the value
position.

2. Row 1 shows the setting value for damping of spreading out right.
spreading out right. Change the value with / and store the
value with Save .
machine.


spreading in right (Y6019-RI).
3. Set start current for Solenoid valve spreading in right (Y6019-RI) in
row 1, Start current spreading in right. Change the value with

spreading in right (Y6019-RI).
3. Set end current for Solenoid valve spreading in right (Y6019-RI) in
row 1, End current spreading in right. Change the value with /
position.

2. Row 1 shows the setting value for damping of spreading in right.
3. Set value for damping of spreading in, in row 1, Damp value
spreading in right. Change the value with / and store the
value with Save .
machine.


2. Row 1 shows the setting value for whether spreading should be
permitted with locked twistlocks.
Row 2 shows the stored value for whether spreading should be
permitted with locked twistlocks.
3. Set the value for whether spreading should be permitted with
locked twistlocks in Row 1, Spreading when locked TW. Change
the value with / and store the value with Save .
8.5.7.6 Initiation menus, Rotation

7.6 Rotation 1/XX INITIATE
rotation clockwise (Y6008).
3. Set start current for Solenoid valve rotation clockwise (Y6008) in
row 1, Start current rotation clockwise. Change the value with

2. Row 1 shows the setting value for end current to Solenoid valve ro-
tation clockwise (Y6008).
3. Set end current for Solenoid valve rotation clockwise (Y6008) in
row 1, End current rotation clockwise. Change the value with
position.


rotation anticlockwise (Y6009).
3. Set start current for Solenoid valve rotation anticlockwise (Y6009)
in row 1, Start current rotation counter clockwise. Change the

2. Row 1 shows the setting value for end current to Solenoid valve ro-
tation anticlockwise (Y6009).
3. Set end current for Solenoid valve rotation anticlockwise (Y6009)
in row 1, End current rotation counter clockwise. Change the
position.

2. Row 1 shows the setting value for the direction of rotation.
Row 2 shows the saved value for the direction of rotation.
3. Set the desired rotation direction in Row 1, Swap rotation direc-
tion. Change the value with / and store the value with Save
.
The setting turns round the control lever's deflection for rotation.
0 = Normal rotation.
1 = Reverse rotation.

On machines with rotation stop.

2. Row 1 shows setting value for the rotation stop function.
Row 2 shows stored value for the rotation stop function.
3. Set desired value for rotation stop in Row 1, Disable rotation stop.
The setting activates/deactivates the rotation stop function.
0 = rotation stop function inactive
1 = rotation stop function active
2 = Container <1000 mm
8.5.7.7 Initiation menus, Tilt

7.7 Tilt 7/XX INITIATE
2. Row 1 shows the setting value for start current to Solenoid valve tilt
in (Y6011).
3. Set start current for Solenoid valve tilt in (Y6011) on row 1, Start
current tilt in. Change the value with / and store the value
with Save .

2. Row 1 shows the setting value for end current to Solenoid valve tilt
in (Y6011).
3. Set end current for Solenoid valve tilt in (Y6011) on row 1, End cur-
rent tilt in. Change the value with / and store the value with
Save .
position.


2. Row 1 shows the setting value for start current to Solenoid valve tilt
out (Y6010).
3. Set start current for Solenoid valve tilt out (Y6010) on row 1, Start
current tilt out. Change the value with / and store the value
with Save .

2. Row 1 shows the setting value for end current to Solenoid valve tilt
out (Y6010).
3. Set end current for Solenoid valve tilt out (Y6010) on row 1, End
current tilt out. Change the value with / and store the value
with Save .
position.
8.5.7.7 Tilt, calibration menu 1-4

Tilt, calibration
This function handles tilt calibration.
7.7 Tilt 5/XX CALIBRATE

1. Navigate to the calibration menu 7.7 Tilt 5/XX CALIBRATE with /
. See Navigation to a menu, work instruction, page 8:169 for an
explanation of navigation.
Row 1 describes tilt angle attachment.
Row 2 shows current value for attachment at calibration point 1.
Row 3 shows saved value for attachment at calibration point 1.
Row 4 shows the current value for the angle of the boom at calibra-
tion point 1.
Row 5 shows saved value for boom angle at calibration point 1.
2. Retract the boom and lower the attachment to the lowest possible
position. Make sure that the attachment is horizontal.
3. Press when the value is stable to store the value.

7.7 Tilt 6/XX CALIBRATE

1. Navigate to the calibration menu 7.7 Tilt 6/XX CALIBRATE with /
. See Navigation to a menu, work instruction, page 8:169 for an
explanation of navigation.
Row 1 describes tilt angle attachment.
Row 2 shows current value for attachment at calibration point 2.
Row 3 shows saved value for attachment at calibration point 2.
Row 4 shows current value for boom angle compared to calibration
point 1.
Row 5 shows saved value for boom angle compared to calibration
point 1.
2. Extend the boom and raise the attachment to the highest possible
position. Make sure that the attachment is horizontal.
8.5.7.8 Initiation menus, Levelling

7.8 Levelling 5/XX INITIATE
levelling clockwise (Y6036).
3. Set start current for Solenoid valve levelling clockwise (Y6036) in
row 1, Start current levelling clockwise. Change the value with

levelling clockwise (Y6036).
3. Set end current for Solenoid valve levelling clockwise (Y6036) in
row 1, End current levelling clockwise. Change the value with
position.


levelling anticlockwise (Y6035).
3. Set start current for Solenoid valve levelling anticlockwise (Y6035)
in row 1, Start current levelling counterclockwise. Change the

levelling anticlockwise (Y6035).
3. Set end current for Solenoid valve levelling anticlockwise (Y6035)
in row 1, End current levelling counter clockwise. Change the
position.

8.5.7.8 Levelling, calibration menu

7.8 Levelling 1/XX CALIBRATE
1. Navigate to the calibration menu 7.8 Levelling 1/XX CALIBRATE

Row 1 describes the setting value for calibration of attachment tilt
angle.
Row 2 shows attachment tilt angle in horizontal position.
Row 3 shows stored attachment tilt angle in horizontal position.
2. Lower the boom to the lowest position (0°) and ensure that the at-
tachment is completely level. Check with the diagnostic menu that
Sensor, tilt angle (B7253) shows approx. 1000 mA, see 7.8 Level-
ling 9/XX DIAGNOSE, page 8:67.
3. If necessary, adjust the sensor as follows:
A a Detach the lever (position B) from the sensor.
b Turn the pin on the sensor (position A) so that the value shown
in the diagnostic menu is approx. 1000 mA.
c Refit the lever (position B) on the sensor.
B 4. Press to save this value.
020595
A Sensor, tilt angle (B7253)

B Lever
7.8 Levelling 2/XX CALIBRATE
5. Navigate to the calibration menu 7.8 Levelling 2/XX CALIBRATE

Row 1 describes the setting value for calibration of attachment tilt
angle.
Row 2 shows attachment tilt angle in maximum tilted position.
Row 3 shows stored attachment tilt angle in maximum tilted
position.
6. Lift the boom and tilt the attachment to the maximum tilted position.
7. Press to save this value.

8.5.7.9 Initiation menus, Load securing

7.9 Load carrier 14/XX INITIATE

2. Row 1 shows setting value for end current for knee in on bottom lift
attachment.
3. Set end current in row 1, Bottom lift End current knee in. Change
the value with / and store the value with .
position.

2. Row 1 shows setting value for end current for knee out on bottom
lift attachment.
3. Set end current in Row 1, Bottom lift End current knee out.
Change the value with / and store the value with .
position.

2. Row 1 shows setting value for end current for leg up on bottom lift
attachment.
3. Set end current in row 1, Bottom lift End current leg up. Change


2. Row 1 shows setting value for end current for leg down on bottom
lift attachment.
3. Set end current in row 1, Bottom lift End current leg down.
position.

2. Row 1 shows setting value for damping knee in on bottom lift
attachment.
3. Set value for damping in row 1, Bottom lift Damp value knee in.
machine.

2. Row 1 shows setting value for damping knee out on bottom lift
attachment.
3. Set value for damping in row 1, Bottom lift Damp value knee out.
machine.


2. Row 1 shows setting value for damping leg up on bottom lift
attachment.
3. Set value for damping in row 1, Bottom lift Damp value leg up.
machine.

2. Row 1 shows setting value for damping leg down on bottom lift
attachment.
3. Set value for damping in row 1, Bottom lift Damp value leg down.
machine.

2. Row 1 shows setting value for speed limitation during lifting the
load with bottom lift.
Row 2 shows the saved value for speed limitation.
3. Set value for speed limitation in row 1, Speed limit bottom lift.

2. Row 1 shows setting value for speed limitation when a lifting tool is
connected to the tool changer or top lift.
3. Set value for speed limitation in row 1, Speed limit external at-
tachment. Change the value with / and store the value with
Save .


2. Row 1 shows setting value for start current to clamping function for
lifting tool on the tool changer.
Row 2 shows stored value for start current to clamping function for
3. Set start current in row 1, Start current clamp close. Change the
value with / and store the value with .

2. Row 1 shows setting value for end current to clamping function for
Row 2 shows stored value for end current to clamping function for
3. Set end current in row 1, End current clamp close. Change the
position.

2. Row 1 shows setting value for start current to release function for
Row 2 shows stored value for start current to release function for
3. Set start current in row 1, Start current clamp open. Change the


2. Row 1 shows setting value for end current to release function for
Row 2 shows stored value for end current to release function for
3. Set end current in row 1, End current clamp open. Change the
position.

2. Row 1 shows setting value for the distance to the load when the
speed of the lower function shall be dampened at top lift on ma-
chines with container damping.
Row 2 shows the saved value for the distance.
Row 3 shows current distance between attachment and load.
Row 4 shows the status for the damping.
0 = Off, no damping.
1 = On, damping active.
3. Set value for the distance in row 1, Attachment lower auto damp.

2. Row 1 shows setting value for the distance to the load when the
speed of the lower function shall be dampened at bottom lift on ma-
chines with container damping.
Row 3 shows current distance between attachment and load.
Row 4 shows the status for the damping.
0 = Off, no damping.
1 = On, damping active.
3. Set value for the distance in row 1, Attachment lower auto damp.


2. Row 1 shows the setting value for indicating load centred laterally
(illumination of green light on attachment).
Row 2 shows the stored value for indicating load centred laterally.
3. Set the value for indicating load centred laterally in Row 1, Skewed
load limit green light. Change the value with / and store the
value with Save . When Save is activated, the saved value is
visible on row 2.

2. Row 1 shows the setting value for max. permitted displacement of
the load's lateral centre of gravity to permit lifting with bottom lift.
Row 2 shows the stored value for max. permitted displacement of
the load's centre of gravity.
3. Set the max. permitted displacement of the load's lateral centre of
gravity in Row 1, Skewed load limit bottom lift. Change the value
with / and store the value with Save . When Save is acti-
vated, the saved value is visible on row 2.

2. Row 1 shows the setting value for max. permitted displacement of
the load's lateral centre of gravity to permit lifting with twistlocks
Row 2 shows the stored value for max. permitted displacement of
the load's centre of gravity.
3. Set the max. permitted displacement of the load's lateral centre of
gravity in Row 1, Skewed load limit top lift. Change the value with
/ and store the value with Save . When Save is activated,
the saved value is visible on row 2.

2. Row 1 shows the setting value for blocking of spreading on the at-
tachment at contact with the load.
Row 2 shows the stored value for spreading on the attachment at
contact with the load.
3. Set the end current in Row 1, Interlock spreader when align-
ment. Change the value with / and store the value with .


2. Row 1 shows the setting value for end current for opening the con-
tainer door.
Row 2 shows the stored value for end current for opening the con-
tainer door.
3. Set end current in Row 1, End current container door open.
position.

2. Row 1 shows the setting value for end current for opening the con-
tainer door.
Row 2 shows the stored value for end current for opening the con-
tainer door.
3. Set end current in Row 1, Start current container door open.
position.


2. Row 1 shows the setting value for the weight of the pipe
attachment.
Row 2 shows stored value for the weight of the pipe attachment.
3. Set the weight of the pipe attachment in Row 1, Tare weight exter-
nal attachment. Change the value with / and store the value
with Save .
WARNING
Incorrectly entered value for the weight of the pipe at-
tachment may compromise the safety and function of
the attachment. This may lead to dropped loads.
Extreme danger!
Check that the correct value has been entered.
NOTE
It is not possible to clamp the load unless menu 48 has been initiated
with the weight of the pipe attachment and the value stored with Save
.

2. Row 1 shows the setting value for blocking automatic damping with
the switch.
Row 2 shows the stored value for blocking of automatic damping. 0
= automatic damping active, 1 = possible to block automatic damp-
ing with the switch.
3. Set the value for blocking automatic damping with the switch in
Row 1, Block attachment lower auto damp with switch. Change
machine.
7.9 Load Carrier 58/XX INITIATE

changes, see Initiation, General, Chapter 8 in the Workshop
Manual.
For a description of navigation to this menu, see Navigating to a
menu, work instructions, Chapter 8 in the Workshop Manual.
2. Row 1 shows the setting value for the number of sensors with con-
tact when operating with load for ELME 952/953/954.
Row 2 shows the stored value for the number of sensors with
contact.
3. Set the value in Row 1, Elme bottom lift no. of alignment sen-
sors. Change the value with / and store the value with Save
.

8.5.7.8 Load securing calibration menu

7.9 Load carrier 1/XX CALIBRATE
For the calibration of the damping function, see Sensor damping at-
tachment, calibration, page 7:31.
7.9 Load carrier 2/XX CALIBRATE
For the calibration of the damping function, see Sensor damping at-
tachment, calibration, page 7:31.
8.5.7.10 Initiation menus, Other functions

7.10 Other functions 11/XX INITIATE
2. Row 1 shows the setting value for automatic lowering of support
jacks.
Row 2 shows the stored value for automatic lowering of support
jacks.
3. Set automatic lowering of support jacks in Row 1, Support jacks
auto move. 1 specifies that automatic lowering is set. Change the

2. Row 1 shows the setup value for the end current for lowering the
support jacks.
3. Set the end current in row 1, End current support jacks down.
functions with off/on function, e.g. support jacks, this is the current
that is actuated after soft start and before end position damping is
activated.


2. Row 1 shows the setup value for the end current for raising the
support jacks.
3. Set the end current in row 1, End current support jacks up.
functions with off/on function, e.g. support jacks, this is the current
that is actuated after soft start and before end position damping is
activated.

2. Row 1 shows the setting value for increasing engine speed on acti-
vation of extra hydraulic functions.
Row 2 shows the stored value for raising engine speed on activa-
tion of extra hydraulic functions.
Row 3 shows the current requested engine speed. Activate the de-
sired hydraulic function to see what engine speed has been
requested.
Row 4 shows the current actual engine speed.
3. Set the engine speed in Row 1, Other Functions engine speed
request. Change the value with / and store the value with .

2. Row 1 shows setting value for shaking the attachment.
Row 2 shows stored value for shaking the attachment.
3. Set shake attachment in Row 1, Shake Spreader status. 1 indi-
cates that shake attachment is set. Change the value with /
and store the value with .

8.5.8 Control system

2. Row 1 shows the setting value for brightness of background light-
ing for the panels in the cab in the dark.
Row 2 shows the stored value for brightness of background lighting
for the panels in the cab in the dark.
3. Set the value for the panel's searchlight in darkness on row 1, Pan-
el searchlight brightness at darkness.Change the value with
/ and store the value with .

ing for the panels in the cab in daylight.
for the panels in the cab in daylight.
3. Set the value for the panel's searchlight in daylight on row 1, Panel
searchlight brightness at daylight. Change the value with /

2. Row 1 shows the setting value for brightness of function lighting in
the panels in the cab in the dark.
Row 2 shows the stored value for brightness of function lighting in
the panels in the cab in the dark.
3. Set the value for the panel's function light in darkness on row 1,
Panel function light brightness at darkness. Change the value

2. Row 1 shows the setting value for brightness of function lighting in
the panels in the cab in daylight.
Row 2 shows the stored value for brightness of function lighting in
the panels in the cab in daylight.
3. Set the value for the panel's function light in daylight on row 1, Pan-
el function light brightness at daylight. Change the value with


ing in the switches in the cab in the dark.
in the switches in the cab in the dark.
3. Set the value for the button searchlight in darkness on row 1, But-
ton searchlight brightness at darkness. Change the value with

ing in the switches in the cab in daylight.
in the switches in the cab in daylight.
3. Set the value for the button searchlight in daylight on row 1, Button
searchlight brightness at daylight. Change the value with /

2. Row 1 shows the setting value for brightness of indicator lights on
the attachment in the dark.
Row 2 shows the stored value for brightness of indicator lights on
the attachment in the dark.
3. Set the value for brightness of indicator lights for attachment in
darkness in row 1, Attach. indication light brightness at dark-
ness. Change the value with / and store the value with .

2. Row 1 shows the setting value for brightness of indicator lights on
the attachment in daylight.
Row 2 shows the stored value for brightness of indicator lights on
the attachment in daylight.
3. Set the value for brightness of indicator lights for attachment in
daylight in row 1, Attach. indication light brightness at daylight.


2. Row 1 shows setting value for display of load capacity in the main
menu on the display in the cab.
Row 2 shows stored value for display of load capacity in the main
menu on the display in the cab.
3. Set the value for displaying load capacity in the main menu on the
display in the cab in Row 1, Enable capacity variable on main
screen. 1 indicates that load capacity is shown in the main menu
in the display. Change the value with / and store the value
with .
8.5.8.2 Initiation menus, Monitoring

8.2 Monitoring 1/XX INITIATE
2. Row 1 shows max. speed forwards in km/h.
Row 2 shows the stored value for max. speed forwards.
3. Set max. speed forward in km/h. on row 1, Speed limit forward.

2. Row 1 shows max. speed reverse in km/h.
Row 2 shows the stored value for max. speed reverse.
3. Set max. speed backward in km/h. on row 1, Speed limit reverse.

2. Row 1 shows the service interval.
Row 2 shows the saved value for the service interval.
3. Set service interval on row 1, Service time interval. Change the
The service interval can be changed between 0 and maximum
service interval for the machine. If the interval is set to 0 then the
service indication is switched off completely.


2. Row 1 shows resetting of the service interval.
Row 2 shows the saved value for resetting.
3. Activate reset on row 1, Service time interval reset. Change the

2. Row 1 shows the number of hours left to service when Event menu,
service, shall be shown.
Row 2 shows the saved value for resetting.
3. Set the number of hours remaining to service when Event menu,
service, should be shown on row 1, Service time pop up hours.

2. Row 1 shows the setting value for load centre limitation.
Row 2 shows the saved load centre limitation.
Row 3 shows the value for load centre.
3. Set load centre limitation in row 1, Load centre (L) min limit.
If the limit is set to -2000 then the load centre limitation is
disengaged.

2. Row 1 shows the setting value for height limitation.
Row 2 shows the saved height limitation.
Row 3 shows the value for total height.
Row 4 shows the value for height under the attachment.
3. Set height limitation in Row 1, Height limit (total). Change the val-
ue with / and store the value with .
If the limit is set to 4000 then the load height limitation is
disengaged.


2. Row 1 shows the setting value for the cab position at which the ma-
chine's speed should be limited on machines with hydraulic cab
movement.
Row 2 shows the saved position of the cab for speed limitation.
Row 3 shows the value for speed limitation. The speed limitation is
set in menu 12, see 8.2 Monitoring 12/XX INITIATE, page 8:224
Row 4 shows the value for the cab's actual position on the
machine.
3. Set the position for the cab in row 1, Cab position speed limit.
Distance from rear position. Change the value with / and
store the value with .
If the limit is set to 0 then the speed limitation is disengaged.

2. Row 1 shows the setting value for speed limitation when the cab is
slid forward on machines with hydraulic cab movement.
Row 3 shows the value for requested speed limitation.
Row 4 shows the value for the cab's measured position on the
machine.
3. Set the position for the cab in row 1, Cab position speed limit.
Max allowed speed. Change the value with / and store the
value with .

2. Row 1 shows the setting value for load centre limitation depending
on the cab's position on machines with hydraulic cab movement,
setting based on the cab's position from the rearmost position.
Row 2 shows the saved value for cab position for load centre
limitation.
Row 3 shows the value for the cab's measured position from the
centre of the drive axle. (A negative value means that the cab is
behind the centre of the drive axle.)
Row 4 shows the value for the load centre's measured position
from the centre of the drive axle. (A negative value means that the
load centre is behind the centre of the drive axle.)
3. Set the position for the cab in row 1, Load centre limit dependent
on cab position. Distance to cab rear position. Change the val-


2. Row 1 shows the setting value for load centre limitation depending
on the cab's position on machines with hydraulic cab movement,
distance limit between the front edge of the cab and load centre.
Row 2 shows the saved value for the distance limit.
Row 3 shows the value for the cab's measured position from the
centre of the drive axle. (A negative value means that the cab is
behind the centre of the drive axle.)
Row 4 shows the value for the load centre's measured position
from the centre of the drive axle. (A negative value means that the
load centre is behind the centre of the drive axle.)
3. Set the position for the cab in row 1, Load centre limit dependent
on cab position. Clearance distance. Change the value with /

2. Row 1 shows setting value for ECO Drive Mode in the machine,
this determines which operating mode the machine is in. For other
setup of Eco Drive mode, see 1.11 Start & Stop 1/XX INITIATE,
page 8:176.
Row 2 shows the saved value for ECO-mode.
0 = Not available.
1 = Power mode
2 = Normal mode.
3 = ECO mode.
4 = Adjustable via customer settings, see Operator's manual.
3. Set the position for Eco Drive Mode on row 1, ECO Drive Mode
selection. Change the value with / and store the value with
.

2. Row 1 shows the setting value for deactivation of engine speed
limitation at cold start.
Row 2 shows saved value for deactivation of engine speed limita-
tion at cold start.
0 = No limitation.
1 = Engine speed limited for cold engine.
3. Set engine speed limitation on row 1, Disable cold start engine
speed limit. Change the value with / and store the value with
.


2. Row 1 shows the setting value for limitation if there is no driver tag.
Row 2 shows saved value for limitation if there is no driver tag.
0 = No limitation.
1 = Not possible to start engine.
2 = Speed is limited to 5 km/h.
3. Set the limitation if there is no driver tag on row 1, Limitation no
driver tag. Change the value with / and store the value with
.

2. Row 1 shows the setting value for blocking the diagnostic code.
Row 2 shows the saved value for blocking the diagnostic code.
0 = Diagnostic code not blocked.
1 = Service code needed to access diagnostics.
3. Set blocking of code for diagnostics in row 1, Block diagnostic
code. Change the value with / and store the value with .

ONLY for machine type supporting VGM, SOLAS
SINGLE: Printout of receipt takes place automatically after each lift
when the weight has been validated (green background).
MULTI: Printout of receipt takes place for a series of lifts, when the op-
erator specifies that the series of lifts is finished (by pressing the dis-
play´s function key for total). the printout contains all lifts in the range
and a total weight.

2. Row 1 shows the setting value for printout mode for load receipts.
Row 2 shows the saved value for printout mode for load receipts.
0 = Manual printout, load receipts only saved during weighing,
printout of saved load receipt is started manually.
1 = Automatic printout, load receipts are printed out automatically
when they are saved.
3. Set printout mode in Row 1, Mode. Change the value with /


2. Row 1 shows the setting value for type of load identification on load
receipts.
Row 2 shows the saved value for type of load identification on load
receipts.
0 = Off, No load identification on load receipts.
1 = ISO, load identification according to ISO standard, four letters
and seven numbers (for example, ABCD 123456 7).
2 = Text, load identification with any 13 letters or numbers.
3. Set type of load identification in Row 1, Lift ID. Change the value

2. Row 1 shows the setting value for printer for load receipt.
Row 2 shows the saved value for printer for load receipt.
3. Set printer in Row 1, Printer active. Change the value with /

2. Row 1 shows the setting value for limitation if there is no access
code tag.
Row 2 shows the saved value for limitation if there is no access
code tag.
0 = No limitation.
1 = Not possible to start engine.
2 = Speed is limited to 5 km/h.
3. Set the limitation if there is no access code in Row 1, Limitation
no access code. Change the value with / and store the value
with .


2. Row 1 shows the setting value for speed warning.
Row 2 shows the saved value for speed warning.
3. Set speed in Row 1, Speed warning. Change the value with /

2. Row 1 shows the setting value for stop code speed limitation.
0 = No limitation.
1 = Any stop code.
2 = Stop code drive-train.
3. Set stop code speed limitation in Row 1, Stop code speed limit.

2. Row 1 shows the setting value for speed limitation stop code.
3. Set speed limitation in Row 1, Stop code speed limit. Change the

2. Row 1 shows setting value for event menu shutdown to indicate
that the height limit has been exceeded.
Row 2 shows saved value for event menu shutdown to indicate
that the height limit has been exceeded.
0 = menu enabled
1 = menu disabled
3. Set in Row 1, Disable event menu when height limit exceeded.

8.5.8.2 Monitoring calibration menu

8.2 Monitoring 5/XX CALIBRATE
1. Navigate to the calibration menu 8.2 Monitoring 5/XX CALIBRATE
with / .
Row 1 describes the calibration of the hydraulic scales without
load.
Row 2 shows current value for the minimum angle for the boom.
Row 3 shows stored value for the minimum angle for the boom.
2. Lower the boom to the lowest position (0°) and wait until the value
in Row 2, Boom minimum angle has been stabilised.

with / .
load.
Row 2 shows current value for the maximum angle for the boom.
Row 3 shows stored value for the maximum angle for the boom.
5. Raise the boom to the highest position and wait until the value in
Row 2, Boom maximum angle has been stabilised.

with / .
load.
Row 2 shows current value for the boom fully retracted.
Row 3 shows stored value for the boom fully retracted.
8. Retract the boom fully and wait until the value in Row 2, Boom
fully retracted has been stabilised.

with / .
load.
Row 2 shows current value for the boom fully extended.
Row 3 shows stored value for the boom fully extended.
11. Extend the boom fully and wait until the value in Row 2, Boom
fully extended has been stabilised.


with / .
Rows 1 and 2 describe the calibration of the hydraulic scales with-
out load. Load sensor, boom fully retracted.
Row 3 shows current value for the left-hand cylinder.
Row 4 shows stored value for the left-hand cylinder.
Row 5 shows current value for the right-hand cylinder.
Row 6 shows stored value for the right-hand cylinder.
14. Retract the boom fully. Lower the boom and lower slowly towards
the end until 2–4 cm remain on the lift cylinders. Wait until the value
in Rows 3 and 5, Left/right cylinder has been has stabilised.

16. Navigate to the calibration menu 8.2 Monitoring 10/XX CALI-
BRATE with / .
Rows 1 and 2 describe the calibration of the hydraulic scales with-
out load. Load sensor, boom fully extended.
17. Extend the boom fully and wait until the value in Rows 3 and 5,
Left/right cylinder has been stabilised.

with / .
load.
Row 2 shows permitted load.
Row 3 shows the current load.
Row 4 shows steering axle weight.
Row 5 shows drive axle weight.
Row 6 shows the distance from load centre to drive axle centre (L).
20. Operate the machine without a load, stop the machine and check
that Actual load = 00000 ± 100 kg.
Check the lifting/lowering of the boom in different operating areas,
as well as the boom further retracted and extended. The boom
must not be fully retracted or extended during inspection.
If the weight is not correct, repeat the calibration.

BRATE with / .
Row 1 describes the calibration of a hydraulic scale with a load of
known mass.
Row 2 shows the defined weight.
Row 3 shows stored value for weight.
23. Lift the load, extend the boom to end position with boom horizontal,
or as low boom angle as possible, and wait until its value in Row 2,
Define weight has been stabilised.


BRATE with / .
Rows 1 and 2 describe the calibration of a hydraulic scale with a
load of known mass. Load sensor, boom extended.
26. Lift the load, extend the boom to end position and wait until its val-
ue in Rows 3 and 5, Left/right cylinder has been stabilised.
8.5.9 Frame, body, cab and accessories


2. Row 1 shows the setting value for whether function group 1 can be
bypassed with code lock.
Row 2 shows the stored value for whether function group 1 can be
3. Set the setting in row 1, Enable override with code. Change the
0 = The function group cannot be bypassed with code lock.
1 = The function group can be bypassed with code lock.






8.5.9.4 Initiation menus, Climate system

9.4 Climate System 1/XX INITIATE

2. Row 1 shows the max. time for pause heating.
Row 2 shows the stored value for max. time for pause heating.
3. Set max. time for pause heating on row 1, Pause heating time.

2. Row 1 shows the setting value for the lowest temperature that the
pause heating is permitted to be active.
Row 2 shows the saved value for the pause heating temperature.
3. Set pause heating temperature when the air conditioning switches
off on Row 1 Pause heating temp. Change the value with /

2. Row 1 shows the sleep mode functionality. Sleep mode means that
cab cooling/heating is switched off when the cab door is open.
Row 2 shows saved value for status for sleep mode functionality.
3. Activate sleep mode functionality in Row 1, Sleep mode function-
ality enable, with a 1. Change the value with / and store the
value with .
8.5.9.5 Initiation menus, Windscreen wipers

9.5 Wiper & Washer Sys 1/XX INITIATE
2. Row 1 shows the time interval for fast wiper interval.
Row 2 shows the saved value for the time interval.
3. Set the time interval for fast intermittent wiping on row 1, Intermit-
tent wiper fast. Change the value with / and store the value
with .


2. Row 1 shows the time interval for slow wiper interval.
Row 2 shows the saved value for the time interval.
3. Set the time interval for slow intermittent wiping on row 1, Intermit-
tent wiper slow. Change the value with / and store the value
with .

2. Row 1 shows pre-wash.
Row 2 shows the stored value for pre-wash.
3. Activate prewash in Row 1, Prewash wiper, with a 1. Change the
8.5.9.6 Initiation menus, Lighting

9.6 Lighting Sys 1/XX INITIATE
2. Row 1 shows the setting for working lights when starting the
engine.
Row 2 shows the stored value for working lights when starting the
engine.
3. Set use of working lights when starting the engine on row 1, Work-
ing lights on during start engine. Change the value with /
0 = switched off when the starter motor is running.
1 = switched on.


2. Row 1 shows the setting for error code display for open circuit for
lighting and revolving beacon.
Row 2 shows the stored value for error code display for open circuit
for lighting and revolving beacon.
3. Set error code display for open circuit on row 1, Disable O.C error
code light/rotating beacon. Change the value with / and
On machines with LED lighting, an error code will be generated be-
cause the power consumption of LED lights is low. By setting this
value, incorrect error codes for lighting can be avoided.
0 = error code display for open circuit active.
1 = error code display for open circuit deactivated.

2. Row 1 shows the setting for activating functions while driving back-
wards. Using this function, you can choose which functions should
be started first when machine speed has fallen below 3 km/h.
Row 2 shows the stored value for activating the functions.
3. Set the value for back-up light/reverse alarm in row 1, Disable rev
light/alarm until moving in reverse direction. Change the value

2. Row 1 shows the setting for flashing working lights when driving
backwards.
Row 2 shows the stored for flashing working lights when driving
backwards.
0 = Solid glow when driving backwards.
1 = Flashing light when driving backwards.
3. Set the value for flashing working lights when driving backwards in
Row 1, Enable flashing work light reverse. Change the value

2. Row 1 shows the setting for flashing brake lights when driving
backwards.
Row 2 shows the stored for flashing brake lights when driving
backwards.
0 = Flashing light when driving backwards.
1 = Non-flashing light when driving backwards.
3. Set the value for flashing brake lights when driving backwards in
Row 1, Disable flashing brake light at reverse. Change the val-

8.5.9.7 Initiation menus, Signal system

9.7 Signalling Sys 1/XX INITIATE
2. Row 1 shows the use of the revolving beacon, boom.
Row 2 shows the saved value for use.
3. Set use of rotating beacon on row 1, Rotating beacon cab and
boom. Change the value with / and store the value with .
0 = off.
1 = activated only with the switch.
2 = activated with the switch or during reversing.
3 = activated with the switch or when the engine is running.
4 = activated with the switch or during ignition on.
5 = activated with the switch or when a gear is engaged.

2. Row 1 shows the use of the revolving beacon, frame.
3. Set use of rotating beacon on row 1, Rotating beacon frame.
0 = off
3 = activated with the switch or during driving forward.
5 = activated with the switch or during automatic functions.
6 = activated with the switch or with high/low beam.

2. Row 1 shows the use of the revolving beacon attachment.
3. Set use of rotating beacon on row 1, Rotating beacon attach-
ment. Change the value with / and store the value with .
0 = off
3 = activated with the switch or during driving forward.
5 = activated with the switch or during automatic functions.
6 = activated with the switch or when height limitation is activated.
7 = activated with the switch or when height limitation is
deactivated.


2. Row 1 shows the use of the open twistlock switch as a horn.
3. Set to have the signal horn function on the open twistlocks switch
in row 1. Change the value with / and store the value with .
0 = Switch does not work as a horn.
1 = Open twistlocks switch (S1020) on the control lever acts as a
signal horn when contact is not active.
2 = Open twistlocks switch (S8070-1) on the linear lever acts as a
horn.

2. Rad 1 shows blocking of reverse alarm with switch.
3. Set blocking of reverse alarm on row 1, Block reverse alarm from
D7971 with switch. Change the value with / and store the
value with .
0 = No blocking of reverse alarm.
1 = Reverse alarm blocked (D7902 C3p19).
2 = Reverse alarm blocked (D7902 C3p17).

2. Row 1 shows whether the warning beacon is activated when
driving.
3. Set activation of warning beacon when driving in Row 1, Hazard
active when driving. Change the value with / and store the
value with .
0 = off.
1 = activated when a gear is engaged.
2 = activated during reversing.

8.5.9.9 Initiation menus, Glass/windows/mirrors,

9.9 Glass Wind Mirr 1/XX INITIATE

2. Row 1 shows the heating time for mirrors.
Row 2 shows the saved value for the heating time.
3. Set heating time for mirror on row 1, Mirror heating time. Change
0 = no time limit.
9.9 Glass Wind Mirr 2/XX INITIATE

2. Row 1 shows the heating time for rear window.
Row 2 shows the saved value for the heating time.
3. Set heating time for rear window on row 1, Window heating time.
0 = no time limit.
8.5.9.10 Cab frame and suspension

9.10 Cab Suspension 1/XX INITIATE

cab forward/up (Y6016).
3. Set start current for Solenoid valve cab forward/up (Y6016) in row
1, Start current sliding cab forward. Change the value with /


cab forward/up (Y6016).
3. Set end current for Solenoid valve cab forward/up (Y6016) in row 1,
End current sliding cab forward. Change the value with /
position.

2. Row 1 shows the setting value for damping of cab forward or up.
3. Set the value for damping of cab forward or up in Row 1, Damp
value sliding cab forward. Change the value with / and
machine.

cab back/down (Y6017).
3. Set start current for Solenoid valve cab back/down (Y6017) in row
1, Start current sliding cab reverse. Change the value with /


cab back/down (Y6017).
3. Set end current for Solenoid valve cab back/down (Y6017) in row 1,
End current sliding cab reverse. Change the value with /
position.

2. Row 1 shows the setting value for damping cab back/down.
3. Set the value for damping of cab back/down in row 1, Damp value
sliding cab reverse. Change the value with / and store the
value with Save .
machine.

2. Row 1 shows the setting value for distance from end position for
damping cab movement.
3. Set value distance in row 1, Damp distance sliding cab. Change
machine.


2. Row 1 shows the setting value for using the thumb control for shift-
ing on the control lever with the shift button on the control lever for
cab movement.
Row 2 shows the stored value for the switch's function.
3. Set the value for the switch's function in row 1, Enable Fwr/Rev
switch for sliding cab. Change the value with / and store
machine.
0 = Cab movement via the control lever's thumb control for shifting
disengaged.
1 = Cab movement via the control lever's thumb control for shifting
with the shift-button activated.

cab up (Y6016).
3. Set start current for Solenoid valve cab up (Y6016) in row 1, Start
current lifting cab up. Change the value with / and store the
value with Save .

cab up (Y6016).
3. Set end current for Solenoid valve cab up (Y6016) in row 1, End
current lifting cab up. Change the value with / and store the
value with Save .
position.


2. Row 1 shows the setting value for damping of cab up.
3. Set the value for damping of cab up in Row 1, Damp value lifting
cab up. Change the value with / and store the value with
Save .
machine.

cab down (Y6017).
3. Set start current for Solenoid valve cab down (Y6017) in row 1,
Start current lifting cab down. Change the value with / and

cab down (Y6017).
3. Set end current for Solenoid valve cab down (Y6017) in row 1, End
current lifting cab down. Change the value with / and store
position.


2. Row 1 shows the setting value for damping cab down.
3. Set the value for damping of cab down in row 1, Damp value lift-
ing cab down. Change the value with / and store the value
with Save .
machine.

2. Row 1 shows the setting value for distance from end position for
damping cab movement.
3. Set the value for distance on row 1, Damp distance cab up/down.
machine.

2. Row 1 shows the setting value for the buzzer if the door is open.
Row 2 shows the stored value for the buzzer's function.
3. Set the value for the buzzer's function on row 1, Enable Summer
if door is open. Change the value with / and store the value
with Save .
0 = Buzzer does not sound when the door is open.
1 = Buzzer sounds when the door is open.

8.5.9.10 Vertically adjustable cab, calibration menu

9.10 Cab Suspension 1/XX CALIBRATE
1. Navigate to the calibration menu 9.10 Cab Suspension 1/XX CALI-
BRATE with / . See Navigation to a menu, work instruction,
page 8:169 for an explanation of navigation.
Row 1 shows the cab's position.
Row 2 shows the saved value for the cab's rear position.
2. Run the cab back to its rearmost position. Press Save to store
this value.
The value in Row 1, Cab in rear position, is saved in Row 2.

Row 2 shows the saved value for the cab's front position.
2. Run the cab forward to its front position. Press Save to store this
value.
The value in Row 1, Cab in front position, is saved in Row 2.

Row 2 shows the saved value for the cab's lower position.
2. Lower the cab to its lowest position. Press Save to store this
value.
The value on row 1, Cab in lower position, is saved on row 2.

Row 2 shows the saved value for the cab's upper position.
2. Raise the cab to its highest position. Press Save to store this
value.
The value on row 1, Cab in upper position, is saved on row 2.

8 Control system – Common hydraulics 8:245
8.5.9.14 Initiation menus, Central lubrication

9.14 Central Lubr 1/XX INITIATE
2. Row 1 shows the setting value for the capacity of central lubrica-
tion, frame.
Row 2 shows the saved value for the capacity.
3. Set the capacity for central lubrication, frame in row 1, Grease ca-
pacity frame adjust 0-150% Change the value with / and
0% means lubrication is turned off and at 150% the central lubrica-
tion system lubricates about 50% more than in normal mode.
9.14 Central Lubr 2/XX INITIATE

2. Row 1 shows the setting value for the capacity of central lubrica-
tion, attachment.
Row 2 shows the saved value for the capacity.
3. Set the capacity for central lubrication, attachment in Row 1,
Grease capacity attach. adjust 0-150% Change the value with
0% means lubrication is turned off and at 150% the central lubrica-
tion system lubricates about 50% more than in normal mode.
8.5.10 Common hydraulics

8.5.10.4 Initiation menus, Pumps
10.4 Pumps 10/XX INITIATE
Row 1 shows the setting value for start current for LS-Pressure
attachment.
Row 3 shows pressure LS-Pressure attachment.

Row 1 shows the setting value for end current for LS-Pressure
attachment.
Row 3 shows pressure LS-Pressure attachment.


2. Row 1 shows the setting for deactivating genset pump.
Row 2 shows stored value for the function. 0 = active, 1 =
deactivated.
3. Set the value for genset pump in Row 1, Disable genset pump.
8.5.11 Common electrics

11.1 Distr Of Electr 1/XX INITIATE
2. Row 1 shows the setting for activating functions while driving back-
wards. Using this function, you can choose which functions should
be started first when machine speed has fallen below 3 km/h.
Row 2 shows stored value for activating the functions. 0 = deacti-
vated, 1 = active.
3. Set the value for back-up light/reverse alarm in Row 1, Disable
output status reverse only when move in forward direction
D7901. Change the value with / and store the value with .
8.5.11.5 Initiation menus, Voltage feed

11.5 Distr Of Electr 1/XX INITIATE
2. Row 1 shows the time for automatic system and engine shut down.
Row 2 shows the saved value for time.
3. Set the time for automatic system and engine shut down on row 1,
Automatic system shut down time. Change the value with /

9:1
9 Frame, body,c ab and accessories
Contents 9 Frame, body, cab and accessories

9 Frame, body, cab and accessories ................................................................... 9:3
9.1.1 Multi-function lever ..................................................................................... 9:13
9.2 Safety and emergency equipment .................................................................. 9:15
9.2.1 Control breaker........................................................................................... 9:16
9.2.2 Seat belt ..................................................................................................... 9:16
9.2.3 Fire extinguisher......................................................................................... 9:16
9.2.5 Alcolock ...................................................................................................... 9:17
9.3 Seat ................................................................................................................. 9:18
9.3.1 Seat cushion............................................................................................... 9:21
9.3.2 Back rest cushion ....................................................................................... 9:23
9.3.3 Heating coil................................................................................................. 9:24
9.3.4 Bumper ....................................................................................................... 9:24
9.3.5 Air suspension............................................................................................ 9:24
9.3.6 Compressor air-suspension seat ............................................................... 9:24
9.3.11 Arm rest ...................................................................................................... 9:25
9.3.17 Head rest .................................................................................................... 9:25
9.3.19 Sensor, operator-in-seat ............................................................................ 9:25
9.4 Heating, ventilation and air conditioning ......................................................... 9:26
9.4.1 Fresh air filter.............................................................................................. 9:31
9.4.2 Fresh air/recirculation damper ................................................................... 9:32
9.4.3 Cab fan ....................................................................................................... 9:33
9.4.4 Heat exchanger heat .................................................................................. 9:36
9.4.5 Water valve................................................................................................. 9:38
9.4.6 Sensor coolant temperature....................................................................... 9:40
9.4.7 Compressor................................................................................................ 9:40
9.4.8 Condenser unit ........................................................................................... 9:41
9.4.9 Receiver drier ............................................................................................. 9:42
9.4.10 Pressure switch .......................................................................................... 9:43
9.4.11 Expansion valve ......................................................................................... 9:45
9.4.12 Temperature deicing sensor....................................................................... 9:45
9.4.13 Heat exchanger, cooling............................................................................. 9:46
9.4.14 Air distributor .............................................................................................. 9:48
9.4.15 Defroster nozzles ....................................................................................... 9:49
9.4.16 Fan temperature sensor ............................................................................ 9:50
9.4.17 Interior temperature sensor ....................................................................... 9:50
9.4.18 Ambient temperature sensor...................................................................... 9:51
9.4.19 Pause heater .............................................................................................. 9:51
9.4.20 Timer for diesel-driven engine and cab heater .......................................... 9:51
9.4.21 Diesel-driven engine and cab heater ......................................................... 9:52
9.4.25 Preparation, cab fan ................................................................................... 9:52
9.5 Wiper/washer system...................................................................................... 9:53
9.5.4 Washer motor and reservoir....................................................................... 9:58
9.5.5 Wiper motor front........................................................................................ 9:60
9.5.6 Wiper motor roof......................................................................................... 9:62
9.5.7 Wiper motor rear ........................................................................................ 9:65
9.5.8 Wiper motor, front and roof......................................................................... 9:68
9.6 Lighting system ............................................................................................... 9:71
9.6.1 Headlights .................................................................................................. 9:74
9.6.2 Running lights............................................................................................. 9:74
9.6.3 Tail lights..................................................................................................... 9:74
9.6.4 Brake light................................................................................................... 9:75
9.6.5 Back-up lights............................................................................................. 9:75
9.6.6 Direction indicators..................................................................................... 9:75
9.6.7 Warning lamp, Hazard................................................................................ 9:75
9.6.8 Revolving beacon....................................................................................... 9:76

9.6.9 Working lights, cab ..................................................................................... 9:77

9.6.10 Work light boom ......................................................................................... 9:77
9.6.11 Working lights, attachment......................................................................... 9:77
9.6.12 Interior lighting............................................................................................ 9:77
9.6.13 Extra working lights frame.......................................................................... 9:78
9.7 Signalling system ............................................................................................ 9:79
9.7.1 Horn............................................................................................................ 9:81
9.7.2 Warning lamp, Hazard................................................................................ 9:81
9.7.3 Revolving beacon....................................................................................... 9:81
9.7.4 Warning parking brake ............................................................................... 9:81
9.7.5 Reverse alarm ............................................................................................ 9:82
9.7.7 Buzzer ........................................................................................................ 9:82
9.8 Entertainment and communication ................................................................. 9:83
9.8.1 Audio system.............................................................................................. 9:83
9.8.7 Voltage converter ....................................................................................... 9:84
9.9 Glass/windows/mirrors.................................................................................... 9:85
9.9.1 Windscreen ................................................................................................ 9:86
9.9.2 Side window ............................................................................................... 9:92
9.9.3 Roof window............................................................................................... 9:93
9.9.4 Rear window............................................................................................... 9:98
9.9.5 Rear view mirror ......................................................................................... 9:98
9.9.8 Rear view camera and load camera .......................................................... 9:99
9.10 Cab structure and suspension ...................................................................... 9:101
9.10.1 Cab frame................................................................................................. 9:101
9.10.2 Doors ........................................................................................................ 9:102
9.10.3 Cab substructure ...................................................................................... 9:104
9.10.4 Sliding cab ................................................................................................ 9:105
9.10.5 Vertically adjustable cab............................................................................9:118
9.11 Cab interior.................................................................................................... 9:131
9.11.1 Instrument and control panels.................................................................. 9:131
9.11.2 Interior fittings, plastic .............................................................................. 9:132
9.11.3 Interior fittings, textile ............................................................................... 9:137
9.11.4 Floor covering........................................................................................... 9:138
9.11.5 Insulation .................................................................................................. 9:138
9.11.6 Sun visors................................................................................................. 9:139
9.12 Frame ............................................................................................................ 9:140
9.13 Body structure ............................................................................................... 9:141
9.13.1 Wings........................................................................................................ 9:141
9.13.2 Hood engine compartment....................................................................... 9:141
9.13.3 Footsteps and hand rail............................................................................ 9:141
9.13.4 Counterweight .......................................................................................... 9:141
9.13.5 Battery compartment................................................................................ 9:142
9.13.8 Tool kit ...................................................................................................... 9:142
9.13.9 Lifting lugs ................................................................................................ 9:143
9.14 Central lubrication ......................................................................................... 9:144
9.14.1 Pump unit ................................................................................................. 9:145
9.14.2 Distribution block ...................................................................................... 9:145
9.14.3 Lines ......................................................................................................... 9:146
9.14.4 Lubricant nipples ...................................................................................... 9:146
9.14.5 Sensor, central lubrication........................................................................ 9:147
9.15 Paint/coatings ............................................................................................... 9:148

9 Frame, body, cab and accessories – Frame, body, cab and accessories 9:3
9 Frame, body, cab and

accessories
Frame, body, cab and accessories,
general
structions for components and systems belonging to the frame, body,
cab and accessories, refer to the relevant supplier documentation.
Frame, body, cab and accessories,

description
The machine consists of frame, body and cab.
The frame is the machine's structural part and is made of high-strength
steel.
The body consists of wings, engine hood and other parts mounted on
the frame.
The cab is built separately and insulated from the frame using heavy-
duty rubber dampers. Driver's seat, steering wheel and control lever for
hydraulics can be adjusted for optimal individual operating position. Ef-
fective insulation results in a minimum of vibration and a low sound lev-
el. The machine is equipped with a heating and ventilation unit with air
conditioning.
WARNING
Each case of mechanical damage to the cab may in-
volve risks since the strength is changed. Conse-
quently, making holes in load bearing parts is forbidden.
Contact Cargotec for recommendations.
WARNING
The strength of the roof window may be significantly re-
duced in case of exposure to substances containing ar-
omatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the surface layer of the roof window and clean
only with washer fluid or mild detergent. Rinse thor-
oughly with lukewarm water afterwards. Replace a dam-
aged roof window that shows cracks or scratches
immediately!

9:4 9 Frame, body, cab and accessories – Frame, body, cab and accessories
CAUTION
All reworking of the roof window is forbidden (e.g. mak-
ing holes or cutting).
Risk of material damage.
Small cracks in the material around outer edges for ex-
ample indicate that the strength of the roof window is
affected and it must be replaced immediately.

9 Frame, body, cab and accessories – Controls and instruments 9:5

Cab overview
1 2 3 4 5
022974
13 12 11 10 9 8
1. Travel direction selector and parking brake 8. Right dashboard panel, rear section
2. Multi-function lever 9. Arm rest and storage box
3. Steering wheel 10. Driver's seat
4. Steering panel 11. Speed pedal
5. Display with function keys 12. Brake pedals
6. Right dashboard panel, front section 13. Joystick or mini-wheel
7. Right dashboard panel, middle section
Cab rear section, see Cab rear section, page 9:8.

9:6 9 Frame, body, cab and accessories – Controls and instruments
Roof panel cab, see Roof panel, page 9:8.

Steering panel
14. Ignition
14 15. Engine start and stop button
21 22 23 30 16 17 16. Indicator light, parking brake
17. Indicator light, high beams
18 18. Indicator light for active error code
19. Indicator light for direction indicators
24 19 20. Warning lamp, by-pass of safety system
20 21. Switch, windscreen wiper front windscreen, continuous
25
Switch for combined windscreen wipers front windscreen/roof win-
26 dows, continuous
22. Switch, windscreen wiper front windscreen, intermittent
012692
Switch for combined windscreen wipers front windscreen/roof win-
27 28 29 32 31 33 15 dows, intermittent
Steering panel 23. Windscreen washer switch
24. Switch, windscreen wiper roof window, intermittent
25. Switch, windscreen wiper roof, continuous
26. Switch, windscreen wiper rear, continuous
27. Switch, windscreen wiper rear window, intermittent
28. Light sensor
29. No function
30. Manual shifting up switch
31. Manual shifting down switch
32. Switch for automatic shifting
33. Travel direction indicator, Forward Neutral Reverse
Right dashboard panel, front section
34. Control breaker for hydraulics
34 35 36 37 38 39 40 43 35. Switch for pause heater
36. Switch for recirculation
37. Switch for defroster
38. Switch for reduced fan speed
39. Switch for automatic control of the climate system
40. Switch for increased fan speed
41 42 44 45 46
41. Switch for increased temperature
42. Switch for reduced temperature
43. Switch for cooling
44. Switch for air distribution, to the floor
012693
45. Switch for air distribution, to the driver

47 48 49 50 51 52 46. Switch for air distribution, to the roof
Right dashboard panel, front section 47. Switch for bypass of safety system
48. Switch for electrically heated rear view mirror
Switch for electrically heated rear window
49. Control lever for electrically operated mirrors
50. Switch for support jacks
51. Spare
52. Switch for Mute for audio system

Right control panel, middle section

53. Control lever
53
i a Travel direction selector, Forward - Neutral - Reverse
h
d-g b Lift/lower control
a c Control for boom in/out
54 55 56 57 58 Control lever EGO: Control for levelling (Shift)
b d Side shift control
c e Spreading control
f Control for rotation
k Control lever Cobra: Controls for levelling (Shift)
j g Control for tilt ( )

h Switch for opening the twistlocks
i Switch for alternative function
64 59 60 61 62 63 j Switch for tilt lock
k Switch for levelling lock
53
54. Switch for radio control
j 55. Switch for bottom lift-attachment, front legs
k d-e
56. Switch for bottom lift-attachment, rear legs
f h 57. Switch for automatic spreading 20'-40'
g 54 55 56 57 58 58. Switch for 30'-stop
i b 59. Spare
c 60. Switch for twistlocks, automatic/manual
61. Switch for bottom lift-attachment, clamping position
Switch for lowering overheight-legs
62. Switch for cab movement
63. Spare
021315
64. Switch for horn

59 60 61 62 63
Right dashboard panel, middle section
Right control panel, rear section

65. Switch for working lamps on cab
65 66 67 68 69 70 71 72 73 66. Switch for working lights on boom
67. Switch for working lights on attachment
68. Switch for extra working lights on frame
69. Switch for reversing light
70. Switch for length adjustment of right control panel
71. Switch for height adjustment of the steering wheel
When the service menus are active, the buttons can be used to se-
74 75 76 77 lect up/down in the menus.
72. Switch for height adjustment of right control panel
10:23am
10 20
2 When the service menus are active, the buttons can be used to se-
0
rpm x 100
22
lect right/left in the menus.
73. Function keys and navigation wheel for control system
21° 18
99999
km/h
74. Switch for headlights

Pwr/Nor/ECO
16.7t
D U 75. Switch, interior lighting
76. Switch for revolving beacon
77. Switch for warning lamp
022842
73
Right dashboard panel, rear section and display

Cab rear section

78. Cover
82
81 79. Electronic box with fuses and relays
80 Connector VDI
79 80. Key lock, by-pass
81. Tag reader for operator identification
82. Timer diesel-driven engine and cab heater
78
019115
Cab rear section
Roof panel
83. Light sensor
83 84 85 86 87 84. Indicator light for lowered support jacks
85. Indicator light for locked twistlocks
019116
86. Indicator light for contact

87. Indicator light for unlocked twistlocks
Roof panel
Control for load handling
For further information about controls for load handling and associated
functions, see section Operator's manual section 4.6 Load handling.

Operating menus, overview

1 10:23 2
10 20
0 22
2
11 0:00pm rpm x 100 10:23
2
1756 rpm
7.8t 21° 18
99999
km/h
32.8 l/h
9.5
20.2
km/h
km/h
Pwr/Nor/ECO 26.1 l/h
74.8 km
3.6m
16.7t
D U
120:36 h 123 14432
10 0:00pm 0:00pm
3
-1.9 t
74.9 t
522.9 t
9 10:23 10:23 4
0 123 1 23476 pcs
123 2 23476 pcs
0
123
1 23476 pcs
123
2 23476 pcs
0
8 0:00pm 12:59pm 5
bar
10.0
8.4 9.9 80°C 5.0bar
7.4 10.0
10.1
7 6
10:23 0:00pm
75°C 50%
28.0V
50°C 50°C
022232
Which operating menus are shown depends on machine equipment

1. Operating menu 7. Operating menu electrical system
2. Operating menu, trip computer work shift 8. Operating menu tyre pressure monitoring
3. Operating menu scales 9. Operating menu system
4. Operating menu load counter and extra functions 10. Operating menu CoastDec
5. Engine operating menu 11. Operating menu load centre
6. Operating menu, transmission and hydraulics

Silicone panel right-hand dashboard panel front

section, replacement
4. Turnover the panel and remove the nuts and washers that secure
the silicone panel.
5. Replace the silicone panel. Do not forget the retaining clip that
holds the connector in position.
CAUTION
015760
The plastic parts of the panels may be damaged if the

screws are tightened too hard.
Product damage.
Exercise caution when tightening, do not tighten the
screws too hard.
Switch right-hand dashboard panel front section,

replacement

4. Detach the connector from the switch.

5. Replace the switch.
CAUTION
015879
Product damage.
screws too hard.
Silicone panel right-hand dashboard panel rear

section, replacement
2. Open the cover on the storage box.
015771
1 2
1. Navigation wheel
2. Lid, storage box
015762

4. Loosen the spring and carefully turnover the storage box.

Avoid stretching the cables.
015781
5. Carefully separate the navigation wheel and silicon panel's
1 2 connectors.
CAUTION
The navigation wheel's contact is only soldered onto
the circuit board.
Product damage.
Exercise caution when the connector is separated in or-
der to avoid damage to the circuit board.
6. Remove the nuts and washers that secure the silicone panel.
015761
4 3
1. Contact, navigation wheel
2. Nut, silicone panel
4. Contact, silicone panel. Do not forget the retain-
ing clip that holds the connector in position.
7. Carefully remove the navigation wheel's circuit board with sensor
1 from the silicone panel.
Pull the navigation wheel straight up and undo the plastic nut
under the wheel.
2 holds the connector in position.
NOTE
For the washer (position 3), the side with the bevelled edge on
the inside must be fitted against the potentiometer.
3
CAUTION
4
Product damage.
017459
screws too hard.

Navigation wheel parts
1. Navigation wheel
2. Plastic nut
3. Washer
4. Circuit board

9 Frame, body, cab and accessories – Multi-function lever 9:13
Navigation wheel, replacement

See Silicone panel right-hand dashboard panel rear section, replace-
ment, page 9:11.
Silicone panel steering panel, replacement

2. Remove the five screws.
015769
3. Turnover the panel and disconnect the contact.

1 2 3
4. Remove the nuts and washers that secure the silicone panel.
holds the connector in position.
015770
1. Silicone panel
2. Connector with retaining clip
3. Nut
9.1.1 Multi-function lever

General
Light control, horn and direction indicators are handled by a multi-func-
2 tion lever (position 2).
015221

9:14 9 Frame, body, cab and accessories – Multi-function lever
Multi-function lever, replacement

2. Remove the gaiter from the multi-function lever.
015778

015776
4. Remove the screws and fold out the multi-function lever.

Mark the pins and then remove them.
5. Replace the multi-function lever.
6. Fit in the reverse order. Replace pins as marked.
015777

9 Frame, body, cab and accessories – Safety and emergency equipment 9:15
9.2 Safety and emergency

equipment
Safety and emergency equipment, description
A good work environment has safety and emergency equipment to fa-
cilitate and make the operator's work safe, as well as safety equipment
to signal to personnel in the surrounding area.
The operator's cab contains equipment designed to fulfil the safety re-
quirements imposed by authorities, customers, operators and Cargotec.
The machine may be equipped with the following:
16 3
14, 15 4, 5, 6
2
018501
13 11, 12 10 9 7, 8
1. Revolving beacon. 12. Switch in driver's seat.
Extra revolving beacon on boom nose and on rear lamp Locks the transmission in neutral position and blocks the
housing . (Not identified in the figure.) load handling functions if the operator leaves the operator's
station. In addition, a warning is activated if the operator
2. Buzzer, automatic spreading 20' – 40' . leaves the operator's station without applying the parking
3. Rear view camera with distance warning . brake.
Camera at boom nose . (Not identified in the figure.) 13. Fire extinguisher .
Fire extinguishers may also be located externally.
Camera at twistlocks . (Not identified in the figure.)
If the machine is equipped with a fire extinguisher then it
Camera at lifting shoe (for bottom lift) . (Not identified in must be approved in accordance with European standard
the figure.) EN3. The fire extinguisher must be specified so that it is de-
4. Buzzer in cab to indicate alarm, overload or forgotten ac- signed for use against fire in: fibrous fuels (Class A), liquid
tion, e.g. if the operator leaves the cab without applying the fuels (Class B), gaseous fuels (Class C) and electrical ap-
parking brake. pliances. Adapted fire extinguishing equipment can be or-
5. Personnel proximity system that alerts when personnel dered from Cargotec.
warning tags are detected in the proximity of the machine Fire extinguishing system . (Not identified in the figure.)
. Can be activated automatically, manually on the display in
6. Tyre pressure monitoring system that alerts when incorrect the cab, or with a switch on the body.
tyre pressure is detected . 14. Reverse alarm.
7. Horn. 15. Back-up lights.
8. Electrically-driven loud horn . 16. Emergency exit cab, right-hand door and rear window ( ).
9. External rear view mirrors. 17. Machine with vertically adjustable cab (not shown in the fig-
Used to provide increased visibility during manoeuvring ure) .
and load handling. One rear view mirror on each side. - Lock against opening the left-hand door when the cab is
10. Control breaker for hydraulics. raised.
Disengages all power transmission and control signals to - Lock against opening the right-hand door lock.
the hydraulics. - Control for emergency lowering of the cab on the control
11. Seat belt. valve.
- Ladder on the cab frame for evacuating the cab.

9:16 9 Frame, body, cab and accessories – Control breaker
9.2.1 Control breaker

Control breaker, description
See Control breaker voltage, description, page 11:20.
9.2.2 Seat belt

Seat belt, description
Two-point seatbelt fitted in the seat. See Driver's seat, page 9:18.
There are also 3-point seatbelt .
For diagnostic menu, see 9.3 Seat 1/XX DIAGNOSE, page 8:110.
An event menu appears on the display and indicates that the speed of
the machine is above 3 km/h and the seat belt sensor's output signal is
0 V (seat belt not buckled).
9.2.3 Fire extinguisher

Fire extinguisher, description
Usage instructions are on the fire extinguisher.

If the machine is equipped with a fire extinguisher then it must be ap-
proved in accordance with European standard EN3. The fire extin-
guisher must be specified so that it is designed for use against fire in:
fibrous fuels (Class A), liquid fuels (Class B), gaseous fuels (Class C)
and electrical appliances. Adapted fire extinguishing equipment can be
ordered from Cargotec.
Fire extinguishers must only be service and repaired by personnel with
special training.
Fire extinguishing system
As an option, the machine can be equipped with a fire extinguishing

system. The fire extinguishing system is activated automatically in the
event of fire and can also be activated manually from the cab or with a
switch on the chassis.
The fire extinguishing system must only be serviced and repaired by
personnel with special training.

9 Frame, body, cab and accessories – Alcolock 9:17
9.2.5 Alcolock
Alcolock, description
The machine may be equipped with an alcolock. Starting the engine re-
quires an approved breath test from the operator. The alcolock is an in-
dependent system which communicates with the machine's control
system. The alcolock unit is fitted in the cab.
For more information, see Supplier documentation.
016631

9:18 9 Frame, body, cab and accessories – Seat
9.3 Seat
Seat, general
The seat's function is to provide the operator with a good sitting position
and contribute to a good work environment. The cab's seat has several
adjustment options and fulfils high comfort standards.
Driver's seat
Standard seat
The driver's seat is equipped with a number of adjustment controls and
11 are as follows (adjustment is easier when the seat is unloaded):
1. Seat belt, 2-point.
Seat belt, 3-point .
2. Seat tilt.
3. Horizontal suspension (forwards/backwards) .
4. Seat length.
5. Seat height position.
10 For mechanical raising:
Turn the knob clockwise or anticlockwise until the desired height is
1 reached.
9
For air suspension raising:
Lift the lever up to raise the seat height or press the lever down to
2 lower the seat height. The suspension is automatically adjusted to
the weight of the operator.
8 An indicator shows a green marking when the correct setting is
reached. The indicator shows red when the seat's suspension is
3 set outside the comfort zone.
7 6. Front/rear adjustment.
Release the seat using the lever and move the seat forwards or
backwards.
4
7. Backrest rake.
5 6 Release the lock with the lever, set the desired angle and release
the lever to lock in position.
8. Adjusting arm rest, left .
9. Lumbar support.
Turn the knob until the desired hardness in the lumbar support is
set.
10. Seat heating .
11. Adjusting the headrest.
017255
Driver's seat with adjustment options

9 Frame, body, cab and accessories – Seat 9:19
Optional seat Grammer
The driver's seat is equipped with several setting controls, they have
the following functions:
1. Seat heating.
1 2. Upper lumbar support.
Press + or - until the required firmness in the lumbar support is
reached.
2 3. Lower lumbar support.
reached.
3 4. Backrest rake.
Release the lock with the lever, set the desired angle and release
10
4 5. Horizontal suspension (forwards/backwards).
Control forward = locked.
9 Control backward = suspension.
To lock the suspension, move the control forward and then press
8 the seat backward until a click is heard when the suspension locks.
6. Front/rear adjustment.
7 Release the seat with the lever, set the desired distance and re-
lease the lever in order to lock in the desired position.
018507
6 5 7. Height and angle of the seat

Angle setting: Set the vertical damping (position 8) to the softest
position, sit on the seat, pull the control upward and release it di-
rectly. The suspension is automatically adjusted to the body weight.
Height control: Move the control upward to increase the seat
height, or downward to lower the seat height.
8. Vertical damping (up/down).
Control to the left = soft.
Control straight up = medium.
Control to the right = hard.
9. Seat length.
Release the length setting with the control, set the desired length
and release the control to lock in the desired position.
10. Seat tilt.
Release the angle setting with the control, set the desired angle
11. Seat belt, 2-point (not shown in the figure).
Seat belt, 3-point (not shown in the figure).

9:20 9 Frame, body, cab and accessories – Seat
Optional seat Isringhausen
15 The driver's seat is equipped with several setting controls, they have
the following functions:
1. Seat belt, 2-point.
Seat belt, 3-point .
2. Seat tilt.
Release the angle setting with the control, set the desired angle
3. Seat length.
1 Release the length setting with the control, set the desired length
14 and release the control to lock in the desired position.
4. Front/rear adjustment.
13 Release the seat with the lever, set the desired distance and re-
lease the lever in order to lock in the desired position.
2 5. Height adjustment
12 Adjust the height of the seat using the control.
6. Vertical damping (up/down).
11 7. Horizontal suspension (forwards/backwards).
3
8. Lower lumbar support.
022056
reached.
4 5 6 7 8 9 10 9. Upper lumbar support.
reached.
Driver's seat with adjustment options 10. Side support.
Stepless side support for the back.
Press + or - to adjust the side support.
11. Ventilation, seat.
12. Seat heating.
13. Setting for seat ventilation and seat heating.
14. Backrest rake.
Release the lock with the lever, set the desired angle and release
15. Adjusting the headrest .
Passenger seat
As an option, the machine can be equipped with an extending passen-

ger seat with two-point belt on the left of the driver’s seat.
020552

9 Frame, body, cab and accessories – Seat cushion 9:21
Driver's seat, replacement

2. Slide the seat fully backwards, remove the two front screws that
hold the seat in place.
015800 3. Slide the seat fully forwards, remove the two rear screws that hold
1 the seat in place.
4. Disconnect the cable harness from the seat.
5. Secure the right-hand console so it does not fall down when the
seat is lifted out.
Secure it with a cord from the roof, or get the help of a colleague.
6. Remove the seat.
015801
2
1. Screw
2. Contact
9.3.1 Seat cushion

Seat cushion, description
Seat cushion fabrics are interchangeable. These should be replaced
with new ones when they show signs of wear.
Seat cushion, replacement
NOTE
Note how the seat cushion's guides and locking catches hold and
lock the seat cushion when it is removed in order to facilitate fitting.
1. Fully tilt up the seat cushion and then slide the seat cushion fully
forward (only the cushion, not the seat).
2. Press up the plastic arm under the seat cushion so that the plastic
arm snaps out of its locking catch.
Note how the plastic arm should align in relation to the mechanism
for the controls at the front of the seat cushion.
015802
Plastic arm, seat cushion

9:22 9 Frame, body, cab and accessories – Seat cushion
1 2 3. Fully slide back the seat cushion and carefully lift at the rear edge
so that the mechanism for the control (position 1) is clear of the
guide grooves in the seat undercarriage.
4. Pull the seat cushion forward enough that the guide grooves in the
seat cushion (position 2) are clear of the seat undercarriage.
5. Lift the seat cushion and turn it over.
017477
Attaching points seat cushion
1. Mechanism for controls
2. Guide grooves seat cushion
6. Remove the pins from the connector behind the seat.
7. Connect the seat cushion's cable harness behind the seat.
015803
8. Position the seat cushion so that the guide grooves in the seat
1 2 cushion engage in the mountings on the seat undercarriage.
9. Fully slide back the seat cushion and align the mechanism for the
control (position 2) into the guide grooves on the seat
undercarriage.
Check that the plastic arm is aligned on the correct side of the con-
trol arm.
017477
Attaching points seat cushion

1. Mechanism for controls
2. Guide grooves seat cushion
10. Slide the seat cushion forward so that the plastic arm locks the
seat cushion in the recess on the mechanism for the controls on
the front of the seat cushion.
11. Check that the longitudinal adjustment of the seat and the seat
cushion is working correctly.
015802
Plastic arm, seat cushion

9 Frame, body, cab and accessories – Back rest cushion 9:23
Seat cushion fabrics, replacement

1. Remove the seat cushion, see Seat cushion, replacement, page
9:21.
2. Place the seat cushion upside down and unscrew the controls.
3. Squeeze together the foam rubber.
015804
1
1. Screw, control
4. Pull the fabric from the seat cushion's groove.
Align the plastic part in the seat cushion's groove.
015805
The fabric's plastic part in the seat cushion groove
9.3.2 Back rest cushion

Back rest cushion, description
Backrest cushion fabrics are interchangeable. These should be re-
placed with new ones when they show signs of wear.
Backrest cushion fabrics, replacement

1. Remove the rotary control on the side of the seat and possibly the
headrest.
2. Pull the fabric down and out from the rear of the backrest.
Remove the fabric.
015807

9:24 9 Frame, body, cab and accessories – Heating coil
9.3.3 Heating coil

Heating coil, description
The heating coil is used for seat and backrest heating.
9.3.4 Bumper
Bumper, description
The shock absorbers are integrated in the suspension unit and are self-
adjusting, that is, adjust automatically to the operator\qs weight.
9.3.5 Air suspension

Air suspension, description
A seat with air suspension has rubber bellows and a compressor. The
air suspension is self-adjusting, that is, it adjusts automatically to the
operator's weight. The compressor supplies the suspension unit with
compressed air.
9.3.6 Compressor air-suspension seat

Compressor air-suspension seat, replacement
2. Remove the seat, see Driver's seat, replacement, page 9:21.
3. Turnover the seat.
4. Cut the cable ties.
5. Disconnect the cable terminals and unscrew the air connection.
6. Change the compressor.
015861
1 2 3 4
1. Cable terminal
2. Air connection
3. Cable ties
4. Compressor

9 Frame, body, cab and accessories – Arm rest 9:25
9.3.11 Arm rest

Armrests, description
Right side armrest is integrated into the right console and is attached to
the seat's seat frame. The height can be adjusted separately.
Arm rest for left side is an option .
The options for the left arm rest are:
A. Mini-wheel
See Joystick control/mini-wheel, function description, page 5:10.
On machines with mini-wheel there is also a switch fitted that de-
tects when the arm rest is lowered, see Arm rest in position sensor,
B. Joystick control
See Joystick control/mini-wheel, function description, page 5:10.
On machines with joystick control there is also a switch fitted that
detects when the arm rest is lowered, see Arm rest in position sen-
sor, description, page 5:27.
9.3.17 Head rest

Head restraint, description
Some models of seat can be adjusted with a head restraint for in-
creased comfort.
9.3.19 Sensor, operator-in-seat

Sensor operator in seat, description
Sensor, operator-in-seat (S2300) detects whether the seat cushion on
the driver's seat is depressed, which indicates to the control system
that the driver's seat is occupied. This is used to warn with a buzzer, lo-
cated in Control unit KPU (D7902) (right console), if the operator leaves
the driver's seat without applying the parking brake. When operator-in-
seat sensor (B2300) indicates that the operator has left the driver’s
seat, the operation and hydraulic functions are blocked.
For diagnostic menu, see 9.3 Seat 1/XX DIAGNOSE, page 8:110.

9:26 9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
9.4 Heating, ventilation and air

conditioning
Heating, ventilation and air conditioning,
description
The machine is equipped with an air conditioning unit, ECC (Electronic
Climate Control, electronic control of fan, air distribution, cooling and
F heating).
The air conditioning unit consists of different modules: fan module, heat
exchange module, air distribution module and silicone panel. The fan
2 module takes in air from the outside (or inside the cab) and directs the
4 air to the heat exchange module. In the heat exchange module the air
temperature is moderated and directed on towards the air distributor.
C The air distributor directs the air towards channels in the cab's interior
D for floor, defroster and air vents.
3 The heat exchange module consists of heat exchangers, one for heat-
ing and one for cooling. The heat exchanger for heating is connected to
the engine's cooling system and provides heat when the engine is hot.
E The heat exchanger for cooling (evaporator) is connected to the AC
compressor, which is activated when cooling is required.
On cooling, the compressor is activated which compresses the refriger-
ant conducted into the condenser. There the warm refrigerant is cooled
using the condenser unit fan and the ambient air with which the refriger-
ant is condensed into fluid. From the condenser, the refrigerant is con-
6 ducted on to the expansion valve via the fluid container / dryer filter.
A B
The refrigerant is evaporated in the evaporator inside the cab. When
the refrigerant is evaporated, cooling is created in the evaporator.
When outside air is forced through the evaporator by the cab fan, the
air is cooled down. The cooling is automatically deactivated when a
door is open. When the door is closed the cooling is reactivated. The
air conditioning unit has a delay of 45 seconds between deactivation
and activation.
1
5 G Air conditioning includes the parts presented in the illustration and en-
015310
sures the operator's cab climate is as comfortable as possible. The

function of the air conditioning is to:
1. Fluid separator/dryer filter • heat the air when it is cold
2. Evaporator • dehumidify the air when it is damp
3. Fan • clean the air of impurities
4. Expansion valve • cool the air when it is hot
5. Condenser • defrost (defroster function)
6. Compressor
The unit is controlled with switches and controls on the dashboard
A. High-pressure gas
panel.
B. High-pressure fluid
C. Low-pressure fluid The system's fan is operated variably 0-100 %.
D. Low-pressure gas
E. Heating, cab air
F. Cooled air to cab
G. Outdoor air for removal of heat

9 Frame, body, cab and accessories – Heating, ventilation and air conditioning 9:27
Heating, ventilation and air conditioning, function

description
1,2,3,4,5,29,30,32
D1 D7950
35
D7902
6 D7901 D7971
D6 9,11,18 20 D7940
15 D13
8 D8
22 D25 D27
34 26
19 D19
D20
D34
M 25 27
D18 23 24 C 28
D7
17 21
M
7 D17
16,31
M 12
D16 D11 D12
M
D33 33 13
10 14
023423
1 The Increase temperature switch U=5V Cab overview, page 9:5
(S1051-1) or Decrease temperature D1: 9.4 Climate System 2/XX DIAGNOSE,
switch (S1051-2) sends a voltage signal page 8:110
to the KPU control unit (D7902).
2 The Increase fan speed switch (S1180-1) U = 5 V Cab overview, page 9:5
or Decrease fan speed switch (S1180-2) D1: 9.4 Climate System 2/XX DIAGNOSE,
sends a voltage signal to the KPU control page 8:110
unit (D7902).
3 Air distribution to roof (S1053-1), to oper- U = 5 V Cab overview, page 9:5
ator (S1053-2) or to floor (S1053-3) D1: 9.4 Climate System 3/XX DIAGNOSE,
switches send a voltage signal to KPU page 8:111
4 Automatic regulation of the climate sys- U=5V Cab overview, page 9:5
tem switch (S1054) sends a voltage sig- D1: 9.4 Climate System 1/XX DIAGNOSE,
nal to the KPU control unit (D7902). page 8:110
5 Cooling switch (S1120) sends a voltage U=5V Cab overview, page 9:5
signal to the KPU control unit (D7902). D1: 9.4 Climate System 1/XX DIAGNOSE,
page 8:110
6 Interior temperature sensor (B7751) R = 10 kΩ at 25 °C Interior temperature sensor, description,
sends a voltage signal proportional to the page 9:50
temperature to KCU control unit (D7901). D6: 9.4 Climate System 4/XX DIAGNOSE,
page 8:111 and 9.4 Climate System 5/XX DI-
AGNOSE, page 8:111


7 Fan temperature sensor (B7752) sends R = 10 kΩ at 25 °C Fan temperature sensor, description, page
a voltage signal proportional to the tem- 9:50
perature to KCU control unit (D7901). D7: 9.4 Climate System 4/XX DIAGNOSE,
AGNOSE, page 8:111
8 Ambient temperature sensor (B7740) R = 10 kΩ at 25 °C Ambient temperature sensor, description,
AGNOSE, page 8:111
9 KCU control unit (D7901) regulates tem- Checked by control sys- 11.5.3.1 KCU control unit (D7901), page
perature and air distribution with signals tem, error shown with er- 11:27
from sensors and controls. ror code.
10 The engine produces heat while running. - Engine, general, page 1:3
It is cooled with the cooling system. The
heat from the cooling system is used to
heat the cab air.
11 KCU control unit (D7901) controls Water U = ±10 V 11.5.3.1 KCU control unit (D7901), page
valve (Y6730), which routes hot water for 11:27
heating heat exchanger. D11: 9.4 Climate System 14/XX DIAGNOSE,
page 8:114 and 9.4 Climate System 15/XX
DIAGNOSE, page 8:114
12 The water valve's opening (%) is fed U = 0.5-4.5 V Water valve, description, page 9:38
back to the KCU control unit (D7901). D12: 9.4 Climate System 7/XX DIAGNOSE,
This gives information for controlling the page 8:112
water valve's position.
13 Sensor, engine temperature, sends a Checked by control sys- Engine, general, page 1:3
voltage signal proportional to the engine tem, error shown with er- D13: 1.7 Cooling system 8/XX DIAGNOSE,
temperature to Control unit, engine ror code. page 8:33
(D7940).
14 Heat exchanger heat supplies heat to the - Heat exchanger heat, description, page 9:36
cab air. The heat is transferred from the
engine's cooling system to the cab air.
15 Control unit, engine (D7940) transmits Checked by control sys- 11.5.3.6 Control unit, engine (D7940), page
engine temperature in the cooling system, error shown with er- 11:38
tem on the CAN bus. ror code.
16 KCU control unit (D7901) controls Actua- Checked by control sys- Fresh air/recirculation damper, description,
tor motor, recirculation (Y6120) which tem, error shown with er- page 9:32
sets the fresh air or recirculation damper ror code. D16: 9.4 Climate System 11/XX DIAGNOSE,
in the required position. page 8:113 and 9.4 Climate System 12/XX
17 KCU control unit (D7901) controls Fan Checked by control sys- Cab fan, description, page 9:33
motor (M6570), which increases the air- tem, error shown with er- D17: 9.4 Climate System 16/XX DIAGNOSE,
flow in the cab. ror code. page 8:114
18 KCU control unit (D7901) controls Damp- U = ±12 V Air distributor, description, page 9:48
er motor (Y6720), which sets the air dis- D18: 9.4 Climate System 16/XX DIAGNOSE,
tributor to the required position. page 8:114 and 9.4 Climate System 17/XX
19 The air distributor's position is fed back U = 0.5-4.5 V Air distributor, description, page 9:48
to KCU control unit (D7901). This gives D19: 9.4 Climate System 8/XX DIAGNOSE,
information for controlling the air distribu- page 8:112
tor's position.
20 Control unit KFU (D7971) supplies volt- U = 24 V 11.5.3.4 Control unit KFU (D7971), page
age to Magnetic clutch (M6450) on the 11:34
compressor. D20: 9.4 Climate System 13/XX DIAGNOSE,
page 8:113
21 The compressor draws gaseous refriger- - Compressor air conditioning, description,
ant from the evaporator, compresses it, page 9:40
and forces it on to the condenser.

9 Frame, body, cab and accessories – Heating, ventilation and air conditioning 9:29

22 The engine's cooling fan draws air - Cooling fan, description, page 1:27
through the condenser and cooling unit. D22: 1.7 Cooling system 5/XX DIAGNOSE,
page 8:32
23 The condenser cools the refrigerant. The - Condenser unit, description, page 9:41
gaseous refrigerant condenses to liquid
form and is pumped on in the circuit.
24 The receiver drier absorbs any moisture - Receiver drier, description, page 9:42
from the cooling circuit. The fluid reser-
voir stores the refrigerant.
25 The pressure switch (B2460) sends a U = 24 V Pressure switch, description, page 9:43
signal to the KCU control unit (D7901) if D25: 9.4 Climate System 6/XX DIAGNOSE,
the pressure in the system becomes ab- page 8:112.
normally high or low.
26 The expansion valve adjusts the amount - Expansion valve, description, page 9:45
of refrigerant that is let in to the evapora-
tor. If the temperature in the evaporator's
outlet pipe increases, the expansion
valve increases the flow of refrigerant so
that heat dissipation in the evaporator
increases.
27 Temperature deicing sensor (B7753) R = 10 kΩ at 25 °C Temperature deicing sensor, description,
AGNOSE, page 8:111
28 Heat exchanger, cooling, dissipates heat - Heat exchanger, cooling, description, page
from the cab air. The heat is transferred 9:46
from the air to the refrigerant and trans-
forms the refrigerant to a gaseous state.
29 Defroster switch (S1390) sends a volt- Checked by control sys- Cab overview, page 9:5
age signal to the KPU control unit tem, error shown with er- D1: 9.4 Climate System 1/XX DIAGNOSE,
(D7902) that activates the defroster pro- ror code. page 8:110
gram for the climate system for nine
minutes.
30 Recirculation switch (S1910) sends a Checked by control sys- Cab overview, page 9:5
voltage signal to the KPU control unit tem, error shown with er- D1: 9.4 Climate System 1/XX DIAGNOSE,
(D7902) that activates recirculation. ror code. page 8:110
31 KCU control unit (D7901) controls Actua- Checked by control sys- Fresh air/recirculation damper, description,
tor motor, recirculation (Y6120) which tem, error shown with er- page 9:32.
sets the fresh air or recirculation damper ror code. D16: 9.4 Climate System 11/XX DIAGNOSE,
in the recirculation mode. page 8:113 and 9.4 Climate System 12/XX
32 Pause heater switch (S1019) sends a Checked by control sys- Cab overview, page 9:5
voltage signal to the KPU control unit tem, error shown with er- D1: 9.4 Climate System 18/XX DIAGNOSE,
(D7902). ror code. page 8:115
33 KCU control unit (D7901) controls the U = 24 V Pause heater, description, page 9:51.
Circulation pump heating system D33: 9.4 Climate System 20/XX DIAGNOSE,
(M6670) which pumps the coolant page 8:115
through the heating system when the en-
gine is turned off.
The pause heater is automatically
switched off by means of a thermostat in
the coolant circuit when the coolant tem-
perature is below a set value
34 Air filter contact (B2190) sends a signal U = 24 V D34: 9.4 Climate System 6/XX DIAGNOSE,
to the KCU control unit (D7901) if the page 8:112
pressure in the fresh air filter becomes
abnormally high.
35 Control unit KID (D7950) shows the heat- Checked by control sys- 11.5.3.3 Control unit, KID (D7950), page
ing and ventilation settings in the display. tem, error shown with er- 11:32
ror code.

General instructions for working on the air

conditioning unit
CAUTION
Authorisation is required for repair of the air condition-
ing unit.
WARNING
In the event of a rupture of a cooling hose or leakage on
the attachment - switch off the unit immediately.
It is dangerous to get refrigerant on the skin or in the
eyes.
Never release refrigerant in an enclosed space, the gas
may cause suffocation e.g. in assembly pits.
Never weld on or in the vicinity of a closed cooling
system.
Drain the refrigerant during repairs on the air
conditioning.
Work on the refrigerant circuit must only be performed
by an accredited company.
Air conditioning unit, troubleshooting the cooling

circuit
NOTE
The air conditioning unit does not work at temperatures below
approx. 0 °C since the pressure in the refrigerant circuit is too
low. If the pressure in the refrigerant circuit becomes too low
then the low pressure switch disconnects the power supply to
the compressor's magnetic coupling, which means that the air
conditioning unit stops working.
NOTE
During normal operation the air conditioning is stopped when a
door is opened. This function may need to be switched off during
troubleshooting. For instructions on how this is performed, see
9.4 Climate System 3/XX INITIATE, page 8:233.
1. Read the safety information for the refrigerant before starting work,
see Refrigerant, page B:17.
2. Read the general instructions before working on the climate sys-
tem, see General instructions for working on the air conditioning
unit, page 9:30.
4. Carry out performance tests on the air conditioning unit in accord-
ance with the maintenance manual, section 9 Frame, body, cab
and accessories, group 9.4 Heating, ventilation and air
conditioning.

9 Frame, body, cab and accessories – Fresh air filter 9:31
5. Check that the hoses and components on the pressure side main-
tain a roughly even temperature by feeling them with your hand.
NOTE
In the event of a stop in one of cooling circuit's components, and
during long-term operation, certain parts (possibly hoses before
the condenser) may be very hot. Risk of burn injuries!
6. All hoses and components on the pressure side (from the com-
pressor to the expansion valve) should be hot.
7. All hoses and components on the suction side (from the evapora-
tor to the compressor) should be cold.
8. Check that the expansion valve is not frosty or cold.
Frost or cold temperatures on the inlet side of the expansion valve
indicate that it is defective or clogged and that circulation is limited
or stopped on the pressure side.
9. Check that the compressor engages and disengages normally.
Run the cab fan at low speed and allow the compressor to work at
high rotation speed. When the temperature of the air vents ap-
proaches 0 °C, the compressor is disengaged via ECC and is re-
engaged when the temperature has risen approx. 3-7 °C. (If the
016878
compressor is not disengaged then there is a risk of the evaporator

icing up and cooling performance diminishing.)
Expansion valve
9.4.1 Fresh air filter

Fresh air filter, description
The fresh air filter is standard equipment on machines with cab. It is lo-
3 cated in the external unit for heat exchange (heat exchange module) to
the cab.
2
1
016870
Fresh air intake to cab with fresh air filter and filter
holder.
1. Cover
2. Fresh air filter
3. Fresh air intake

9:32 9 Frame, body, cab and accessories – Fresh air/recirculation damper
9.4.2 Fresh air/recirculation damper

Fresh air/recirculation damper, description
Fresh air/recirculation damper is an electrically operated damper fitted
in the fan module in the cab. The damper controls fresh air or recircula-
tion air to the air vents in the cab.
Fresh air/recirculation damper, is operated by motor recirculation
(Y6120).
016872
Recirculation motor, replacement

1 2 3
2. For access to the centre screw to recirculation motor:
Remove the cab fan housing, see Cab fan, replacement, page
9:33.
3. Remove the connectors from the motor and loosen the centre nut
and screws that hold the recirculation motor.
4. Replace the recirculation motor.
Before reassembly: Connect the connectors and test the recircula-
tion motor and operate to fresh air mode.
016082
NOTE
Make sure the hoses to the cab temperature sensor and filter
4 switch are fitted so that the airflow through them is not hindered.
1. Motor, recirculation
2. Centre screw, access from the top of the cab fan
housing
3. Screw, recirculation motor
4. Connectors

9 Frame, body, cab and accessories – Cab fan 9:33
9.4.3 Cab fan

Cab fan, description
Cab fan (M6570) on the right side of the cab is located in the external
unit for fresh air intake into the cab (accessible from the right side of the
cab).
016871
Cab fan, replacement

2. Remove the screws and the outer front cover.
3. Remove the screws holding the cab's front cover, remove the front
cover.
4. On machines with double wipers, remove the wiper arms.
Hold the wiper arm during removal so that torque is not transferred
to the motor which may then be damaged.
5. On machines with double wipers, remove the upper front cover.
015257

9:34 9 Frame, body, cab and accessories – Cab fan
6. Loosen the locking screws and remove the cover plate in front of
the fresh air filter.
015258
7. Remove the fresh air filter and brace.
016200
1
2
1. Brace
2. Fresh air filter
8. Remove the cover over the cab fan.
2
1
017460
1. Cover
2. Lock pin

9 Frame, body, cab and accessories – Cab fan 9:35
1 2 3 4 9. Remove the screws that hold the cab fan's air duct in the air
conditioning.
10. Loosen the hose to the filter switch.
016061
1. Screw, cab fan housing
2. Housing, cab fan
3. Hose, filter switch
4. Screw, air channel
11. Remove the screws and the grille in front of the recirculation filter.
Remove the recirculation filter.
016401
1 2
1. Grille in front of the recirculation filter
2. Screw, grille
12. Loosen the hose to the cab temperature sensor from the connector
on the fan unit.
13. Loosen the connector from the cab temperature sensor and pull
out the wiring through the fan unit's rubber grommet.
14. Loosen the connectors to the fan motor and filter switch.
15. Carefully tilt and lift out the cab fan housing, starting at the heat
exchanger.
16. Remove the screws that hold the cab fan's housing in the cab.
016402

9:36 9 Frame, body, cab and accessories – Heat exchanger heat
17. Remove the screws that hold the cab fan in the housing.
18. Replace the cab fan.
NOTE
Make sure the hoses to the cab temperature sensor and filter
switch are fitted so that the airflow through them is not hindered.
016062
1
1. Screw, cab fan
9.4.4 Heat exchanger heat

Heat exchanger heat, description
Pipes and fins in the heat exchanger transfer heat from the hot coolant
in the engine to the ventilation air in the cab.
The heat exchanger for heating is located in the external unit for fresh
air intake to the cab (between the tilt cylinders).
NOTE
Clamps should be installed on the hoses to prevent unnecessary
loss of coolant when any work is done on the coolant circuit.
Wear protective gloves and use a collection vessel to collect the
1 coolant that runs out.
016873
2
NOTE
1. Heat exchanger, cooling After work is performed, check the coolant circuit for leaks and check
2. Heat exchanger heat the coolant level. Top up coolant if necessary.
Heat exchanger, heating, replacement

cover.
015257

9 Frame, body, cab and accessories – Heat exchanger heat 9:37
3. Loosen the locking screws and remove the cover plate.

4. Drain the cooling system of coolant, see Maintenance manual.
WARNING
The cooling system is pressurised. Steam or hot cool-
ant may jet out.
Risk or scalding or burn injuries!
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled before filling.
016403
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid skin contact, wear protective
glasses and protective gloves. In the event of skin con-
tact, wash your hands.
5. Clamp the hoses to and from the heat exchanger with pinch-off pli-
ers to prevent coolant escaping.
016066
1 2
1. Heat exchanger heat
2. Hose, heat exchanger heat

9:38 9 Frame, body, cab and accessories – Water valve
6. Loosen the hoses

7. Withdraw the heat exchanger from its rest position.
8. Replace the heat exchanger.
016067
1
1. Connection of heat exchanger, heat under the
cab
9.4.5 Water valve

Water valve, description
The water valve controls the climate control system's capacity for heat-
ing from 0 (closed valve) to 100% (open valve). The water valve is elec-
trically controlled.
The signal can be checked with diagnostic menu 9.4 Climate System 7/
016877
Water valve, replacement

cover.
015257

9 Frame, body, cab and accessories – Water valve 9:39
3. Loosen the locking screws and remove the cover plate.
016403
4. Install clamps on the hoses to prevent coolant from running out.
3 2
5. Undo the hose clamps and remove the hoses. Use a receptacle to
collect any coolant that runs out.
6. Undo the water valve connector.
7. Unscrew the water valve.
8. Fit in the reverse order
NOTE
After fitting the water valve, check the valve for leaks and check
the coolant level. Top up coolant if necessary.
NOTE
The water valve centre shaft has a groove that can be used for
fault tracing the heating system.
016068
1 2
1. Water valve
2. Hoses
3. Connectors

9:40 9 Frame, body, cab and accessories – Sensor coolant temperature
9.4.6 Sensor coolant temperature

Coolant temperature sensor, description
Sensor, coolant temperature, is fitted on the engine and detects the en-
gine's coolant temperature, see Supplier documentation.
9.4.7 Compressor
Compressor air conditioning, description
The compressor drives the air conditioning by working as a pump. It
draws in cold, low-pressure gas from the evaporator, compresses the
gas which then becomes warm, and then forces out high-pressure gas
to the condenser.
The compressor is driven by V-belts directly by the machine's engine.
Activation and deactivation of the compressor is handled by an electro-
magnetic clutch, which is controlled by a thermostat.
The signal can be checked with the diagnostic menu, see 9.4 Climate
System 13/XX DIAGNOSE, page 8:113.
For location, see Engine, component location, page 1:7.
018400
Compressor air conditioning
Compressor, replacement
IMPORTANT
Working on the air conditioning requires special
authorisation.
NOTE
It is extremely important to prevent contamination and foreign
particles from getting into the refrigerant circuit. Carefully clean
the area where the cooling circuit is to be worked on, before
starting to dismantle.
Always replace the receiver driers when work is performed in the
refrigerant circuit.
NOTE
For tightening torque of refrigerant hoses and pressure switch,
see section F Technical data.
unit, page 9:30.
4. Drain the A/C system of refrigerant R134a using the intended
draining equipment.

9 Frame, body, cab and accessories – Condenser unit 9:41
5. Loosen the belt tension (position 1) and remove the belt.

6. Loosen the hose connections and disconnect the inlet and outlet
hoses from the compressor. Plug the couplings in order to prevent
contaminants.
7. Remove the compressor from the engine.
8. Empty the oil from the old compressor (through inlet/outlet) and
measure the quantity.
1 9. Empty the oil from the new compressor. The compressor is filled
with cooling oil on delivery.
10. Refill the new compressor with the new oil in the same amount
drained from the old one.
In the event of refrigerant loss, there may also be a certain oil loss
because approx. 25% of the oil volume is taken up by the
refrigerant.
017493
For oil volume and type in the system, see section F Technical
data.
1. Belt tensioner recess for pull handles
12. Turn the compressor over several turns by hand.
13. Using vacuum equipment, refill the system with R134a refrigerant
and test for leaks.
14. Check the function of the system.
9.4.8 Condenser unit

Condenser unit, description
The condenser unit is fitted on the cooling unit behind the engine. The
condenser is a heat exchanger and its function is to convert the hot
1 high-pressure gas from the compressor into liquid form. Pipes and
flanges in the condenser battery absorb the heat, which is then dissi-
pated with a fan.
2
Refrigerant temperature in the condenser varies depending on the am-
bient temperature and the air flow through the condenser. When the re-
3 frigerant has condensed to fluid, the fluid is forced onward to the
receiver drier.
4
IMPORTANT
5
017979
authorisation.
Cooling unit
1. Intercooler NOTE
2. Cooling fan intercooler left and right It is extremely important to prevent contamination and foreign par-
3. Coolant radiator ticles from getting into the refrigerant circuit. Carefully clean the area
where the cooling circuit is to be worked on, before starting to
4. Condenser air conditioning unit dismantle.
5. Radiator, transmission oil Always replace the receiver driers when work is performed in the re-
frigerant circuit.

9:42 9 Frame, body, cab and accessories – Receiver drier
9.4.9 Receiver drier

Receiver drier, description
The filter, which contains a particle trap and a hygroscopic medium, col-
lects liquid refrigerant, binds moisture and filters out impurities. The
housing functions as an expansion tank in the cooling circuit.
For inspection of drying filter, see Maintenance manual.
016874
1. Receiver drier
Receiver drier, replacement
IMPORTANT
authorisation.
NOTE
NOTE
Normally the receiver drier is not a consumable component in
the refrigerant circuit.
The receiver drier should only be replaced when the refrigerant
circuit has been opened, depressurised for a long time or when
one of the refrigerant circuit's other components has been re-
placed, when it is also recommended to replace filters.
NOTE
unit, page 9:30.

9 Frame, body, cab and accessories – Pressure switch 9:43
4. Remove the front left-hand cover on the cab.
5. Drain the air conditioning of refrigerant R134a, with the intended

draining equipment.
6. Release the pipe fittings from the receiver drier.
7. Plug the hoses to avoid contamination of the refrigerant circuits.
8. Undo the hose clamps and remove the receiver drier.
9. Replace the receiver drier.
NOTE
An unused receiver drier is pressurised with nitrogen gas and its
connections are equipped with plugs in order to avoid contami-
nation during storage and handling.
015266
During fitting it is therefore useful to see how the overpressure

flows out when the plugs are loosened.
Once the plugs have been loosened, fitting should take place as
soon as possible in order to avoid contamination of the air's
moisture content. A receiver drier that has no overpressure for
an unknown reason may be contaminated and should not be
used.
10. Connect the pipe fittings to the receiver drier.

11. Check for leaks and refill the machine with refrigerant R134a, with
the intended equipment.
For volume, see section F Technical data.
12. Fit the front left-hand cover on the cab.
9.4.10 Pressure switch

Pressure switch, description
The pressure switch (B2460) is fitted on the receiver drier. In the event
of a pressure drop, the pressure switch warns via the KCU control unit
(D7901) and cooling circuit ceases to function.
1
016875
1. Pressure switch

9:44 9 Frame, body, cab and accessories – Pressure switch
Pressure switch, replacement
IMPORTANT
authorisation.
NOTE
NOTE
unit, page 9:30.
5. If the system contains the correct amount of refrigerant then it does
not need to be drained. The connection of the receiver drier to the
pressure switch is equipped with a non-return valve that prevents
the refrigerant from flowing out.
If the system does not contain the correct amount of refrigerant
then the air conditioning must be drained of refrigerant R134a, with
the equipment intended for the purpose.

7. Undo the cable connectors.
8. Unscrew the pressure switch.
9. Screw in a new pressure switch and refit the cable terminals.
10. Check for leaks and refill the machine with refrigerant R134a if
necessary, using the intended equipment.
016566

9 Frame, body, cab and accessories – Expansion valve 9:45
9.4.11 Expansion valve

Expansion valve, description
The expansion valve (evaporator) is the part in the circuit that sepa-
rates the high-pressure side from the low-pressure side. The refrigerant
arrives in liquid form at the expansion valve under high pressure and
leaves it under low pressure. After the expansion valve, the refrigerant
converts to a gaseous state and is transported to the compressor once
again.
The amount of refrigerant that passes through the expansion valve
varies depending on the heat load. The valve works from fully open to
016878
fully closed and searches between these for an optimal evaporation
point.
When replacing the expansion valve, see the appropriate information
under section Heat exchanger, cooling, replacement, page 9:46 and
Temperature deicing sensor, description, page 9:45.
9.4.12 Temperature deicing sensor

Temperature deicing sensor, description
Temperature deicing sensor (B7753) is fitted on the rear connection
pipe of heat exchanger, cooling.
03.00
2
05
006316
.00
Figure 1
1. Pipe
016074
2. De-icing sensor
NOTE
When the de-icing sensor is replaced on a horizontal pipe, it is impor-
tant 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 sen-
sor has full contact with the pipe, it is fixed to the pipe with a cable tie
and that insulation material is applied over the de-icing sensor and
pipe.

9:46 9 Frame, body, cab and accessories – Heat exchanger, cooling
9.4.13 Heat exchanger, cooling

Heat exchanger, cooling, description
The heat exchanger for cooling consists of pipes carrying refrigerant
through the cooling fins. The heat from the cab's air is channelled via
the flanges to the refrigerant in the pipes.
The refrigerant circulates and returns to a gaseous state, becoming
cold, and is drawn from the heat exchanger for cooling back to the com-
pressor. The cycle has come full circle.
The heat exchanger for cooling is located in the external unit for fresh
air intake to the cab.
016873
2
1. Heat exchanger, cooling

2. Heat exchanger heat
Heat exchanger, cooling, replacement
IMPORTANT
authorisation.
NOTE
NOTE
unit, page 9:30.
4. Drain the air conditioning of refrigerant R134a, with the intended
draining equipment.

9 Frame, body, cab and accessories – Heat exchanger, cooling 9:47
cover.
015257
015258
7. Detach the thick hose from the expansion valve.

8. Detach the front copper pipe from the expansion valve and the re-
ceiver drier.
9. Detach the thin hose from the copper pipe (behind the attachment)
and remove the nut that secures the copper pipe's connection
thread to the unit's housing.
10. Detach the rear copper pipe from the receiver drier as well as the
clamp that secures the pipe to the unit's housing.
11. Release the rear copper pipe from the "eye" in the drip plate.
12. Detach the four lower screws (position 2) that secure the drip plate
to the unit's housing.
13. Carefully pull the heat exchanger forward a few millimetres from its
018677
rest position in the unit's housing in order to release the cable to

the temperature deicing sensor and cut the cable tie (that holds to-
gether the cables to the temperature deicing sensor, amongst oth-
1 2 3 4 5 6 7
er things).
1. Heat exchanger, cooling
14. Carefully pull the drip plate out from the unit's housing together
2. Screw, drip plate with heat exchanger, cooling, and the expansion valve (NB!
3. Connections heat exchanger for cooling The drip plate is sealed against the unit's housing with joint sealing
4. Expansion valve compound that must be scraped away if necessary.
5. Plate 15. Remove the insulation material and detach the temperature deic-
6. Heat exchanger heat ing sensor from the evaporator's rear connection pipe.
7. Cable ties 16. Disconnect the fitting nuts to the expansion valve.
17. Clean the sealing surfaces on the drip plate and in the unit's hous-
ing and replace heat exchanger, cooling.
18. Reinstall in reverse order and make sure that the insulation materi-
al is restored as well as that the drip plate is sealed against the
unit's housing and the wiring is affixed.

9:48 9 Frame, body, cab and accessories – Air distributor
19. Use new O-rings when installing and replace the old receiver drier
before refilling the cooling system.
20. Check for leaks and refill the machine with refrigerant R134a, with
the intended equipment.
9.4.14 Air distributor

Air distributor, description
The air distributor distributes the air between the defroster and the floor
nozzles. It is fitted on top of the climate unit under the dashboard panel.
The air distributor contains dampers that are controlled by Motor air dis-
tribution (Y6720) that controls the air distribution in the cab.
016876
Air distribution motor, replacement

cover.
015257
015258

9 Frame, body, cab and accessories – Defroster nozzles 9:49
4. Disconnect the connector, remove the screws that hold the air dis-
tribution motor and the centre screw to the motor.
5. Replace the air distribution motor.
6. Fit the connector and test run the new motor in defroster mode.
016083
1 2 3
1. Connector, air distribution motor
2. Air distribution motor
3. Screw
9.4.15 Defroster nozzles

Defroster nozzles, description
There are a number of adjustable defroster nozzles in the cab interior,
for example, five at the windscreen for defrosting and six adjustable de-
froster nozzles in the dashboard panel. Adjustable flow and direction
(flow is proportional to fan speed).
A large air vent is located low in the cab (floor). This allows the adjust-
ment of the air flow from the lower part of the cab to defroster.
015218
Defroster nozzles to cab.
Defroster nozzles, replacement

2. Angle the damper and pull out the defroster nozzle.
016058

9:50 9 Frame, body, cab and accessories – Fan temperature sensor
9.4.16 Fan temperature sensor

Fan temperature sensor, description
Sensor fan temperature (B7752) is positioned after the heat exchanger
heat and measures the temperature of the air blown into the cab.
017461
9.4.17 Interior temperature sensor

Interior temperature sensor, description
Interior temperature sensor (B7751) is located in the air stream by the
climate unit's recirculation inlet.
014762

9 Frame, body, cab and accessories – Ambient temperature sensor 9:51
9.4.18 Ambient temperature sensor

Ambient temperature sensor, description
Ambient temperature sensor (B7740) is located on the rear edge of the
roof. It detects the current outside temperature without being affected
by the heat from the vehicle.
016073 9.4.19 Pause heater

Pause heater, description
Pause heating is an option for the heating unit, which uses residual
heat in the engine's cooling system to keep the cab warm.
1
An extra electrically operated heating system circulation pump (M6670)
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
2 is automatically switched off when the coolant temperature is below a
set value. The pause heater is activated with the pause heater switch.
016077
1. Pause heater switch, on the front part of the right

dashboard panel
2. Circulation pump, pause heater (M6670)
9.4.20 Timer for diesel-driven engine and cab

heater
Timer for diesel-driven engine and cab heater,
description
C A C
The heater is controlled by a separate timer that is fitted in the cab. The
timer can be used to set running time and three separate activation
times.
P
13:35 20 °C To set the timer for the diesel-driven engine and cab heater, see Opera-
tor's manual.
019141
D B E
A. Menu bar
B. Status bar (Main menu)
Input field (Sub-menu)
C. Selection front / rear
D. Button 1
E. Button 2

9:52 9 Frame, body, cab and accessories – Diesel-driven engine and cab heater
9.4.21 Diesel-driven engine and cab heater

Diesel-driven engine and cab heater, description
The heater is used to heat the cab and engine without needing to start
the engine.
The heater heats and circulates the engine's coolant. An extra electri-
cally-driven circulation pump pumps the coolant though the heater and
heater unit. The heater is supplied with fuel via a separate fuel pump
which is connected to the fuel tank via a separate fuel line.
018350
9.4.25 Preparation, cab fan

Preparation, cab fan, description
The machine can be prepared for connection of an electrically-driven

1 cab fan in different units together with heater for engine, hydraulic oil
tank and oil tank brake system.
The cab socket is supplied with high voltage from an external mains
2 minal boxes above the left-hand footstep.
CAUTION
The electrical socket is connected to mains voltage (110
- 400 V).
High voltage.
Installation and reconnection of the socket must only
be performed by personnel authorised for electrical
installations.
018551
1. Holder cab fan

2. Electrical socket cab fan

9 Frame, body, cab and accessories – Wiper/washer system 9:53
9.5 Wiper/washer system

Wiper/washer system, general information
There are wipers on the cab for the windscreen and roof windows and
one wiper for the rear window. Their function is to clean the windows
and maintain good visibility from the cab. Wiper installation is available
in two variants.
•
Combined wipers for the windscreen and roof window and one
wiper for the rear window.
• Separate wipers for the windscreen and roof window and one
wiper for the rear window. The wipers for the windscreen are dou-
ble wipers.
Wiping and washing of windows, description

(combined windscreen wipers windscreen/roof
window)
2
There are combined wipers on the cab for the windscreen and roof win-
dows and one wiper for the rear window. Their function is to clean the
1 windows and maintain good visibility from the cab.
WARNING
Attempts to manually move the wiper arms damage the
wiper motor gear or shaft.
3
Risk of damage to the wiper motor gear or axles.
Never attempt to manually move the wiper arms.
The wiper arms are mounted on a linkage system that is supported by

a carriage in a guide rail along the front edge of the roof which means
that the wiper blades move in parallel over the windows and give a
maximum clean area on the windows. The linkage system is activated
via a connecting rod, which is bearing mounted in a flywheel on a motor
015306
mounted on the cab roof. The motor axle's fastening surface is tapered
and made of hardened steel. The flywheel's fastening surface is made
of aluminium. The wiper arms' parking position can be adjusted freely
1. Wiper front
by mounting the motor axle's flywheel in any position. On delivery, the
2. Wiper roof
wiper motor is in the parking position.
3. Wiper rear

9:54 9 Frame, body, cab and accessories – Wiper/washer system
Wiping/washing of windows, function description

(combined windscreen wipers windscreen/roof
window)
1 2 3 4 8 9 13
D8 D9 D13
D1 D2 D3 D4
D7950
17
D7902
16 D16 D7901 D7971

5,10,14
D7 D6
D12 D11 D15 D15
023192
6,7 M 11,12 M 15 M 15 M

1 Combined wiper continuous front wind- U = 24 V Cab overview, page 9:5.
screen/roof windows switch (S1190-FR) 11.5.3.2 KPU control unit (D7902), page
sends a voltage signal to KPU control 11:30.
unit (D7902). D1: 9.5 Wiper Washer Sys 1/XX DIAGNOSE,
page 8:116.
2 Combined wiper intermittent front wind- U = 24 V Cab overview, page 9:5.
screen/roof windows switch (S1520-FR) 11.5.3.2 KPU control unit (D7902), page
page 8:116.
3 Combined wiper continuous front wind- U = 24 V s Cab overview, page 9:5.
screen/roof windows switch (S1190-UP) 11.5.3.2 KPU control unit (D7902), page
page 8:116.
4 Combined wiper intermittent front wind- U = 24 V Cab overview, page 9:5.
screen/roof windows switch (S1520-UP) 11.5.3.2 KPU control unit (D7902), page
page 8:116.
5 KCU control unit (D7901) feeds power to I = 6 A. 11.5.3.1 KCU control unit (D7901), page
the wiper motor front windscreen/roof 11:27.
windows (M6503).
6 Wiper motor front windscreen/roof win- - Wiper motor, front and roof, description,
dows (M6503) powers the wiper blades page 9:68.
on the front and roof windows D6: 9.5 Wiper & Washer Sys 2/XX DIAG-
NOSE, page 8:116.
7 The wiper motor's position is fed back to U = 0.5-4.5 V D7: 9.5 Wiper & Washer Sys 2/XX DIAG-
Control unit KCU (D7901). This gives in- NOSE, page 8:116.
formation for controlling the wiper blade's
position.
8 Wiper continuous rear window switch U = 24 V Cab overview, page 9:5.
(S1190-RE) sends a voltage signal to 11.5.3.2 KPU control unit (D7902), page
KPU control unit (D7902). 11:30.
D8: 9.5 Wiper & Washer Sys 4/XX DIAG-
NOSE, page 8:117.


9 Wiper intermittent rear window switch U = 24 V Cab overview, page 9:5.
KPU control unit (D7902). 11:30.
NOSE, page 8:117.
the wiper motor rear window (M6502). 11:27.
11 Wiper motor rear window (M6502) - Wiper motor rear, description, page 9:65.
powers the wiper blade on the rear D11: 9.5 Wiper & Washer Sys 5/XX DIAG-
window. NOSE, page 8:117.
Control unit KCU (D7901). This gives in- NOSE, page 8:117.
position.
13 Washer switch (S1200) sends a voltage U = 24 V Cab overview, page 9:5.
signal to the KPU control unit (D7902). 11.5.3.2 KPU control unit (D7902), page
11:30.
NOSE, page 8:116.
14 KCU control unit (D7901) sends current I = 6 A. 11.5.3.1 KCU control unit (D7901), page
to the washer motor front windscreen/ 11:27.
roof windows (M6513) or washer motor
rear window (M6512).
15 Washer motor front windscreen/roof win- - Washer motor and reservoir, description,
dow (M6513) or washer motor rear win- page 9:58.
dow (M6512) washes the windows. D15: 9.5 Wiper & Washer Sys 3/XX DIAG-
Washing is done on the windows where NOSE, page 8:116 and
the wipers are activated. 9.5 Wiper & Washer Sys 6/XX DIAGNOSE,
If none of the wipers are activated, the page 8:117.
combined wipers on the front wind-
screen/roof windows and washing on
each window are activated.
If the machine is equipped with a reversi-
ble seat the wiper on the rear window is
activated when the seat is in the re-
versed position.
16 Contact level washer fluid (B2991) sends U = 24 V Washer motor and reservoir, description,
a voltage signal to the KCU control unit page 9:58.
(D7901) with a low washer fluid level. D16: 9.5 Wiper & Washer Sys 3/XX DIAG-
NOSE, page 8:116.
17 KID control unit (D7950) shows the event Checked by control sys- 11.5.3.3 Control unit, KID (D7950), page
menu for low washer fluid level. tem, error shown with er- 11:32.
ror code.

9:56 9 Frame, body, cab and accessories – Wiper/washer system

(separate windscreen wipers windscreen/roof
window)
The wiper arms on the double front wipers are attached in pairs to each
A motor. The movement of each pair of arms forms a circle sector and
wiper blades move in parallel over the window. The axles' fastening
surfaces are tapered and made of hardened steel. The wiper arms' at-
B tachments are made of soft, die-cast material.
C On the roof wiper the wiper arm is mounted on a stub axle in the centre
of the radius of the rear edge of the roof and is activated via a connect-
ing rod journalled in a flywheel on the wiper motor. The wiper arm and
blade move within a circular sector above the window.
C
018386
A. Wiper roof
B. Wiper rear
C. Wiper front

(separate windscreen wipers windscreen/roof
window)
1 2 3 4 8 9 13
D8 D9 D13
D1 D2 D3 D4
D7950
17
D7902
16 D16 D7901 D7971

5,10,14
D7 D6
D12 D11 D15 D15
023192
6,7 M 11,12 M 15 M 15 M

1 Wiper continuous front windscreen U = 24 V Cab overview, page 9:5.
switch (S1190-FR) sends a voltage sig- 11.5.3.2 KPU control unit (D7902), page
nal to KPU control unit (D7902). 11:30
NOSE, page 8:118
2 Wiper intermittent front windscreen U = 24 V Cab overview, page 9:5.
switch (S1520-FR) sends a voltage sig- 11.5.3.2 KPU control unit (D7902), page
nal to KPU control unit (D7902). 11:30
NOSE, page 8:118
3 Control unit KCU (D7901) feeds power to I = 6 A 11.5.3.1 KCU control unit (D7901), page
wiper motor front left (M6501-LE) and 11:27
wiper motor front right (M6501-RI).


4 Wiper motor front left (M6501-LE) and - Wiper motor front, description, page 9:60
wiper motor front right (M6501-RI) drive D4: 9.5 Wiper & Washer Sys 8/XX DIAG-
the wiper blades on the windscreen. NOSE, page 8:118 and 9.5 Wiper & Washer
5 The position of the wiper motors is fed U = 0.5-4.5 V D5: 9.5 Wiper & Washer Sys 8/XX DIAG-
back to Control unit KCU (D7901). This NOSE, page 8:118 and 9.5 Wiper & Washer
gives information for controlling the posi- Sys 9/XX DIAGNOSE, page 8:118
tion of the wiper blades.
6 Wiper continuous roof window switch U = 24 V Cab overview, page 9:5
(S1190-UP) sends a voltage signal to 11.5.3.2 KPU control unit (D7902), page
KPU control unit (D7902). 11:30
NOSE, page 8:119
7 Wiper intermittent roof window switch U = 24 V Cab overview, page 9:5.
(S1520-UP) sends a voltage signal to 11.5.3.2 KPU control unit (D7902), page
NOSE, page 8:119
the wiper motor roof window (M6503). 11:27
9 Wiper motor roof window (M6503) drives - Wiper motor roof, description, page 9:62
the wiper blades on the roof window. D9: 9.5 Wiper & Washer Sys 12/XX DIAG-
NOSE, page 8:119
10 The position of the wiper motors is fed U = 0.5-4.5 V Wiper motor roof, description, page 9:62
back to Control unit KCU (D7901). This D10: 9.5 Wiper & Washer Sys 8/XX DIAG-
gives information for controlling the wiper NOSE, page 8:118 and 9.5 Wiper & Washer
blade's position. Sys 12/XX DIAGNOSE, page 8:119
11 Wiper continuous rear window switch U = 24 V Cab overview, page 9:5
NOSE, page 8:117
12 Wiper intermittent rear window switch U = 24 V Cab overview, page 9:5
NOSE, page 8:117
the wiper motor rear window (M6502). 11:27.
14 Wiper motor rear window (M6502) - Wiper motor rear, description, page 9:65
powers the wiper blade on the rear D14: 9.5 Wiper & Washer Sys 5/XX DIAG-
window. NOSE, page 8:117
Control unit KCU (D7901). This gives in- NOSE, page 8:117
position.
16 Washer switch (S1200) sends a voltage U = 24 V Cab overview, page 9:5
signal to the KPU control unit (D7902). 11.5.3.2 KPU control unit (D7902), page
11:30
NOSE, page 8:119
17 Control unit KCU (D7901) feeds power to I = 6 A. 11.5.3.1 KCU control unit (D7901), page
washer motor windscreen (M6511), 11:27
washer motor rear window (M6512) or
washer motor roof window (M6513).

9:58 9 Frame, body, cab and accessories – Washer motor and reservoir

18 Washer motor windscreen (M6511), - Washer motor and reservoir, description,
washer motor rear window (M6512) or page 9:58
washer motor roof window (M6513) D18: 9.5 Wiper & Washer Sys 6/XX DIAG-
washes the windows. NOSE, page 8:117 9.5 Wiper & Washer Sys
Washing is done on the windows where 10/XX DIAGNOSE, page 8:119 and 9.5
the wipers are activated. Wiper & Washer Sys 13/XX DIAGNOSE,
If none of the wipers are activated, the page 8:120
double wipers on the windscreen and
windscreen washing are activated.
If the machine is equipped with a reversi-
ble seat the wiper on the rear window is
activated when the seat is in the re-
versed position.
19 Contact level washer fluid (B2991) sends U = 24 V Washer motor and reservoir, description,
a voltage signal to the KCU control unit page 9:58
(D7901) with a low washer fluid level. D19: 9.5 Wiper & Washer Sys 6/XX DIAG-
NOSE, page 8:117, 9.5 Wiper & Washer Sys
10/XX DIAGNOSE, page 8:119 or 9.5 Wiper
& Washer Sys 13/XX DIAGNOSE, page
8:120
20 KID control unit (D7950) shows the event Checked by control sys- 11.5.3.3 Control unit, KID (D7950), page
menu for low washer fluid level. tem, error shown with er- 11:32
ror code.
9.5.4 Washer motor and reservoir

Washer motor and reservoir, description
The washer motors and washer fluid level sensor are fitted on and in
the washer fluid reservoir. The reservoir is positioned externally, to the
left on the cab's left-hand side (accessible when the cover is removed).
There are non-return valves on the lines from the reservoir to the wiper
arms. The nozzles are mounted on the wiper arms.
Machines with separate windscreen and roof wipers
Washer motor, windscreen (M6511) is supplied with voltage on activa-
tion of Control unit KCU (D7901), the signal can be checked using diag-
nostic menu, see 9.5 Wiper & Washer Sys 10/XX DIAGNOSE, page
8:119.
Washer motor, roof window (M6513) is supplied with voltage on activa-
tion of Control unit, KCU (D7901), the signal can be checked using the
diagnostic menu, see 9.5 Wiper & Washer Sys 13/XX DIAGNOSE,
page 8:120.
Machines with combined windscreen and roof wipers
Washer motor, windscreen/roof window (M6513) is supplied with volt-

age on activation of Control unit, KCU (D7901), the signal can be
checked using the diagnostic menu, see 9.5 Wiper & Washer Sys 3/XX
Washer motor, rear window (M6512) is supplied with voltage on activa-
tion of Control unit, KCU (D7901), the signal can be checked using the
diagnostic menu, see 9.5 Wiper & Washer Sys 6/XX DIAGNOSE, page
8:117.
Sensor, level washer fluid (B2991) sends a voltage signal to Control
unit, KCU (D7901), when the washer fluid level is low.

9 Frame, body, cab and accessories – Washer motor and reservoir 9:59
Washer motor and reservoir, replacement

3. Undo the two screws and tilt the washer fluid reservoir forward.
4. Drain the washer fluid into a receptacle.
1
015267
1. Washer fluid level sensor

5. When replacing the washer fluid level sensor, turn it so that the
1 white moving part points down in the reservoir.
6. Remove the hoses from the pumps.
7. Undo the connector on the electric cable for the pumps.
8. Remove the pumps from the reservoir. A rubber bushing seals be-
tween the pumps and the reservoir.
3
9. Replace the pump.
11. Fill the reservoir up with screenwasher fluid.
2
015268
1. Reservoir
2. Pumps (two or three pumps)
3. Hoses

9:60 9 Frame, body, cab and accessories – Wiper motor front
9.5.5 Wiper motor front

Wiper motor front, description
The double wipers for the windscreen are driven by one wiper motor
each, wiper motor front left (M6501-LE) and wiper motor front right
(M6501-RI). The wiper motors are located under the covers at the front
of the cab. The wiper arms are fitted on a linkage that transfers the
power from each wiper motor.
Wiper motor front left (M6501-LE) and wiper motor front right (M6501-
RI) are supplied with voltage by Control unit KCU (D7901), the wiper
motors also send a position signal back to Control unit KCU (D7901).
The signals can be checked with the diagnostic menus, see 9.5 Wiper
& Washer Sys 8/XX DIAGNOSE, page 8:118 and 9.5 Wiper & Washer
Sys 9/XX DIAGNOSE, page 8:118.
Wiper motor front left, replacement

Removing
2. Remove the screws and the front left-hand cover on the cab.
3. Undo the lock screw (position 1) that attaches the connecting rod
to the wiper motor shaft.
4. Lift the connecting rod off from the wiper motor shaft.
5. Disconnect the wiring from the wiper motor.
6. Remove the attaching bolts (position 2) that secure the wiper mo-
tor and lift away the wiper motor.
Installing
7. Lift the wiper motor into position and fit the attaching bolts (position
2).
8. Connect the wiring to the wiper motor.
1. Lock screw
2. Attaching bolt 9. Activate the wiper motor with the switch on the dashboard panel.
Stop the wiper motor with the switch and allow it to stop moving.
This way the motor finds its parking position.
10. Set the wiper arm in the desired parking position.
11. Align the connecting rod in position and tighten the lock screw (po-
sition 1).
Hold the wiper arm so that torque is not transferred to the motor
which may then be damaged.

9 Frame, body, cab and accessories – Wiper motor front 9:61
12. Fit the screws that secure the front left-hand cover on the cab.
Wiper motor front right, replacement

Removing
2. Remove the screws and the front right-hand cover on the cab.
3. Undo the lock pin (position 2) and remove the cover (position 1)
over the cab fan.
2
1
017460
1. Cover
2. Lock pin
4. Undo the lock screw (position 1) that attaches the connecting rod
to the wiper motor shaft.
5. Lift the connecting rod off from the wiper motor shaft.
6. Remove the attaching bolts (position 2) that secure the wiper
motor.
7. Carefully lift the wiper motor out to the side and release the wiring.
Installing
8. Connect the wiring to the wiper motor.
1. Lock screw 9. Carefully lift the wiper motor into position and fit the attaching bolts
2. Attaching bolt (position 2).
10. Activate the wiper motor with the switch on the dashboard panel.
11. Set the wiper arm in the desired parking position.

9:62 9 Frame, body, cab and accessories – Wiper motor roof
12. Align the connecting rod in position and tighten the lock screw (po-
sition 1).
13. Fit the cover (position 1) over the cab fan. The cover may need to
be bent slightly in order to make it hook in firmly and adopt the cor-
2 rect position.
1
Secure the cover with the lock pin (position 2).
017460
1. Cover
2. Lock pin
14. Fit the screws that secure the front right-hand cover on the cab.
9.5.6 Wiper motor roof

Wiper motor roof, description
The wiper motor drives the wiper for the roof window. The wiper arm is
fitted on a linkage that transfers the power from the motor.
Wiper motor roof window (M6503) is supplied with voltage by Control
unit KCU (D7901), the wiper motor also sends a position signal back to
Control unit KCU (D7901). The signals can be checked with the diag-
nostic menu, see 9.5 Wiper & Washer Sys 12/XX DIAGNOSE, page
8:119.
Wiper motor roof, replacement (separate windscreen

wiper windscreen/roof window)
See Wiper motor, front and roof, replacement, page 9:68.

9 Frame, body, cab and accessories – Wiper motor roof 9:63
Wiper motor roof, replacement (separate windscreen

wiper windscreen/roof window)
Removing
2. Remove the screws and the cover on the cab roof.
3. Unplug the connector from the wiper motor.
018397
4. Loosen the four Allen screws sufficiently for the motor to be
018680 removed.
5. Remove the screw in the bearing for the connecting rod in the
flywheel.
6. Lift the connecting rod off from the flywheel.
018682
7. Remove the motor shaft's nut in the centre of the flywheel and re-
move the flywheel.
Hold the flywheel so that torque is not transferred to the motor
018683

9:64 9 Frame, body, cab and accessories – Wiper motor roof
8. Remove the screws which secure the wiper motor. Remove the
motor.
Installing
9. Fit the new wiper motor. Tighten the screws.
10. Connect the connector to the wiper motor.
018504
12. Align the flywheel in position. Fit the nut on the motor shaft but do
not tighten it.
018683
13. Set the wiper arm in the recommended parking position.
14. Align the connecting rod in position. Fit the screw in the bearing for
the connecting rod in the flywheel. Secure the screw with Loctite
242 or similar.
Hold the wiper arm during assembly so that torque is not trans-
ferred to the motor which may then be damaged.
NOTE
The flywheel has four different holes for the bearing, of which
three of them have a marking. All have different distances to the
centre of the wheel. First, refit the bearing in the corresponding
hole as before. If a larger or smaller stroke is required for the
018682
wiper blades, fit the bearing in a suitable position.
15. Tighten the motor shaft's nut to tightening torque 13-17 Nm.
16. To compensate for an unsymmetrical wiper pattern, the mounting
plate for the motor can be displaced via the four rear oval holes in
the upper plate bracket.
020554

9 Frame, body, cab and accessories – Wiper motor rear 9:65
17. Tighten the four Allen screws.
018680
18. Fit the screws that secure the cover on the cab roof.
018397
9.5.7 Wiper motor rear

Wiper motor rear, description
The wiper motor drives the wiper for the rear window. The wiper arm is
mounted directly on the motor. The motor produces the movement of
the wiper.
Wiper motor rear window (M6502) is supplied with voltage by Control
unit KCU (D7901), the wiper motor also sends a position signal back to
Control unit KCU (D7901). The signals can be checked with the diag-
nostic menus, see 9.5 Wiper & Washer Sys 5/XX DIAGNOSE, page
8:117.
Wiper motor rear, replacement

Removing
2. Open the cover (position 4) and remove the nut (position 3) and
wiper arm.
3. Remove the rubber cap and attaching nut (position 1).
4. Remove the lock nut (position 2).
015809
1 2 3 4
1. Rubber cap, fastening nut
2. Lock nut
3. Nut, wiper arm
4. Cover

9:66 9 Frame, body, cab and accessories – Wiper motor rear
5. Loosen the two screws and remove the plastic cover over the
wiper motor in the cab.
015808
6. Remove the plastic covers over the door pillar (position 2) and rear
1 2 section (position 1).
7. Carefully open the rear section's plastic cover.
015796
1. Plastic cover, rear section

2. Plastic covers, door pillar
8. Remove the wiper motor from the inside.
015815
9. Disconnect the connector.

015816

9 Frame, body, cab and accessories – Wiper motor rear 9:67
Installing
10. Lift the new wiper motor into place and secure it with attaching nuts
(position 1). Refit the rubber caps on the attaching nuts.
12. Fit the lock nut (position 2).
13. Fit the wiper arm and set it in the desired parking position.
14. Fit the nut (position 3).
015809
1 2 3 4 When installing it is important to make sure that the grooves are
free from metal shavings and similar. Also, the nuts must be tight-
1. Rubber cap, fastening nut
ened so tight that the grooves are pressed into the bracket and
2. Lock nut work as a drive. Hold the wiper arm when assembling so that tor-
3. Nut, wiper arm que is not transferred to the motor which may be damaged (16-20
4. Cover Nm tightening torque).
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.
15. Fold back the cover (position 4).

16. Fit the rubber caps over the attaching nuts.
17. Fold back the cover.
18. Fit the two screws that secure the plastic cover over the wiper mo-
tor in the cab.
015808

9:68 9 Frame, body, cab and accessories – Wiper motor, front and roof
19. Fit the plastic covers over the door pillar and rear section.
1 2
015796

9.5.8 Wiper motor, front and roof

Wiper motor, front and roof, description
Wiper motor (M6503) operates the wipers for the windscreen and roof
window and is fitted in the rear edge of the cab roof under the cover.
The wiper arms are fitted on a linkage that transfers the power from the
wiper motor.
Wiper motor (M6503) is supplied with voltage by Control unit KCU
(D7901), the wiper motor also sends a position signal back to Control
unit KCU (D7901). The signals can be checked with the diagnostic me-
nus, see 9.5 Wiper & Washer Sys 2/XX DIAGNOSE, page 8:116.
Wiper motor, front and roof, replacement
Removing
3. Unplug the connector from the wiper motor.
018397

9 Frame, body, cab and accessories – Wiper motor, front and roof 9:69
4. Loosen the four Allen screws sufficiently for the motor to be

removed.
018680
5. Remove the screw in the bearing for the connecting rod in the
flywheel.
6. Lift the connecting rod off from the flywheel.
018682
7. Remove the motor shaft's nut in the centre of the flywheel and re-
move the flywheel.
Hold the flywheel so that torque is not transferred to the motor
018683
8. Remove the screws which secure the wiper motor. Remove the
motor.
Installing
9. Fit the new wiper motor. Tighten the screws.
10. Connect the connector to the wiper motor.
018504

9:70 9 Frame, body, cab and accessories – Wiper motor, front and roof
12. Align the flywheel in position. Fit the nut on the motor shaft but do
not tighten it.
13. Set the wiper arm in the recommended parking position.
018683
14. Align the connecting rod in position. Fit the screw in the bearing for
the connecting rod in the flywheel. Secure the screw with Loctite
242 or similar.
15. Tighten the motor shaft's nut to tightening torque 13-17 Nm.
018682
16. Tighten the four Allen screws.

018680
17. Fit the screws that secure the cover on the cab roof.
018397

9 Frame, body, cab and accessories – Lighting system 9:71
9.6 Lighting system

Lighting system, description
The lighting system includes interior lighting, service lighting (head-
lights, position lights, direction indicators, back-up lights, brake lights
and rear lights) working lights (cab, boom, attachment and machine)
and warning beacon.
The working lights are shut off automatically after 5 minute's idle in or-
der to prevent discharge of the batteries. Extra working lights are shut
off after 2 minutes. The lights are automatically reactivated when the
operator sits in the seat or a gear is selected.
NOTE
It is important that the right type of bulb is used for each area. See
section F Technical data.
Lighting system, function description

The working lights are shut off automatically after 5 minute's idle in or-
der to prevent discharge of the batteries. Extra working lights are shut
off after 2 minutes. The lights are activated automatically again when
the operator sits in the seat, a gear is selected or the accelerator pedal
is pressed.
NOTE
1 2 3 4 5 6 7 8 9 37 11 12 12
14
13
D1 D2 D3 D4 D5 D6 D7 D8
D9 D12
D14
D13
D11
10, 35 15,16
D7902 D7901
D17 17 D18 18
D28 D7971 D7911
28 20 32
M
D24 D21
D23 D26 D27 D21 D31 D22
D29 D25 D23
D33 D34
016880
23 26 27 21 19 D19 29 30 31 33 34
22 25 24 23 21

1 Work light on cab switch (S1050-1) sends a Switch in ON position: U D1: 9.6 Lighting Sys 11/XX DIAGNOSE,
voltage signal to the KPU control unit (D7902). = 5 V, page 8:123
off position: U = 0 V
2 Switch, working lights on boom (S1050-2) Switch in ON position: U D2: 9.6 Lighting Sys 14/XX DIAGNOSE,
sends voltage signals to Control unit KPU = 5 V, page 8:124
(D7902). off position: U = 0 V
3 Switch, working lights on attachment (S1050-3) Switch in ON position: U D3: 9.6 Lighting Sys 21/XX DIAGNOSE,
sends voltage signals to Control unit KPU = 5 V, page 8:125 and 9.6 Lighting Sys 22/XX
(D7902). off position: U = 0 V DIAGNOSE, page 8:126

9:72 9 Frame, body, cab and accessories – Lighting system
4 Switch, extra working lights on frame (S1050-4) Switch in ON position: U D4: 9.6 Lighting Sys 17/XX DIAGNOSE,
sends voltage signals to Control unit KPU = 5 V, page 8:124
5 Reversing light switch (S1032) sends a voltage Switch in ON position: U D5: 9.6 Lighting Sys 10/XX DIAGNOSE,
signal to the KPU control unit (D7902). = 5 V, page 8:123
6 Headlight switch (S1000) sends a voltage sig- Switch in ON position: U D6: 9.6 Lighting Sys 1/XX DIAGNOSE,
nal to the KPU control unit (D7902). = 5 V, page 8:120
7 Revolving beacon switch (S1100) sends a volt- Switch in ON position: U D7: 9.7 Signalling Sys 2/XX DIAG-
age signal to the KPU control unit (D7902). = 5 V, NOSE, page 8:127 and 9.7 Signalling
off position: U = 0 V Sys 3/XX DIAGNOSE, page 8:128
8 Warning light switch (S1090) sends a voltage Switch in ON position: U D8: 9.7 Signalling Sys 7/XX DIAG-
signal to the KPU control unit (D7902). = 5 V, NOSE, page 8:129
9 Multi-function lever (S1600) sends a voltage High beam mode: US1600/ D9: 9.6 Lighting Sys 1/XX DIAGNOSE,
signal to the KPU control unit (D7902). 56d = 24 V page 8:120 and 9.6 Lighting Sys 6/XX
Direction indicator left: DIAGNOSE, page 8:122
US1600/L = 24 V
Direction indicator right:
US1600/R = 24 V
10 KPU control unit, (D7902) transmits "switch on Checked by control sys- 11.5.3.2 KPU control unit (D7902),
lights" messages on the CAN bus. tem, error shown with er- page 11:30
ror code.
11 Interior lighting switch (S1160) sends a voltage Switch in ON position: U D11: 9.6 Lighting Sys 18/XX DIAG-
signal to the KCU control unit (D7901). = 5 V, NOSE, page 8:125
12 The door NC switch (S2660-LE & S2660-RI) Door open: U = 24 V D12: 9.6 Lighting Sys 18/XX DIAG-
sends a voltage signal to the KCU control unit NOSE, page 8:125
(D7901).
13 High/low beam switch (S1992) on the arm rest Switch in ON position: U D13: 9.6 Lighting Sys 1/XX DIAGNOSE,
mini-wheel/joystick control sends a voltage sig- = 24 V page 8:120
nal to the KCU control unit (D7901).
14 Direction indicator switch (S1470) on the arm Left: US1470/3 = 24 V D14: 9.6 Lighting Sys 6/XX DIAGNOSE,
rest mini-wheel/joystick control sends a voltage Right: US1470/1 = 24 V page 8:122
signal to the KCU control unit (D7901).
15 KCU control unit, (D7901) transmits "switch on Checked by control sys- 11.5.3.1 KCU control unit (D7901),
lights" messages on the CAN bus. tem, error shown with er- page 11:27
ror code.
16 KCU control unit (D7901) supplies voltage to Checked by control sys- 11.5.3.1 KCU control unit (D7901),
the lights in and around the cab. tem, error shown with er- page 11:27
ror code.
17 Working lights cab (E4042-LE & E4042-RI) is Light on: U = 24 V Working lights, cab, description, page
switched on when working lights cab are 9:77
activated. D17: 9.6 Lighting Sys 11/XX DIAG-
NOSE, page 8:123
18 Interior lighting (E4340-LE & E4340-RI) comes Light on: U = 24 V Interior lighting, description, page 9:77
on when a door is opened or when the interior D18: 9.6 Lighting Sys 19/XX DIAG-
lighting is activated with the interior lighting NOSE, page 8:125
switch (S1160).
19 The brake pressure sensor (B7681) sends a U = 0.5-4.5 V Brake pressure sensor, description,
voltage signal corresponding to the brake pres- page 4:35
sure to the KFU control unit (D7971). D19: 4.3 Power Assisted 3/XX DIAG-
NOSE, page 8:44
20 KFU control unit (D7971) supplies voltage to Checked by control sys- 11.5.3.4 Control unit KFU (D7971),
the machine lights. tem, error shown with er- page 11:34
ror code.
21 Position lights (H4160-RL, H4160-RR, H4160- Light on: U = 24 V Running lights, description, page 9:74
FL & H4160-FR) are switched on when the D21: 9.6 Lighting Sys 10/XX DIAG-
headlights are activated with the switch. NOSE, page 8:123

9 Frame, body, cab and accessories – Lighting system 9:73
22 Reversing lights (E4050-LE & E4050-RI) white Light on: U = 24 V Back-up lights, description, page 9:75
come on when reverse gear is engaged and D21: 9.6 Lighting Sys 10/XX DIAG-
when the reversing lights are activated with the NOSE, page 8:123
switch.
23 Direction indicators (H4220-FL, H4220-RL, Light on: U = 24 V Direction indicators, description, page
H4220-FR & H4220-RR) come on when the di- 9:75
rection indicators or warning lights are Warning lamp, Hazard, description,
activated. page 9:75
D23: 9.6 Lighting Sys 7/XX DIAGNOSE,
page 8:122 9.6 Lighting Sys 8/XX DI-
AGNOSE, page 8:122 and 9.7 Signal-
ling Sys 7/XX DIAGNOSE, page 8:129
24 Tail lights (H4120-LE & H4120-RI) red come on Light on: U = 24 V Tail lights, description, page 9:74
when headlights are activated. D24: 9.6 Lighting Sys 4/XX DIAGNOSE,
page 8:121
25 Brake lights (H4110-LE & H4110-RI) come on Light on: U = 24 V Brake lights, description, page 9:75
when the brake is activated. D25: 9.6 Lighting Sys 5/XX DIAGNOSE,
page 8:121
26 Headlights low beam (E4000-LE & E4000-RI) Light on: U = 24 V Headlights, description, page 9:74
come on when the headlights are activated. D26: 9.6 Lighting Sys 3/XX DIAGNOSE,
page 8:121
27 Headlights high beam (E4020-LE & E4020-RI) Light on: U = 24 V Headlights, description, page 9:74
come on when high beam is activated. D27: 9.6 Lighting Sys 2/XX DIAGNOSE,
page 8:120
28 Revolving beacon, boom (H4283) is switched Light on: U = 24 V Work light, boom, description, page
on when the revolving beacon is activated. 9:77
D28: 9.7 Signalling Sys 1/XX DIAG-
NOSE, page 8:127
29 Revolving beacon, boom nose (H4284) is Light on: U = 24 V Revolving beacon, description, page
switched on when the revolving beacon is 9:76
activated. D29: 9.7 Signalling Sys 1/XX DIAG-
NOSE, page 8:127
30 Revolving beacon frame, rear left (H4281-RL) Light on: U = 24 V Revolving beacon, description, page
is switched on when the revolving beacon is 9:76
activated. D30: 9.7 Signalling Sys 1/XX DIAG-
NOSE, page 8:127
31 Revolving beacon, rear right (H4281-RR) is Light on: U = 24 V Revolving beacon, description, page
switched on when the revolving beacon is 9:76
activated. 9.7 Signalling Sys 1/XX DIAGNOSE,
page 8:127
32 Working lights boom (E4043-LE-A & E4043-RI- Light on: U = 24 V Work light, boom, description, page
A) (four), are switched on when working lights 9:77
boom are activated. D32: 9.6 Lighting Sys 14/XX DIAG-
NOSE, page 8:124
33 Extra working lights boom (E4043-LE-B & Light on: U = 24 V Work light, boom, description, page
E4043-RI-B) are switched on when working 9:77
lights boom are activated. D33: 9.6 Lighting Sys 14/XX DIAG-
NOSE, page 8:124
34 Extra working lights frame (E4041-RI-A, Light on: U = 24 V Extra working lights frame, description,
E4041-RI-A, E4041-LE-A & E4041-LE-B) are page 9:78
switched on when extra working lights are D34: 9.6 Lighting Sys 17/XX DIAG-
activated. NOSE, page 8:124
35 Control unit KAU (D7911) supplies voltage to Checked by control sys- 11.5.3.8 Control unit KAU (D7911),
the attachment's lights. tem, error shown with er- page 11:40
ror code.
36 Working lights attachment (E4044-LE-A & Light on: U = 24 V Working lights, attachment, description,
E4044-RI-A) are switched on when working page 9:77
NOSE, page 8:125

9:74 9 Frame, body, cab and accessories – Headlights
37 Extra working lights attachment (E4044-LE-B & Light on: U = 24 V Working lights, attachment, description,
E4044-RI-B) are switched on when working page 9:77
NOSE, page 8:126
38 KPU control unit (D7902) lights the indicator - -
lights on the dashboard panel.
9.6.1 Headlights
Headlights, description
Headlights are located in the front part of the machine in order to give
the operator enhanced vision when manoeuvring in darkness, and to
provide surrounding traffic and the environment an indication of the ma-
chine's position.
018538 The headlights are turned on and off using a switch on the dashboard
1 2 3 4 5 6 panel.
1. Back-up lights Headlight bulbs are not replaced individually but the whole unit is
replaced.
2. Rear and brake lights
3. Direction indicator, rear
4. Running lights As an option, the headlights are available with high beam and low
5. Direction indicator, front beam. The headlights switch between high and dipped beam using the
6. Headlights multi-function lever. Bulbs can be replaced individually on machines
with this option.
9.6.2 Running lights

Running lights, description
Position lights are fitted on the sides of each lamp housing on the ma-
chine in order to give other traffic and the environment an indication of
the machine's position in darkness.
018538
1 2 3 4 5 6
1. Back-up lights
4. Running lights
5. Direction indicator, front
6. Headlights
9.6.3 Tail lights

Tail lights, description
The tail lights are fitted in the lamp housing on the upper counterweight
at the rear of the machine. The tail light gives surrounding traffic and
the environment an indication of the machine's position in darkness.
018538
1 2 3 4 5 6
1. Back-up lights
4. Running lights
6. Headlights

9 Frame, body, cab and accessories – Brake light 9:75
9.6.4 Brake light

Brake lights, description
The brake lights are fitted in the lamp housing on the upper counter-
weight at the rear of the machine. The brake lights are illuminated to
give others in traffic and the surroundings an indication that the ma-
chine is braking and is thus reducing speed.
018538
1 2 3 4 5 6
1. Back-up lights
4. Running lights
6. Headlights
9.6.5 Back-up lights

Back-up lights, description
The back-up lights are fitted in the lamp housing on the upper rear
counterweight on the machine. The back-up lights show surrounding
traffic and the environment that the machine is driving backwards and
give the operator increased visibility in darkness.
The back-up lights are switched on when reverse gear is selected. The
018538
1 2 3 4 5 6 back-up lights can be deactivated with the switch for back-up lights.
1. Back-up lights
4. Running lights
6. Headlights
9.6.6 Direction indicators

Direction indicators, description
There are direction indicators on both the front and the rear of the ma-
chine to indicate to others in traffic and the surroundings that the ma-
chine 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.
018538
1 2 3 4 5 6
1. Back-up lights
4. Running lights
6. Headlights
9.6.7 Warning lamp, Hazard

Warning lamp, Hazard, description
The machine is equipped with hazard warning flashers. By pressing a
switch, all the direction indicators can be made to flash simultaneously,
to show others that there is danger, such as a mechanical failure.

9:76 9 Frame, body, cab and accessories – Revolving beacon
9.6.8 Revolving beacon

Revolving beacon, description
A revolving beacon is located on the rear of the machine's boom and is
used to provide surrounding traffic and the environment an indication
that a working vehicle is moving and at work. An indication to bystand-
ers to exercise caution.
The revolving beacon is controlled by the revolving beacon switch.
Available as an option:
• Revolving beacon on the boom nose .
• Revolving beacons on the rear lamp housings .
• Flashlight .
017405
Revolving beacon, pole mounted, replacement

2. Undo the wing nut which fixes the revolving beacon to the pole.
3. Lift the rotating warning beacon off.
4. Install the new revolving beacon.
5. Tighten the wing nut.
017405

9 Frame, body, cab and accessories – Working lights, cab 9:77
9.6.9 Working lights, cab

Working lights, cab, description
Working lights on the cab provide visibility when handling a load in
darkness.
The working lights are turned on with a switch on the dashboard panel.
020993
9.6.10 Work light boom
Work light, boom, description
Work lights on the cab provide enhanced visibility when handling a load
in darkness.
As an option, the boom can be equipped with two extra work lights .
020993
9.6.11 Working lights, attachment

Working lights, attachment, description
Working lights on the attachment provide increased visibility when han-
dling a load in darkness.
As an option, the attachment can be equipped with extra, the number
and location vary depending on type of attachment .
020993
9.6.12 Interior lighting

Interior lighting, description
The interior lighting lights up the inside of the cab, and is turned on with
an interior lighting switch and door switches when the doors are
opened. The interior lighting comes on for a limited time, when a door
is opened and the machine is turned off.
There is background illumination in all switches, function keys and ro-
tary controls. This is so that the driver will be able to read their functions
and settings in darkness.
A reading lamp is an accessory for the writing panel combined
document compartment. The reading lamp is an LED lamp with a
clamp and comes attached to the writing panel. The reading lamp has
an internal battery that is charged via USB. The lamp is switched on us-
ing the switch on the lamp housing. The combined writing panel with
document compartment has brackets to be hung on a door handle,
supported against the steering wheel or fitted on the inner handle.

9:78 9 Frame, body, cab and accessories – Extra working lights frame
9.6.13 Extra working lights frame

Extra working lights frame, description
The machine can be equipped with additional working lights located on

the frame (normally on the lamp hoods) in order to provide better visibil-
ity for work in the dark.
As an option, the extra work lights on the wings can be controlled to-
020993
gether with the high beam .

9 Frame, body, cab and accessories – Signalling system 9:79
9.7 Signalling system

Signalling system, description
The signal system includes revolving beacon, back-up lights, direction
indicators, horn, reverse alarm, buzzer for automatic spreading and
buzzer in the cab.
NOTE
Signalling system, function description
NOTE
1 2 3 4 5 24 20 7
D5
D1 D2 D4 8
D3
22 D7950
6
D7902
D7
D16 D7971 D7972 D7901 D8
16 15 9,10
M
D11
D17
17 D13
M D20 D21
D12
D18
18
M 20 21 11 12 13 14
D19
19
023386
M
Pos Description Signal description Reference

1 Revolving beacon switch (S1100) Switch in ON position: U = D1: 9.7 Signalling Sys 2/XX DIAGNOSE, page
sends a voltage signal to the KPU 5 V, 8:127 and 9.7 Signalling Sys 3/XX DIAGNOSE,
control unit (D7902). off position: U = 0 V page 8:128
2 Warning light switch (S1090) sends a Switch in ON position: U = D2: 9.7 Signalling Sys 7/XX DIAGNOSE, page
voltage signal to the KPU control unit 5 V, 8:129
3 The travel direction selector in posi- U = 24 V Travel direction selector and parking brake, de-
tion for activated parking brake scription, page 2:11
(S1310) sends a voltage signal to the D3: 4.5 Park Brake Sys 1/XX DIAGNOSE,
KPU control unit (D7902). page 8:45
4 Multi-function lever (S1600) sends a Signal button pressed in: D4: 9.7 Signalling Sys 1/XX DIAGNOSE, page
voltage signal to the KPU control unit US1600/31b = 24 V 8:127 and 9.6 Lighting Sys 6/XX DIAGNOSE,
(D7902). Direction indicator left: page 8:122
US1600/L = 24 V
Direction indicator right:
US1600/R = 24 V
5 Horn switch (S1490) sends a voltage Switch in ON position: U = D5: 9.7 Signalling Sys 1/XX DIAGNOSE, page
signal to the KPU control unit (D7902). 24 V 8:127
6 KPU control unit, (D7902) transmits Checked by control system, 11.5.3.2 KPU control unit (D7902), page 11:30
"activation" messages on the CAN error shown with error
bus. code.

9:80 9 Frame, body, cab and accessories – Signalling system

7 Make-contact (closing switch) opera- Operator in seat: U = 24 V Sensor operator in seat, description, page 9:25
tor-in-seat (B2300) sends a voltage D7: 9.3 Seat 1/XX DIAGNOSE, page 8:110
signal to KCU control unit (D7901)
when there is a load on the driver's
seat.
8 Direction indicator switch (S1470) on Left: US1470/3 = 24 V D8: 9.6 Lighting Sys 6/XX DIAGNOSE, page
the arm rest mini-wheel/joystick con- Right: US1470/1 = 24 V 8:122
trol sends a voltage signal to the KCU
9 KCU control unit (D7901) transmits Checked by control system, 11.5.3.1 KCU control unit (D7901), page 11:27
"switch on lights" messages on the error shown with error
CAN bus. code.
10 KCU control unit (D7901) supplies Checked by control system, 11.5.3.1 KCU control unit (D7901), page 11:27
voltage to the lights in and around the error shown with error
cab. code.
11 Reversing lights (E4050-LE & E4050- Light on: U = 24 V Back-up lights, description, page 9:75
RI) white come on when reverse gear D11: 9.6 Lighting Sys 10/XX DIAGNOSE, page
is engaged and when the reversing 8:123
lights are activated with the switch.
12 Horn (H8500) sounds when the horn Horn active: U = 24 V Horn, description, page 9:81
is activated. D12: 9.7 Signalling Sys 1/XX DIAGNOSE,
page 8:127
13 Relay loud horn (K3016) is activated UK3016/30 = 24 V Horn, description, page 9:81
when horn is activated. UK3016/85 = 0 V D13: 9.7 Signalling Sys 1/XX DIAGNOSE,
Horn activated: page 8:127
UK3016/86 = 24 V
UK3016/87 = 24 V
14 Loud horn (H8500-2) sounds when Horn active: U = 24 V Horn, description, page 9:81
the horn is activated.
15 Control unit KFU (D7971) supplies Checked by control system, 11.5.3.4 Control unit KFU (D7971), page 11:34
voltage to the lamps. error shown with error
code.
16 Revolving beacon frame, rear left Light on: U = 24 V Revolving beacon, description, page 9:76
(H4281-RL) is switched on when the D16: 9.7 Signalling Sys 1/XX DIAGNOSE,
revolving beacon is activated. page 8:127
17 Revolving beacon frame, rear right Light on: U = 24 V Revolving beacon, description, page 9:76
(H4281-RR) is switched on when the 9.7 Signalling Sys 1/XX DIAGNOSE, page
revolving beacon is activated. 8:127
18 Revolving beacon, boom nose Light on: U = 24 V Revolving beacon, description, page 9:76
(H4284) is switched on when the re- D18: 9.7 Signalling Sys 1/XX DIAGNOSE,
volving beacon is activated. page 8:127
19 Revolving beacon, boom (H4283) is Light on: U = 24 V Revolving beacon, description, page 9:76
switched on when the revolving bea- D19: 9.7 Signalling Sys 1/XX DIAGNOSE,
con is activated. page 8:127
20 Direction indicators (H4220-FL, Light on: U = 24 V Direction indicators, description, page 9:75
H4220-RL, H4220-FR & H4220-RR) Warning lamp, Hazard, description, page 9:75
come on when the direction indicators D20: 9.6 Lighting Sys 7/XX DIAGNOSE, page
or warning lights are activated. 8:122 and 9.6 Lighting Sys 8/XX DIAGNOSE,
page 8:122
21 Back-up alarm (H9650) is activated Reverse gear selected: U = Reverse alarm, description, page 9:82
when reverse gear is selected. 24 V D21: 9.7 Signalling Sys 5/XX DIAGNOSE,
page 8:128
22 The buzzer is voltage fed by the KPU Checked by control system, Buzzer, description, page 9:82
control unit (D7902). error shown with error 11.5.3.2 KPU control unit (D7902), page 11:30
code.

9 Frame, body, cab and accessories – Horn 9:81

23 KID control unit (D7950) alerts the - 11.5.3.3 Control unit, KID (D7950), page 11:32
driver to certain event menus.
24 Indicator lights inform the driver if the A click is heard when the Cab overview, page 9:5
functions that are active or need ac- event menu is shown in
tion by the driver or service personnel. combination with an indica-
tor light.
Only certain pop-ups have
sound.
9.7.1 Horn
Horn, description
Electromagnetic horn, operated from the multi-function lever (S1600)
or Horn switch (S1490).
The horn is fitted in the space above the drive axle in the frame.
As an option, the machine can be equipped with loud horn. The loud
horn has an electric compressor and is operated with the same switch
that activates the standard horn.
It is also possible to initiate a button on the joystick for the horn (stand-
ard for Ego joystick and option for Cobra joystick). Menu 9.7 Signalling
system 4/XX Init. on twistlock button as signal when no contact is ac-
tive, see 9.7 Signalling Sys 4/XX INITIATE, page 8:237
017464
9.7.2 Warning lamp, Hazard

Warning lamp, Hazard, description
See Warning lamp, Hazard, description, page 9:75.
9.7.3 Revolving beacon

Revolving beacon, description
See Revolving beacon, description, page 9:76
9.7.4 Warning parking brake

Warning parking brake, description
A buzzing sound is activated when the operator leave the seat without
activating the parking brake.
A sensor in the seat indicates whether the seat is occupied.
The buzzer is located in the Control unit KPU (D7902), see 11.5.3.2
KPU control unit (D7902), page 11:30.

9:82 9 Frame, body, cab and accessories – Reverse alarm
9.7.5 Reverse alarm

Reverse alarm, description
When reverse direction is selected, a warning sound and the reversing
lights are activated. This is to indicate to other road users and the envi-
ronment that the machine is reversing. An indication to bystanders to
exercise caution.
The reverse alarm receives an input signal from the travel direction se-
lector and the output signal goes to the reverse alarm and back-up
lights.
The reverse alarm is fitted on the rear counterweight.
Alarm volume is determined by the ambient sound level.
017418
Reverse alarm, replacement

2. Unplug the connector from the reverse alarm.
3. Remove the screws which secure the reverse alarm.
4. Fit the new reverse alarm in reverse order.
017418
9.7.7 Buzzer
Buzzer, description
The buzzer is located in the Control unit KPU (D7902) which is fitted in
the right-hand dashboard panel's front section, see 11.5.3.2 KPU con-
trol unit (D7902), page 11:30.
To alert the operator, different sounds are given in certain event menus:
• the parking brake is not applied and the engine is switched off and
the driver is not sitting in the seat (continuous sound)
• the parking brake is not engaged and the ignition key lock is in op-
erating mode, but the driver is not sitting in the seat (continuous
sound)
• low accumulator pressure (continuous sound)
• overload (pulsing, low frequency sound)
• activated direction indicators (ticking sound, high/low frequency).

9 Frame, body, cab and accessories – Entertainment and communication 9:83
9.8 Entertainment and

communication
Entertainment and communication, description
This section describes items for supporting the driver or facilitating
communication for the driver.
Entertainment and communication consist of the following:
• Radio with CD
• Voltage converter
• Rear view camera with monitor in the cab, see Rear view cam-
era system, description, page 9:99.
9.8.1 Audio system

Audio system, description
The cab can be equipped with different variants of audio system. It is

powered by battery voltage. A switch is fitted on the front part of the
right-hand dashboard panel for switching off the sound from the audio
system.
Radio antenna, description

The cab roof provides provisions for the installation of a radio and/or
communication radio.
The radio antenna is fitted in the rear edge of the cab, above the rear
window on the right-hand side of the cab. The antenna is made of a
flexible material.
Radio antenna, replacement

2. Loosen the speaker to facilitate the replacement.
023588
Speaker

9:84 9 Frame, body, cab and accessories – Voltage converter
1 3. Lift out the radio.

4. Undo the antenna cable connector.
015855
1. Antenna cable connection
018397
6. Remove the radio antenna and cable.

7. Replace the radio antenna.
023590
9.8.7 Voltage converter

Voltage converter, general
See Voltage converter, description, page 11:24.

9 Frame, body, cab and accessories – Glass/windows/mirrors 9:85
9.9 Glass/windows/mirrors
Glass/windows/mirrors, description
The cab's windscreen is made of tinted laminated glass.
The roof window is a safety detail and is therefore always made of poly-
1 carbonate plastic.
The mirrors are all convex. Interior rear view mirror with extra large
4 viewing angle available as an option.
Exterior rear view mirrors are fitted in the rear edge of the front wings.
2 As an option, the machine's rear view mirrors can be specified with

electric heating, electrical control from the operator's station and fitted
3 on the lamp hoods on the front wings.
As an option the machine can be equipped with a rear view camera
and monitor in the cab to improve visibility.
016300
1. Roof window
2. Windscreen
3. Side windows
4. Rear window
Window adhesive, handling advice

The windows are fastened with elastic glass adhesive, polyurethane
(1K PU adhesive).
NOTE
With regard to safety and function, Cargotec does not guarantee the
bonding of windows using other bonding methods than the method
approved by Cargotec.
NOTE
The purpose of these instructions is to describe the process when re-
placing the windscreen and roof window.
The PU adhesive is a high performance elastic glass adhesive of a
single component type and is commonly used in connection with se-
curing windows on vehicles. The adhesive cures from the surface ap-
prox. 4 mm/day by means of the air's relative humidity and
temperature. The adhesive is usually fully cured after 1-2 days at
room temperature and 50% Rh.
The truck can be put into service before the adhesive is cured.
The time after bonding until the truck can be put into service is called
"Fixing time" but varies with the ambient conditions and in part by the
weight of the screen and driving conditions.
Fixing time in hours at respective temperatures and relative humidity:
At <5°C/80%Rh - 17°C/30%Rh, Approx. 2 hours.
At <17°C/30%Rh - 23°C/50%Rh, Approx. 1.5 hours.
The front windscreen is heaviest and the truck should not be driven
until the above conditions are carefully considered.

9:86 9 Frame, body, cab and accessories – Windscreen
9.9.1 Windscreen
Windscreen, description
The windscreen consists of tinted laminated safety glass and is glued
to the cab frame.
Windscreen, replacement
NOTE
Read the handling instructions for product 924506.0003 used to
bond glass windows.
NOTE
Replacing/bonding windows at temperature <5 °C or >35 °C;
Contact Cargotec support.

2. Remove the interior and, where necessary covers and windscreen
wipers.
3. If the windscreen is not already broken, cover the windscreen in-
side and out with masking tape to minimise the spread of broken
glass in the cab.
Also cover body parts, ventilation ducts and the like.
015718
4. Remove the broken window.

If the windscreen is intact and of toughened glass, break it by tap-
ping it with a sharp object in order to facilitate removal.
015719

9 Frame, body, cab and accessories – Windscreen 9:87
5. Cut away and remove all parts of the old windscreen.
015720
6. When the broken window has been removed, smooth out the old
adhesive bed with a smoothing knife or the like. Cut down the ad-
hesive bed to 1-2 millimetres thick, then remove any loose
adhesive.
NOTE
Do not cut off the old adhesive joint completely, the new joint
fuses with the existing joint and creates a strong bond.
015721
7. Protect the cab interior with masking tape.

015724
8. Lift the new windscreen into position and fit into the cab frame, use
spacers to set it at the right height.
015722

9. Mark the position of the screen with masking tape, this is helpful
when the windscreen is finally aligned in position in the adhesive
bed, cut off the tape and remove the windscreen again.
016406
10. Mark with a pen on the inside of the screen where the cab frame
connects, this is so it's possible to mask the windscreen sight part
and protect it from adhesive.
NOTE
It is essential that the screen fits and does not touch the cab
frame, but that there is an evenly distributed expanding space
around the screen edges.
If the screen is forced into position against the cab frame this will
create tension which will damage the screen material.
015723

11. Prepare the new windscreen for bonding.

a) Check the new windscreen to ensure there is no damage,
cracks or scratches.
b) Mask up the joint width to be glued in accordance with the pre-
vious markings.
Also mask the outer edge of the screen's outside, in order to
protect areas not bonded.
015725 c) Clean the surface to be bonded with 924506.0004, this is to re-

move any "silicone contamination" which impairs the adhesi-
ve's adhesion properties.
"Silicone contamination" is established by spraying cleaning
agent 924506.0008 on the surface to be bonded.
If the cleaning agent does not flow evenly over the surface, but
instead crawls the surface is "silicone contaminated" and must
be treated with 924506.0004 as set out above. If the cleaning
agent flows out evenly over the surface, this procedure can be
ignored.
d) Apply 924506.0001 in a thin layer on surfaces with a ceramic
coating to be bonded, apply in one stroke and wipe off in one
stroke with a lint-free cloth.
Then allow the agent on the screen to vent for a few minutes
before the next step.
NOTE
The screen is now ready to be bonded to the cab body within
two hours.
If it takes longer before bonding, the treatment with 924506.0001
must be repeated.
NOTE
When bonding in environments with fluctuating temperatures the
time may vary.
e) The windscreen is now fully treated and ready for bonding.

12. Blow clean and activate the adhesive bed on the cab frame with
924506.0001.
016408

13. Treat clean plate surfaces and surfaces where paint shows
through the adhesive bed with 924506.0007.
015713
14. Cut the adhesive nozzle so that the bead of adhesive on applica-
tion forms a triangle shape.
015714
4 3
2xH
H 015842
B 2 B
1 Screen
2 Cab frame
3 Correct shape of adhesive bead
4 Incorrect shape of adhesive bead
H Height of the bead of adhesive
B Width of the bead of adhesive

15. Use an appropriate application tool such as Sika Application Gun

Set and apply a triangular shaped bead 924506.0003, with the
point outwards, on the cab frame.
Minimum bead width is 10 mm.
Start/stop bonding at the top edge of the screen in order to mini-
mise the risk of leakage.
015726
16. Position the windscreen on the spacers and align the windscreen
according to the tape markings.
Position and press down slightly in the adhesive joint, fix it if
necessary.
NOTE
This must be done no later than 20 minutes after applying the
adhesive.
015727
17. Spray the joint with soapy water and smooth it out with a tool or fin-
ger. Top seal adhesive joints if necessary with 924506.0003.
Use 924506.0009 to remove excess uncured adhesive.
Remove the strips of masking tape.
IMPORTANT
Mark the window panes with "New adhesive. Do not
touch".
18. Let the adhesive joint cure.
NOTE
015728
The adhesive joint cures about 4 mm/day, this varies depending

on temperature and humidity.
NOTE
When bonding in environments with fluctuating temperatures the
time may vary.
19. Refit the windscreen wipers, covers and interior equipment.

20. Clean the windscreen with cleaning agent 924506.0008 or a simi-
lar mild window cleaning agent.

9:92 9 Frame, body, cab and accessories – Side window
9.9.2 Side window

Side window, description
The side windows are screwed into the door frame.
Side window, replacement
NOTE
bond glass windows.

2. Cut apart the jointing seal between the pane of glass and the
door's panel edge using a sharp tool.
3. Secure the pane of glass with a suitable tool for handling glass.
4. Remove the attaching bolts for the pane of glass.
5. Remove the pane of glass from the door frame.
6. Clean the area for the jointing seal on the pane of glass, and clean
the door frame using 924506.0008.
7. Fit the new pane of glass to the door frame.
8. Fit the attaching bolts for the pane of glass.
9. Seal the joint between the pane of glass and the door frame.
a) Mask around the gap in order to obtain a smooth and neat
joint.
b) Apply a jointing seal using 924506.0003 across the gap be-
tween the pane of glass and the door's panel edge.

9 Frame, body, cab and accessories – Roof window 9:93
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 sur-
face layer that increases its durability and resistance to UV light and
chemicals.
WARNING
The strength of the roof window may be significantly re-
duced in case of exposure to substances containing ar-
omatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the surface layer of the roof window and clean
only with washer fluid or mild detergent. Rinse thor-
oughly with lukewarm water afterwards. Replace a dam-
aged roof window that shows cracks or scratches
immediately!
CAUTION
All reworking of the roof window is forbidden (e.g. mak-
ing holes or cutting).
Risk of material damage.
Small cracks in the material around outer edges for ex-
ample indicate that the strength of the roof window is
affected and it must be replaced immediately.
Polycarbonate screens, replacement
NOTE
bond glass windows.

9:94 9 Frame, body, cab and accessories – Roof window
NOTE
Replacing/bonding windows at temperature <5 °C or >35 °C;
Contact Cargotec support.

2. Remove the interior and, where appropriate windscreen wipers,
exterior roof cover, radio antenna, condenser to enable the roof
window to be replaced.
3. Prepare the new window for bonding.
CAUTION
Strong dissolvents, e.g. acetone, must not come into
contact with a window made of polycarbonate plastic.
Dissolvents have a chemical effect on the polycarbon-
ate plastic which reduces the strength of the roof.
a) Check the new window to ensure there is no damage.

Clean the surface to be bonded with 924506.0004, this is to re-
move any "silicone contamination" which impairs the adhesi-
ve's adhesion properties.
b) Mask the joint width to be bonded, in order to protect the surfa-
ces that are not bonded.
NOTE
Alternatively, the protective film on the window can be marked
and cut away on the parts to be bonded.
015705
c) Flatten the surface to be bonded with emery cloth or similar,

grain size >200.
Blow clean and dry the surface so there is no sanding dust
remaining.
015706
d) Apply 924506.0001 in a thin layer on surfaces to be bonded,

apply in one stroke and wipe off with a lint-free cloth. Then al-
low the agent on the screen to vent for a few minutes before
the next step.
NOTE
The screen is now ready to be bonded to the cab body within
two hours.
If it takes longer before bonding, the treatment with 924506.0001
must be repeated.
015707

e) Apply a covering layer of 924506.0006 the surfaces to be

bonded, shake the container before use. Apply with a brush or
primer applicator, allow 924506.0006 to ventilate for ten
minutes.
015708
f) Remove the mask tape, the new roof window is now fully trea-
ted and ready for fitting.
4. Remove the broken window.
015709
5. When the broken window has been removed, smooth out the old
adhesive bed with a smoothing knife or the like. Cut down the ad-
hesive bed to 1-2 millimetres thick, then remove any loose
adhesive.
NOTE
Do not cut off the old adhesive joint completely, the new joint
fuses with the existing joint and creates a strong bond.
015710
6. Lift the new roof window into place and fit into the cab frame.
Mark the position of the screen with masking tape, this is helpful
when the screen is finally put in place in the adhesive bed, cut off
the tape and remove the roof window again.
NOTE
It is essential that the screen fits and does not touch the cab
frame, but that there is an evenly distributed expanding space
around the screen edges.
If the screen is forced into position against the cab frame this will
create tension which will damage the screen material.
015711

9:96 9 Frame, body, cab and accessories – Roof window
7. Blow clean and activate the adhesive bed on the cab frame with
924506.0001.
015712 8. Treat clean plate surfaces and surfaces where paint shows
through the adhesive bed with 924506.0007.
015713
9. Cut the adhesive nozzle so that the bead of adhesive on applica-

tion forms a triangle shape.
015714

4 3
2xH
H
015842
B 2 B
1 Screen
2 Cab frame
3 Correct shape of adhesive bead
4 Incorrect shape of adhesive bead
H Height of the bead of adhesive
B Width of the bead of adhesive
10. Use an appropriate application tool (e.g. Sika Application Gun Set)
and apply a triangular shaped bead 924506.0003, with the point
outwards, on the cab frame, minimum bead width 10 mm.
Start/stop bonding at a high point on the body to minimise the risk
of leakage.
015715
11. Align the roof window with the tape markings.

Position and press down slightly in the adhesive joint, fix it if
necessary.
NOTE
This must be done no later than 20 minutes after applying the
adhesive.
015716

9:98 9 Frame, body, cab and accessories – Rear window
12. Spray the joint with soapy water and smooth it out with a tool or fin-
ger. Top seal adhesive joints if necessary with 924506.0003.
Use 924506.0009 to remove excess uncured adhesive.
CAUTION
Strong dissolvents, e.g. acetone, must not come into
contact with a window made of polycarbonate plastic.
Dissolvents have a chemical effect on the polycarbon-
ate plastic which reduces the strength of the roof.
015717
IMPORTANT
Mark the window panes with "New adhesive. Do not
touch".
13. Let the adhesive joint cure.
NOTE
The adhesive joint cures about 4 mm/day, this varies depending
on temperature and humidity.
14. Refit the windscreen wipers, condenser, covers, radio antenna,

mirrors and interior.
15. Clean the roof window with cleaning agent 924506.0008 or a simi-
lar mild window cleaner.
9.9.4 Rear window

Rear window, description
The rear window consists of tinted laminated safety glass and is glued
to the cab frame.
For location, see Glass/windows/mirrors, description, page 9:85.
Rear window, replacement

See Windscreen, replacement, page 9:86.
9.9.5 Rear view mirror

Rear view mirror, description
The machine is equipped with rear view mirrors on both sides of the
machine, either on the fenders or on the lamp hoods ( ) and in the
cab.
Exterior rear view mirrors are also available as electrically heated
and/or electrically adjustable from the operator's station.

9 Frame, body, cab and accessories – Rear view camera and load camera 9:99
9.9.8 Rear view camera and load camera

Rear view camera system, description
The machine can be equipped with two different systems with rear view
camera.
• Rear view camera.
• Rear view camera with distance warning.
Rear view camera systems are standalone systems.
The rear view camera system can be extended with more cameras, e.g.
camera on boom for improved vision during loading.
9.9.8.1 Rear view camera

Rear view camera, description
The rear view camera is fitted in a recess in the rear counterweight for
improved visibility during reversing.
The rear view camera sends colour images and audio to the monitor in
the cab; see Monitor, rear view camera, description, page 9:99.
017407
9.9.8.2 Monitor, rear view camera

Monitor, rear view camera, description
The monitor conveys images and sound from the rear view camera.
The picture is in colour and the brightness is adjusted automatically ac-
cording to the light conditions in the cab. The monitor supports signals
from four different cameras.
The monitor is mounted on a hinged bracket to the right in front of the
door in the cab. As an option, the monitor can be specified mounted on
the left-hand side.
B A
017918
D C
F E
A. Right / Left (volume)
B. Up / Down
C. Off / On
D. Confirm selection (change camera)
E. Show menu
F. Light sensor

9:100 9 Frame, body, cab and accessories – Rear view camera and load camera
Monitor rear view camera with distance warning,

description
A B C The monitor conveys images and sound from the rear view camera.
The picture is in colour and the brightness is adjusted automatically ac-
cording to the light conditions in the cab. The monitor supports signals
from four different cameras.
F1
On machines with rear view camera system with distance warning the
F2
D monitor also warns with audio and visually in the image from the rear
F3
view camera if objects come within the surveillance area behind the
F4 machine during reversing. Distance warning uses separate sensors,
see Sensor distance warning, description, page 9:100.
The monitor is mounted on a hinged bracket to the right in front of the
017933
door in the cab. As an option, the monitor can be specified mounted on
G F the left-hand side.
E
A. Screen display off / on
B. Indicator light, power
C. Light sensor
D. Shortcuts 1 - 4
E. Cancel
F. Menu navigation
G. Confirm selection
9.9.8.3 Sensor distance warning

Sensor distance warning, description
On machines with rear view camera with distance warning the sensor
for back-up warning is connected to the rear view camera system and
this way gives a visual warning of objects behind the machine in the im-
age from the rear view camera.
Distance warning uses two ultrasound sensors fitted by the counter-
weight on the rear of the machine in order to measure the distance to
objects behind and warn the operator. The sensors are activated during
reversing.
017419
Sensor, back-up warning device

9 Frame, body, cab and accessories – Cab structure and suspension 9:101
9.10 Cab structure and suspension

Structure and suspension, description
The cab has a flat floor with a bracket for the driver's seat. It is mounted
in a cab substructure via strong rubber dampers fitted on the underside
of the cab. This minimises vibrations from the frame to the cab. Each
damper mounting has one rubber bushing and one bolt.
There are different types of cab suspension:
• Manual sliding cab, description, page 9:105
• Hydraulic sliding cab, description, page 9:106
• Vertically adjustable cab, general information, page 9:118
NOTE
Cab suspension does not affect cab version.
9.10.1 Cab frame

Cab frame, description
The cab's frame is made of high-strength steel sheet profiles. The cab
is dimensioned to handle impacts and, to some degree, protect the
driver against dropped loads.
The cab is equipped with door mouldings. The door moulding is a con-
tinuous strip, mounted on and along the outer edge of the inside of the
door, to seal against the cab.
The door moulding are "clip-on types", with a permanently vulcanised
tubular moulding. The door moulding can only be replaced when the
plastic components have been loosened or removed. The moulding
should be glued together when assembled and where the seam faces
downwards.
021714

9:102 9 Frame, body, cab and accessories – Doors
9.10.2 Doors
Doors, description
The cab has two doors. The left-hand door is the driver's door and the
right-hand door is the emergency exit. The door has:
• support rail (inside)
• opening handle (inside and outside)
• door locks
The door locks have the same key code as the ignition key lock.
The cab can be equipped with unique key codes.
The doors can be equipped without key locks. In which case, there
are plastic plugs fitted in the recesses for the lock cylinders.
• opening window.
• gas spring damping that prevents the door from being damaged
when it is opened.
The cab can be equipped for different door opening angles. There
are two different lengths for gas springs. The long variant can allow
the door to open up to and including 180°. The shorter variant only
allows a limited opening angle.
The cab can be equipped with a special door-open holder (nor-
mally on left-hand side).
016926
Door stop with gas spring damping, replacement

2. Place the door in fully open position.
3. Remove the spring clip from the piston rod head.
1 2
4. Secure the door position and lift off the piston rod head.
015874
3
1. Spring clip
2. Piston rod head
3. Ball joint

9 Frame, body, cab and accessories – Doors 9:103
5. Remove the plastic covers over the door pillar and rear panel.
1 2
015796
1. Rear panel
6. Open the rear panel and unscrew the nut holding the gas damper.
1
7. Replace the gas damper.
8. Fit in reverse order. Lock the screws with thread locking fluid be-
fore fitting.
015875
1. Lock nut
Door, replacement
1 2
2. Place the door in fully open position.
3. Remove spring clip that fastens gas damper in the door.
4. Secure the door position and lift off the piston rod head.
Unscrew the ball joint if it is to be reused.
5. Unscrew the set screws on the hinges.
6. Hold the door, and knock out the hinge axles.
7. Replace the door.
Normally, the ball joint should be placed in the same hole on the
old door. If the ball joint is moved then the hole for the previous lo-
cation must be treated with anti-corrosion paint or a screw with a
015871
low head that has clearance when opening/closing the door.

Secure the thread on ball joint with locking fluid.
3 4 5
1. Gas damper
2. Spring clip
3. Stop screw
4. Axle, hinge
5. Ball joint

9:104 9 Frame, body, cab and accessories – Cab substructure
9.10.3 Cab substructure

Cab substructure, description
The cab is mounted on a cab substructure via strong rubber insulators
fitted on the underside of the cab. This minimises vibrations from the
frame to the cab.
The cab substructure is fitted on the machine's chassis (frame) via a
mounting. The body mounting depends on whether the machine is
equipped with:
• manual sliding cab
• hydraulic sliding cab
• hydraulic vertically adjustable cab
016912
There are joints at the rear of the cab for the hoses for brake pedal,
1 8
control valve cab heating and refrigerant AC combined into a single in-
9 terface, in order to facilitate hose replacement.
2
10 The connections for brake pedal, control valve are colour coded in or-
3 der to avoid mixing them up. The refrigerant connections are in different
4 11 sizes and cannot be mixed up. Before starting work on the climate sys-
tem, read the general instructions, see General instructions for working
5 on the air conditioning unit, page 9:30.
6
017466
Example illustration.
1. Supply brake pedal [PB] (red)
2. Tank return brakes [TB] (blue)
3. Brake pressure to wheel brake [AB] (white)
4. Control signal steering right [R0] (green)
5. Tank return steering valve [T0] (grey)
6. Control signal steering left [L0] (brown)
7. Supply steering valve, [P0] (black)
8. Cab heating
9. Cab heating
10. Refrigerant AC
11. Refrigerant AC
9.10.3.1 Cab undercarriage, sliding cab

Cab undercarriage, sliding cab, description
The cab substructure is fitted on the machine's chassis (frame) via a
mounting. The body mounting consists of four ball bearing metal rollers
that run in rails above the machine's frame.
016912

9 Frame, body, cab and accessories – Sliding cab 9:105
9.10.3.2 Cab undercarriage, vertically adjustable

cab
Cab undercarriage, vertically adjustable cab,
description
1 2 3 The cab substructure is fitted on the machine's chassis (frame) via a

mounting. The mounting runs in a lift mast that is attached to the ma-
chine's frame behind the right-hand front wing so that the cab is posi-
tioned above the right-hand side drive wheels.
The lift mast consists of the outer mast, inner mast lift cylinder and
chains. The inner mast runs in the outer mast on bearing-mounted
rollers.
4
001873
1. Hydraulic cylinder vertically adjustable cab

2. Mast, vertically adjustable cab
3. Cab undercarriage, vertically adjustable cab
4. Safety lock
9.10.4 Sliding cab

Manual sliding cab, description
Manual sliding cab means that the cab can be moved forward to facili-
tate access for service and maintenance in the engine compartment.
The cab is pushed forward and back by hand. Two cable chains on
A each side ensure that hoses and cables to and from the cab are not
damaged when the cab is moved. The cab is secured in the rear posi-
tion during operation with two locking catches at the rear edge of the
cab.
DANGER
The cab is very heavy and the machine must never be
moved without first securing the cab. It is important to
that the locking catches are intact.
Secure the cab on both sides, with the locking catches
and pins before starting to operate the machine. Re-
place damaged lock handles.
016232
B C
A. Position locking catch
B. Lock pin
C. Locking catch for securing the cab

9:106 9 Frame, body, cab and accessories – Sliding cab
Hydraulic sliding cab, description
The cab can be slid forward in order to facilitate access for service and
maintenance in the engine compartment.
Hydraulic sliding cab also means that the cab can be moved hydrauli-
cally during operation in order to improve driver visibility. The cab is slid
forward and back by a hydraulic motor that is coupled to a chain at-
tached in the cab undercarriage. The cab's position is automatically
locked by the hydraulic motor when sliding cab is not in use.
Damping
A length sensor detects when damping should be activated. When
The gear on the hydraulic motor can be disengaged in order to move
the cab manually. For instructions, see Operator's manual.
DANGER
Fit the screws on the gear for the hydraulic motor for
sliding cab and the protective cover before starting to
operate.

Hydraulic sliding cab, function description
Reference
Doors Closed Doors, description, page 9:102.
1 D1
2
D7902
D7971 D7901
6 5, 7, 10, 17 4, 16, 20
D7940
3
D10
D7930 D3
D7 11 D15
m
P1
A 15
8 B
TP
LSP1 A H 14, 19
LSP2
98
LSPR 13, 18
LSP3 LSHY
C12
12
022770
1 Switch (S1751) sliding cab sends voltage U = 24 V Cab overview, page 9:5
signals to Control unit KPU (D7902). D1: Diagnostic menu, see 9.10 Cab suspen-
sion 1/XX DIAGNOSE, page 8:130
2 Control unit KPU (D7902) sends cab for- 11.5.3.2 KPU control unit (D7902), page 11:30
ward or cab backward on the CAN bus.
3 Contact closed door (S2660-LE & S2660- U = 24 V Doors, description, page 9:102
RI), sends signals to Control unit KCU D3: Diagnostic menu, see 9.6 Lighting Sys 18/
(D7901) when the door is closed. XX DIAGNOSE, page 8:125
4 Control unit KCU (D7901) sends doors Checked by control sys- 11.5.3.1 KCU control unit (D7901), page 11:27
closed on the CAN bus. tem, error shown with er-
ror code.
5 Control unit KFU (D7971) sends request Checked by control sys- KFU control unit (D7971), description, page
for raised engine speed on CAN bus tem, error shown with er- 11:34
drive-train. ror code.
6 Control unit transmission (D7930) calcu- Checked by control sys- 11.5.3.6 Control unit, engine (D7940), page
lates the rotation speed that the engine tem, error shown with er- 11:38
needs and sends a message with the en- ror code.
gine speed request to Control unit engine
(D7940) via the drive-train's CAN-bus
7 Control unit KFU (D7971) controls Pro- U = 24 V 11.5.3.4 Control unit KFU (D7971), page


ment (Y6002), opens and actuates a pre- (Y6002), description, page 10:25
determined load signal.
load signal to hydraulic oil pump 1. A 10:25
shuttle valve in Valve block, servo pres-
sure, selects the strongest load signal if
other functions are activated at the same
time.
10 Control unit KFU (D7971) activates Sole- I = 250–440 mA KFU control unit (D7971), description, page
noid valve cab forward/up (Y6016) or Sol- 11:34
enoid valve cab backward/down (Y6017). D7: Diagnostic menu, see 9.10 Cab suspen-
sion 2/XX DIAGNOSE, page 8:130 or 9.10
Cab suspension 3/XX DIAGNOSE, page
8:130
11 Solenoid valve cab forward/up (Y6016) or - Control valve cab movement, description,
Solenoid valve cab backward/down page 9:110
(Y6017) activates and pressurises the D7: Diagnostic menu, see 9.10 Cab suspen-
valve slide in Control valve cab sion 2/XX DIAGNOSE, page 8:130 or 9.10
movement. Cab suspension 3/XX DIAGNOSE, page
8:130
beam.
13 Control valve cab movement pressurises - Control valve cab movement, description,
hydraulic motor sliding cab. page 9:110
14 Hydraulic motor, sliding cab pulls the cab - Hydraulic motor sliding cab, description, page
forward or backward. 9:113
15 Sensor cab position (B7254) sends volt- U = 0-5 V Sensor cab position, description, page 9:117
age signals proportional to the cab's posi- D14: Diagnostic menu, see 9.10 Cab suspen-
tion to Control unit KCU (D7901). sion 1/XX DIAGNOSE, page 8:130
16 Control unit KCU (D7901) sends informa- Checked by control sys- 11.5.3.1 KCU control unit (D7901), page 11:27
tion about the position of the cab on the tem, error shown with er-
CAN bus. ror code.
17 When the cab's position approaches the - KFU control unit (D7971), description, page
end position Control unit KFU (D7971) re- 11:34
duces the control current to Solenoid D7: Diagnostic menu, see 9.10 Cab suspen-
valve cab forward/up (Y6016) or Solenoid sion 2/XX DIAGNOSE, page 8:130 or 9.10
valve cab backward/down (Y6017) on Cab suspension 3/XX DIAGNOSE, page
Control valve cab movement. 8:130
18 Control valve, cab movement, reduces - Control valve cab movement, description,
the hydraulic pressure to valve block slid- page 9:110
ing cab.
19 Hydraulic motor sliding cab reduces the - Hydraulic motor sliding cab, description, page
speed of sliding cab. 9:113
20 When the cab is moved from its rear posi- 11.5.3.1 KCU control unit (D7901), page 11:27
tion, Control unit KCU (D7901) activates Max. speed: 5 km/h.
load centre limitation.
As an option, Control unit KCU (D7901)

also activates speed limitation when the
cab is moved from its rear position.

Hydraulic sliding cab, calibration

1. Machine in service position.
10:23
CUSTOMER SETTINGS
014981
0

10:23
with .
0 WRITE PIN CODE
NOTE
0
015625
5. Select 9. Frame, Cab & Accessories by scrolling with or and

*SETTINGS & DIAGNOSTICS* confirm with .
9. Frame, cab & accessories
017473
6. Select 9.10 Cab Suspension by scrolling with or and confirm

* FAME CAB & ACCESSORIES * with .
9.1 Controls & instruments

9.2 Safety & Emergency Equip.
9.3 Seat
9.4 Climate System
9.5 Lighting System
9.7 Signalling System
9.8 Entertanment & Com.
9.9 Glass Windows & Mirrors
9.10 Cab suspension
017474
9.11 Cab interior

* FAME CAB & ACCESSORIES *

9.3 Seat
9.4 Climate System
9.5 Lighting System
9.9 Glass, Windows & Mirrors
9.10 Cab suspension
017475
9.11 Cab interior

8. Navigate to the calibration menu 9.10 Cab Suspension, menu 1

Row 2 shows the saved value for the cab's rear position.
9. Run the cab back to its rearmost position. Press Save to store
this value.
10. Navigate to Calibration menu 9.10 Cab Suspension, menu 2 with
/ .
Row 2 shows the saved value for the cab's front position.
11. Run the cab forward to its front position. Press Save to store this
position.
9.10.4.1 Cab substructure

Cab substructure, description
See Cab substructure, description, page 9:104.

Hydraulic oil pump, description
Hydraulic sliding cab is supplied with pressure from hydraulic oil pump
1, see Axial piston pump with variable displacement, description, page
10:8.
9.10.4.3 Control valve cab movement

Control valve cab movement, description
1 2 3 4 5 6
The hydraulic sliding cab is controlled by a separate section in the con-
trol valve, cab movement.
pressure and reducing valves convert electric current to servo pressure.
pressure and flow for the function in question. The valve slide has a lim-
The control valve is fitted on the right-hand side of the hydraulic plate in
the engine compartment and is controlled by Control unit KFU (D7971).
Control valve, cab movement, is made up of several sections, each
section controls one function. The following functions are controlled by
control valve, option frame:
Valve slide, sliding cab
022771
The valve slide controls the direction and speed of the sliding cab by
controlling hydraulic pressure to hydraulic motor, sliding cab.
1. Connection hydraulic motor (B) The valve slide is controlled by servo valve front and servo valve rear.
2. Connection hydraulic motor (A)
4. Tank return (T)
5. Solenoid valve cab backward/down (Y6017)
6. Solenoid valve cab forward/up (Y6016)

Servo valve sliding cab forward

Servo valve sliding cab forward controls servo pressure to valve slide
sliding cab so that this controls oil pressure to hydraulic motor sliding
cab forward.
Servo valve sliding cab forward is controlled electrically by Solenoid
valve cab forward/up (Y6016) that is activated by Control unit KFU
(D7971).
The signal can be checked with the diagnostic menu, see 9.10 Cab
suspension 2/XX DIAGNOSE, page 8:130.
Servo valve sliding cab backward
Servo valve sliding cab backward controls servo pressure to valve slide
sliding cab so that this controls oil pressure to hydraulic motor sliding
cab backward.
Servo valve sliding cab back is controlled electrically by Solenoid valve
cab backward/down (Y6017) that is activated by Control unit KFU
(D7971).

Control valve cab movement, replacement
NOTE
Safety.

NOTE
1 2 3 4 5 6
NOTE
from impurities.
5. Remove the control valve.
NOTE
correctly.
022771
NOTE
1. Connection hydraulic motor (B)
2. Connection hydraulic motor (A) mixed up.
4. Tank return (T) 7. Mark up the servo valves on the new control valve.
5. Solenoid valve cab backward/down (Y6017) 8. Fit the valve.
marking.
the marking.
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.

CAUTION
product damage.
manual.
9.10.4.6 Hydraulic motor sliding cab

Hydraulic motor sliding cab, description
The hydraulic motor is positioned at the front on the right-hand side of

the cab chain. The hydraulic motor draws the chain, which in turn pulls
the cab forward and back.
The gear on the hydraulic motor can be disengaged in order to move
the cab manually. For instructions, see Operator's manual.
DANGER
016924
operate.

Hydraulic motor, sliding cab, changing
NOTE
Safety.

NOTE
3. Remove the protective cover.

4. Slacken the chain, loosen the chain tensioner and the adjusting
screw.
5. Disconnect the chain from its mounting.
6. Remove the hydraulic hoses from the motor.
1. Protective cover
2. Hydraulic motor
3. Chain tensioner
7. Remove the ring gear. Remove the screw in the centre of the gear
and pull out the ring gear.
8. Remove the hydraulic motor from its mounting.
9. Change the hydraulic motor.
017416

11. Check that the screws (A) on the hydraulic motor's gears are intact
A and tightened.
DANGER
operate.
hydraulic system.
015583 NOTE
the lock ring.

manual.
9.10.4.7 Chain sliding cab

Chain sliding cab, description
1 2
The chain pulls the cab forward and back and is attached into the front
3 and rear edges of the cab substructure. The chain tension is adjusted
by moving the hydraulic motor for sliding cab.
4
5
016925
1. Rear gear
2. Rear mounting chain (in cab undercarriage)
3. Front mounting chain (in cab undercarriage)
4. Chain sliding cab
5. Front gear mounted on the hydraulic motor for
sliding cab

Chain and chain wheel, sliding cab, changing

2. Slacken the chain, loosen the chain tensioner and the adjusting
screw.
3. Disconnect the chain at the front edge.
4. Disconnect the chain at the rear edge.
5. Change chain.
7. Adjust the chain with the adjusting screw.
8. Tighten the chain tensioner.
1. Protective cover
2. Hydraulic motor
3. Chain tensioner
9. Check that the screws (A) on the hydraulic motor's gears are intact
A and tightened.
DANGER
operate.
015583

9.10.4.9 Sensor cab position

Sensor cab position, description
Sensor, cab position (B7254) measures cab position and is used in or-
der to activate end position damping as well as to calculate and control
LC limitation. The sensor is fitted in the front edge on the left-hand side.
The sensor is a wire sensor, which measures the position of a wire con-
nected to the front edge of the left-hand rail for sliding cab.
Sensor, cab position (B7254) is supplied with voltage by, and sends a
voltage signal proportional to the position to Control unit KCU (D7901).
023696
Sensor cab position, replacement

2. Disconnect the cable from the mounting in the front edge of the
machine.
Note the routing of the cable around the wheel at the sensor.
3. Disconnect the wiring from the sensor.
The sensor is replaced as a complete unit, do not attempt to dis-
mantle the sensor.
5. Connect the wiring to the new sensor.
6. Pull out and connect the cable in the front edge of the machine.
Check that the cable is routed correctly around the wheel at the
sensor. If necessary, adjust the position of the sensor so that the
023696
cable does not chafe at any point.

7. Calibrate cab movement, see Hydraulic sliding cab, calibration,
page 9:109.

9:118 9 Frame, body, cab and accessories – Vertically adjustable cab
9.10.5 Vertically adjustable cab

Vertically adjustable cab, general information
Vertically adjustable cab means that the cab can be raised or lowered
A hydraulically during operation to improve operator visibility. The cab's
vertical height is controlled by a hydraulic cylinder in a frame that holds
the cab.
When the cab is raised, the left-hand door of the cab is blocked by a
mechanical lock. The right-hand door has a short wire that blocks the
door lock so that the door cannot be opened, regardless of cab position.
For safety reasons, the machine's speed is reduced and transmission
is locked in second gear when the cab is raised.
Damping
Position sensors detect when damping should be activated. When
014270
A. Lock
The cab can be secured manually in raised position for maintenance

with two lock lugs on the frame.
A
001977
A. Lock lug

9 Frame, body, cab and accessories – Vertically adjustable cab 9:119
Vertically adjustable cab, function description

Doors Closed. Doors, description, page 9:102.
If the door is open with the cab lifted, the lift and lower
functions for the boom are limited.
1 D1
2
D7902
D7971 D7901
6 5, 7, 10, 19 4, 18, 23
D7940
3
D10
D7930 D3 D17
D7 11, 20 14
16, 22 m
P1
LS A 17
B
8
TP
LSP1 A H 15
LSP2
98
LSPR 13, 21
LSP3 LSHY
C12
022772
12

1 Switch vertically adjustable cab U = 24 V Cab overview, page 9:5
(S1751) sends a voltage signal to D1: Diagnostic menu, see 9.10 Cab suspension
Control unit KCU (D7901). 4/XX DIAGNOSE, page 8:131
2 Control unit KPU (D7902) sends cab 11.5.3.2 KPU control unit (D7902), page 11:30
forward or cab backward on the
CAN bus.
3 Contact closed door (S2660-LE & U = 24 V Doors, description, page 9:102
S2660-RI), sends signals to Control D3: Diagnostic menu, see 9.6 Lighting Sys 18/XX
unit KCU (D7901) when the door is DIAGNOSE, page 8:125
closed.
4 Control unit KCU (D7901) sends Checked by control sys- 11.5.3.1 KCU control unit (D7901), page 11:27
doors closed on the CAN bus. tem, error shown with er-
ror code.
5 Control unit KFU (D7971) sends re- Checked by control sys- KFU control unit (D7971), description, page
quest for raised engine speed on tem, error shown with er- 11:34
CAN bus drive-train. ror code.
6 Control unit, engine (D7940) in- Checked by control sys- 11.5.3.6 Control unit, engine (D7940), page 11:38
creases the engine speed. tem, error shown with er-
ror code.
7 Control unit KFU (D7971) controls U = 24 V 11.5.3.4 Control unit KFU (D7971), page 11:34
Proportional valve, load signal at- D3: Diagnostic menu, see 10.4 Pumps 6/XX DI-
tachment (Y6002), with a predeter- AGNOSE, page 8:134
mined voltage signal.


tachment (Y6002), opens and ac- (Y6002), description, page 10:25
tuates a predetermined load signal.
9 Valve block, servo pressure, sends - Valve block servo pressure, description, page
the load signal to hydraulic oil pump 10:25
1. A shuttle valve in Valve block, ser-
vo pressure, selects the strongest
load signal if other functions are acti-
10 Control unit KFU (D7971) activates I = 435–650 mA KFU control unit (D7971), description, page
Solenoid valve cab forward/up 11:34
(Y6016) or Solenoid valve cab back- D7: Diagnostic menu, see 9.10 Cab suspension
ward/down (Y6017). 5/XX DIAGNOSE, page 8:131 or 9.10 Cab sus-
pension 6/XX DIAGNOSE, page 8:131
11 Solenoid valve cab forward/up - Control valve cab movement, description, page
(Y6016) or Solenoid valve cab back- 9:123
ward/down (Y6017) activates and D7: Diagnostic menu, see 9.10 Cab suspension
pressurises the valve slide in Control 5/XX DIAGNOSE, page 8:131 or 9.10 Cab sus-
valve cab movement. pension 6/XX DIAGNOSE, page 8:131
12 Hydraulic oil pump 1 pumps oil from See the pressure plate on Axial piston pump with variable displacement, de-
the hydraulic oil tank. the left-hand frame beam. scription, page 10:8
13 Control valve cab movement pres- - Control valve cab movement, description, page
surises the accumulator and the 9:123
load control valve.
14 The accumulator stores pressure. - Accumulator, vertically adjustable cab, descrip-
tion, page 9:125
15 The load control valve lets the pres- - Load control valve, description, page 9:125
sure through to hydraulic cylinder for
vertically adjustable cab.
When lowering, the load control
valve changes position and restricts
flow from hydraulic cylinder for verti-
cally adjustable cab.
16 Hydraulic cylinder for vertically ad- - Hydraulic cylinder, vertically adjustable cab, de-
justable cab lifts or lowers the cab. scription, page 9:126
17 Sensor cab position (B7254) sends U = 0-5 V Sensor cab position, description, page 9:130
voltage signals proportional to the D16: Diagnostic menu, see 9.10 Cab suspension
cab's position to Control unit KCU 4/XX DIAGNOSE, page 8:131
(D7901).
18 Control unit KCU (D7901) sends in- Checked by control sys- 11.5.3.1 KCU control unit (D7901), page 11:27
formation about the position of the tem, error shown with er-
cab on the CAN bus. ror code.
19 When the cab's position approaches - KFU control unit (D7971), description, page
the end position Control unit KFU 11:34
(D7971) reduces the control current D7: Diagnostic menu, see 9.10 Cab suspension
to Solenoid valve cab forward/up 5/XX DIAGNOSE, page 8:131 or 9.10 Cab sus-
(Y6016) or Solenoid valve cab back- pension 6/XX DIAGNOSE, page 8:131
ward/down (Y6017) on Control valve
cab movement.
20 Solenoid valve cab forward/up - Control valve cab movement, description, page
(Y6016) or Solenoid valve cab back- 9:123
ward/down (Y6017) reduces the D7: Diagnostic menu, see 9.10 Cab suspension
control pressure to the sliding cab 5/XX DIAGNOSE, page 8:131 or 9.10 Cab sus-
slide in Control valve cab movement. pension 6/XX DIAGNOSE, page 8:131
21 Control valve, cab movement, re- - Control valve cab movement, description, page
duces the hydraulic pressure to Hy- 9:123
draulic cylinder vertically adjustable
cab.


22 Hydraulic cylinder for vertically ad- - Hydraulic cylinder, vertically adjustable cab, de-
justable cab reduces the speed of scription, page 9:126
raising or lowering the cab.
23 When the cab is raised, Control unit Max. speed: 5 km/h. 11.5.3.1 KCU control unit (D7901), page 11:27
KCU (D7901) activates speed limita-
tion and load centre limitation.
Vertically adjustable cab, calibration

1. Machine in service position.
10:23
CUSTOMER SETTINGS
0
014981

10:23
with .
0 WRITE PIN CODE
NOTE
0
015625
5. Select 9. Frame, Cab & Accessories by scrolling with or and

*SETTINGS & DIAGNOSTICS* confirm with .
9. Frame, cab & accessories
017473
6. Select 9.10 Cab Suspension by scrolling with or and confirm

* FAME CAB & ACCESSORIES * with .

9.3 Seat
9.4 Climate System
9.5 Lighting System
9.9 Glass Windows & Mirrors
9.10 Cab suspension
017474
9.11 Cab interior


* FAME CAB & ACCESSORIES *

9.3 Seat
9.4 Climate System
9.5 Lighting System
9.9 Glass, Windows & Mirrors
9.10 Cab suspension
017475
9.11 Cab interior
8. Navigate to the calibration menu 9.10 Cab Suspension, menu 3

Row 2 shows the saved value for the cab's lower position.
9. Lower the cab to its lowest position. Press Save to store this
value.
10. Navigate to Calibration menu 9.10 Cab Suspension, menu 4 with
/ .
Row 2 shows the saved value for the cab's upper position.
11. Raise the cab to its highest position. Press Save to store this
position.

Hydraulic oil pump, description
Hydraulic raising of the cab is supplied with pressure from hydraulic oil
pump 1, see Axial piston pump with variable displacement, description,
page 10:8.

9.10.5.2 Control valve cab movement

Control valve cab movement, description
3 The vertically adjustable cab is controlled by a separate section in con-

trol valve, option frame, for details see Control valve cab movement,
2 4 description, page 9:110.
Valve slide raise/lower cab
1
The valve slide controls the direction and speed of raising and lowering
the cab by controlling the hydraulic pressure for hydraulic cylinder, ver-
tically adjustable cab.
The valve slide is controlled by servo valve raise cab and servo valve
5 lower cab.
6 Servo valve raise cab
7 Servo valve raise cab controls servo pressure to valve slide raise/lower
8
cab so that this controls oil pressure to hydraulic cylinder, vertically ad-
justable cab, for raising the cab.
Servo valve raise cab is controlled electrically by Solenoid valve cab
forward/up (Y6016) that is activated by Control unit KFU (D7971).
The signal can be checked with the diagnostic menu, see section 9.10
022773
Cab suspension 2/XX DIAGNOSE, page 8:130.
1. Accumulator Servo valve lower cab

2. Emergency lowering valve Servo valve lower cab controls servo pressure to valve slide raise/lower
3. Solenoid valve cab backward/down (Y6017) cab so that this drains hydraulic cylinder, vertically adjustable cab, for
4. Measurement connection lowering the cab.
5. Solenoid valve cab forward/up (Y6016) Servo valve lower cab is controlled electrically by Solenoid valve cab
6. Pressure feed (P) backward/down (Y6017), activated by Control unit KFU (D7971).
7. Tank return (T1) Servo valve lower cab can be controlled with the diagnostic menu, see
8. Connection, hydraulic cylinder (B) 9.10 Cab suspension 3/XX DIAGNOSE, page 8:130.

Control valve cab movement, replacement
3
NOTE
2 4 Read the safety instructions for oil before working, see section B
Safety.
1
5 NOTE
6 Leave the valves open during replacement.
7
8 3. Mark and disconnect the hydraulic hoses from the control valve.
NOTE
from impurities.
022773
1. Accumulator 5. Remove the control valve.

2. Emergency lowering valve Remove the attaching bolts and lift away the valve. Place the valve
3. Solenoid valve cab backward/down (Y6017)
4. Measurement connection 6. Transfer parts to the new control valve.
6. Pressure feed (P) NOTE
7. Tank return (T1) Change the O-rings. Check that the O-rings are positioned
8. Connection, hydraulic cylinder (B) correctly.
NOTE
mixed up.

8. Fit the valve.
marking.
the marking.
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.

CAUTION
product damage.
manual.
9.10.5.4 Accumulator, vertically adjustable cab

Accumulator, vertically adjustable cab, description
The accumulator stores pressure so that the cab does not lower if the
engine stops and the machine becomes depressurised.
9.10.5.5 Load control valve

Load control valve, description
The load control valve reduces the speed when lowering the cab.
When the pressure is released behind the valve, the valve slide
changes position and restricts the channel through the valve.
000621

9.10.5.6 Hydraulic cylinder vertically adjustable cab

Hydraulic cylinder, vertically adjustable cab,
description
1 2 3 The hydraulic cylinder lifts the inner mast and thus the cab.
4
001873

4. Safety lock
Hydraulic cylinder, vertically adjustable cab, changing
NOTE
Safety.
1. Raise the cab as high as possible and secure its position with both
lock lugs (position A).
Lower the cab so that it rests on the lock lugs.
DANGER
When working under a raised cab.
Extreme danger!
A Secure the cab with the lock lugs (position A) on the
sides of the cab frame.
001977

A. Lock lug brake systems, depressurising, page B:5.
NOTE
4. Mark up and disconnect the hydraulic hoses from the extension

cylinder.
NOTE
from impurities.

5. Disconnect the upper cylinder mounting (position 1) from the mov-

ing part of the cab frame.
008206
1. Upper mounting hydraulic cylinder

2. Retaining bracket hydraulic cylinder
6. Remove the load control valve and compress the hydraulic
cylinder.
NOTE
from impurities.
7. Connect lifting equipment to the hydraulic cylinder.

8. Remove the hydraulic cylinder's retaining brackets from the fixed
part of the cab frame.
9. Tilt and lift out the hydraulic cylinder upward.
10. Transfer parts to the new hydraulic cylinder.
11. Install the hydraulic cylinder in reverse order.
hydraulic system.
NOTE
the lock ring.
13. Turn the start key to position 1 and check the sealing integrity.
000621
manual.
Load control valve


9.10.5.7 Mast, vertically adjustable cab

Mast, vertically adjustable cab, description
1 2 3 The mast holds the cab secure and enables raising and lowering.
4
001873

4. Safety lock
9.10.5.10 Emergency lowering valve

Emergency lowering valve, description
The emergency lowering valve (position A) opens a connection be-

tween the hydraulic cylinder's piston side and tank, and makes it possi-
ble to lower the cab if the machine becomes depressurised or de-
energised.
016944
Location of the emergency lowering valve

9.10.5.11 Safety lock, vertically adjustable cab

Safety lock, vertically adjustable cab, description
There are two lock lugs on the mast, which are used to secure the cab
in the raised position during maintenance work with raised cab.
001977
A. Lock lug
9.10.5.12 Door catch

Door catch, description
The mechanical lock prevents the operator from opening the left-hand
A door by mistake when the cab is raised. The lock releases the driver's
door when the cab is lowered to its lowest position.
The right-hand door has a short wire that blocks the door lock so that
the door cannot be opened, regardless of cab position.
014270
A. Lock

9.10.5.13 Sensor cab position

Sensor cab position, description
Sensor, cab position (B7254) measures cab position and is used in or-
der to activate end position damping as well as to calculate and control
LC limitation. The sensor is fitted in the centre of the cab frame's inner
section. The sensor is a wire sensor, which measures the position of a
wire connected to the lower part of the cab frame's outer section.
Sensor, cab position (B7254) is supplied with voltage by, and sends a
voltage signal proportional to the position to Control unit KCU (D7901).
018514
Sensor cab position, replacement

2. Disconnect the cable from the mounting in the lower edge of the
cab frame.
3. Disconnect the wiring from the sensor.
The sensor is replaced as a complete unit, do not attempt to dis-
mantle the sensor.
5. Connect the wiring to the new sensor.
6. Pull out and connect the cable in the lower edge of the cab frame.
7. Calibrate cab movement, see Vertically adjustable cab, calibration,
page 9:121.
018514

9 Frame, body, cab and accessories – Cab interior 9:131
9.11 Cab interior

Cab interior equipment, description
The cab is designed for optimum operator comfort. Switches, controls,
warning and indicator lamps are grouped on the dashboard panels to
provide the operator with a good driving environment.
Recyclable materials have been used for all parts.
• Dashboard panels
• Interior parts, plastic
• Interior parts, textile
• Insulation
9.11.1 Instrument and control panels

Instrument and control panels, function description
1 4 7
D3
D1 D4 D7
D2
3 M
D6
2,5,8
D5 D7902
6 M
D9 D7971 D7901
D8
9 M
016110
1 Length adjustment forwards of right front con- Switch in ON position: U D1: 9.1 Controls & Instr 4/XX DIAG-
trol panel switch (S1056-1) or backwards = 24 V NOSE, page 8:108.
(S1056-2) sends a voltage signal to the KPU
2 KPU control unit (D7902) governs the control U = 0.5-4.5 V D2: 9.1 Controls & Instr 5/XX DIAG-
motor panel forwards/backwards (M6941) NOSE, page 8:108.
which sets the panel in the desired position.
3 The position of the control motors is fed back to U = 0.5-4.5 V D3: 9.1 Controls & Instr 5/XX DIAG-
the KPU control unit (D7902). This gives infor- NOSE, page 8:108.
mation for control of the panel position.
4 Height adjustment up of right, control panel Switch in ON position: U D4: 9.1 Controls & Instr 6/XX DIAG-
switch (S1057-1) or down (S1057-2) sends a = 24 V NOSE, page 8:109.
voltage signal to the KPU control unit (D7902).
motor panel up/down (M6942) which sets the NOSE, page 8:109.
panel in the desired position.
7 Height adjustment up of steering wheel switch Switch in ON position: U D7: 9.1 Controls & Instr 2/XX DIAG-
(S1058-1) or down (S1058-2) sends a voltage = 24 V NOSE, page 8:107.
signal to the KPU control unit (D7902).

9:132 9 Frame, body, cab and accessories – Interior fittings, plastic
motor panel up/down (M6943) which sets the NOSE, page 8:108.
panel in the desired position.
9.11.2 Interior fittings, plastic

Interior fittings, plastic, description
The interior plastic components of the cab are made of recyclable
material.
Interior plastic components, replacement

Steering column cover
015776
3. Remove the screws and adjuster lever.

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

9 Frame, body, cab and accessories – Interior fittings, plastic 9:133
5. Remove the rear cover.
015782
1 2 3
1. Cover
2. Screw
Plastic cover over wiper motor

2. Loosen the two screws and remove the plastic cover over the
wiper motor in the cab.
015808
Right dashboard panel, front section


Right dashboard panel, middle section

3. Turn the panel over and disconnect the contacts. Note how the
connectors are connected.
4. Remove the control lever.
5. Remove the switches from the panel.
Right dashboard panel, rear section

1
016195
2
1. Silicone panel
2. Screw

9 Frame, body, cab and accessories – Interior fittings, plastic 9:135
3. Loosen the springs and carefully turnover the storage box.
015781
4. Carefully separate the navigation wheel and silicon panel's
1 2 connectors.
015761
4 3
1. Contact, navigation wheel
4. Contact, silicone panel. Do not forget the retain-
ing clip that holds the connector in position.
Front section
2. For better access, move the steering wheel to the rearmost posi-
tion and lift the steering column to the highest position.
Loosen one end of the actuator motor from the steering column
and block up the steering column in the highest possible position.
3. Unscrew the four screws.
4. Carefully remove the dashboard panel.
2
016002
1
1. Front section
2. Screws

Cover by pedals
1 2 1
015856
1. Screws
2. Cover
Covers on pillars
2. Loosen the locking pins that attach the plastic covers on the door
pillar. There is a screw fitted in the centre in order to facilitate re-
moval and fitting.
3. Remove the plastic covers.
018686

9 Frame, body, cab and accessories – Interior fittings, textile 9:137
Rear section
2. Remove the plastic cover over the rear wiper motor, see Plastic
cover over wiper motor, page 9:133.
3. Loosen the locking pins that attach the plastic cover on the door
1 2 pillar. Remove the screw holding the plate.
4. Remove the door pillar's lower plastic cover.
5. Fold back the floor mat to access the lower locking pins.
6. Unscrew the snap lock.
7. Remove the rear section.
015899
4 3
1. Snap lock, rear section
2. Locking pins, door pillar
3. Plate, door pillar
4. Locking pins, during mat edge
9.11.3 Interior fittings, textile

Interior fittings, textile, description
The interior textile components of the cab are made of recyclable
material.
Interior textile components, replacement

2. Remove the covers sitting in the door openings, see Covers on pil-
lars, page 9:136.
3. Dismantle the radio console's plastic cover.
1 2
016003
5 4 3 2
1. Plastic cover, radio console
2. Screw, roof panel
3. Speaker
4. Lamp
5. Radio

9:138 9 Frame, body, cab and accessories – Floor covering
1 2 4. Carefully pull out the radio with radio's special tool.

Loosen the radio connectors and antenna cable.
5. Remove the radio console from the roof.
6. Carefully unscrew the speakers and remove the connectors.
7. Carefully remove the interior lighting and separate its connectors.
8. If the roof panel is replaced, move all the equipment installed in the
roof to the new roof panel.
9. Remove the screws securing the roof panel.
10. Remove the roof panel.
016004
1. Screw
2. Connectors
9.11.4 Floor covering

Floor covering, description
The floor covering is recyclable and is made of wear and water resist-
ant 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. Detach and remove the cab equipment which is screwed through
the floor mat or otherwise secures the mat, e.g. the plastic cover
below the driver's seat (driver's seat in cab with flat floor), pedal
carrier and steering column.
5. Replace the floor matting.
016410
9.11.5 Insulation
Insulation, description
The cab insulation consists of recyclable material.
The insulation material consists of both self-adhesive foam plastic ma-
terial 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 9:139
9.11.6 Sun visors

Sun visors, description
Sun visors can be specified for the windscreen, roof window and the
rear window:
1. Sun visors, front and rear window: Adjustable up and down with
the cord on the right-hand side. Stops in the chosen position.
2. Sun visor, roof window: It is pulled out forwards. Stops in the chos-
en position.
017440
Sun visors, Windscreen

Pulled from the side and in towards the centre for bet-
017442
ter upward visibility.
Sun visor rear window

017441
Sun visor roof window

9:140 9 Frame, body, cab and accessories – Frame
9.12 Frame
Frame, description
The function of the body is to serve as the supporting structure for the
machine's components. The body is built around a frame with welded
mounts for boom, lift cylinders, steering axle, drive axle, side panel,
tanks, exhaust system and footsteps. Fenders, counterweights, steer-
ing axle, drive axle and mounts for engine, transmission and cab are
bolted to the frame.
The body is a modular construction and consists of front section, rear
section and a beam pair. This design provides advantages in terms of
rigidity and strength.
There are mounting points in the frame for engine, transmission, drive
axle, steering axle, fuel and hydraulic tanks, cab, boom, and body parts.
The space in the rear section of the frame is used for counterweights,
the number and size of which are adapted to the machine in question.
016913
The counterweights are designed to allow as good visibility rearwards

as possible.
The front wings are bolted into the frame (which has advantages when
delivering the machine).

9 Frame, body, cab and accessories – Body structure 9:141
9.13 Body structure

Body structure, description
The function of the body is to be part of the frame. There are fenders to
deflect dirt, footsteps and hand rails to facilitate access onto the body,
engine hood to deflect dirt and objects from the engine compartment
and a counterweight to balance the machine's lifting capacity.
The body is regarded as being the following:
• Wings
• Engine covers
• Footstep
• Counterweights
• Hydraulic oil tank
• Oil tank brake system
• Fuel tank
• Side panel
• Battery compartment
9.13.1 Wings
Wings, description
There are wings over the wheels to protect from dirt thrown up by the
wheels during operation.
The wings can be equipped with extra mudguards when the ma-
chine's work environment requires such.
The front wings can be fitted with a non-slip plate.
9.13.2 Hood engine compartment

Hood engine compartment, description
The machine's engine compartment is protected by engine covers con-
sisting of tread plates with noise insulation that act as hoods. The tread
plates are divided into several sections, the hoods are secured with
rubber bushings or with screws. The tread plates are designed for walk-
ing on and are ribbed to provide sure footing.
9.13.3 Footsteps and hand rail

Footsteps and hand rail, description
The machine's running boards are made of perforated steel plate that
is designed to be walked on with footholds. The footsteps are bolted in-
to brackets on the frame.
There are hand rails by the cab steps for the cab and the platform by
the cab.
As an option, the machine can be specified with steps, and hand
rails are also available for the left-hand front fender.
9.13.4 Counterweight
Counterweights, description
The machine has counterweights to balance the machine's lift capacity
and these may therefore vary in quantity and weight.
The machine has counterweights in the following locations:
• Under the steering axle.

9:142 9 Frame, body, cab and accessories – Battery compartment
• Furthest back on the machine there are vertical counterweights se-

cured in the rear edge of the frame; the outer has a towing eye.
Between the outer counterweight and frame, there are smaller
counterweights whose dimensions and quantity are adapted to bal-
ance the machine's lifting capacity.
• Upper horizontal counterweight.
Under the horizontal counterweight, there are smaller counter-
weights whose dimensions and quantity are adapted to balance
the machine's lifting capacity.
DANGER
The counterweights are factory fitted and are adapted
according to the machine's properties.
The machine's driving characteristics change if the
counterweights are removed or added!
Never change the quantity of counterweights.
9.13.5 Battery compartment

Battery compartment, description
The battery compartment is located behind the cover lid on the rear
left-hand side of the machine (behind the fuel tank). The cover lid is
opened with a lockable T-handle.
The compartment has two sections separated by a fixed shelf. The
upper section contains the starter batteries. On machines with SCR
system, the lower section contains control electronics for emission con-
trol. On machines without SCR system, the compartment can be used
for storage.
NOTE
The compartment with starter batteries must not be used as a stor-
age space.
016304
9.13.8 Tool kit

Tool kit, description
The machine can be equipped with a tool kit.

9 Frame, body, cab and accessories – Lifting lugs 9:143
9.13.9 Lifting lugs

Lifting and lashing points, description
To transport the machine it is equipped with lifting points and lashing
points in several places:
• Rear of the frame at the steering axle (lashing point for securing on
a transport vehicle)
• Rear of the frame under the rear boom mounting (welded lifting
points for lifting the machine)
• Front of the frame above the drive axle (holes for securing on a
transport vehicle)
• Front of the frame above the drive axle (welded lifting points for lift-
ing the machine)
• On the sides of the attachment (for lifting the attachment or secur-
ing loose attachment on a transport vehicle)
• Rear of the lift boom (for lifting the boom or securing loose boom
on a transport vehicle)
• Front of the lift boom (for lifting the boom or securing loose boom
on a transport vehicle)

9:144 9 Frame, body, cab and accessories – Central lubrication
9.14 Central lubrication

Central lubrication, description
Central lubrication lubricates the machine's lubrication points automati-

cally during operation in accordance with pre-programmed intervals
and replaces parts of lubrication during preventive maintenance. Cen-
tral lubrication is activated and the time interval starts when the engine
is started and the speed is above 0.5 km/h, or when a hydraulic func-
tion is active. When the time interval (pause) has counted out, the
pump unit is restarted and runs in accordance with a predetermined
running time.
The machine has two separate central lubrication systems, one for the
machine and one for the attachment. Central lubrication pause and run-
ning times can be adapted according to requirements, contact Cargo-
tec Service.
Central lubrication consists of the following components:
• Pump unit (M6930), with lubricant reservoir.
Example illustration, components central lubrication • Distribution blocks, which distribute and doses the grease between
1. Central lubrication sensor (B7242) the different lubrication points.
2. Grease nipple, manual lubrication of system The distribution blocks lubricate progressively, i.e. one point at a
time. If a point cannot be lubricated properly, e.g. due to a blocked
3. Safety valve line, subsequent points will not be lubricated. The grease will be
4. Lubricant nipple for filling pushed out through the safety valve on the pump unit.
5. Distribution block • Lines, between main unit and distribution blocks and between dis-
tribution blocks and grease nipples.
• Grease nipples, at the lubrication points.
• Central lubrication sensor (B7242).
The sensor is fitted on the distribution block at the pump unit and
sends signals to the control system. Faults in central lubrication
are indicated by error codes in the display.
Signals can be monitored with the diagnostic menu, see 9.14 Central
Lubr 1/XX DIAGNOSE, page 8:132.
NOTE
The central lubrication does not lubricate all lubrication points, some
still need to be lubricated during preventive maintenance.

9 Frame, body, cab and accessories – Pump unit 9:145
9.14.1 Pump unit

Pump unit, description
The pump unit consists of a reservoir with agitator and filler nipple, as
well as pump housing with built-in motor and pump element.
The unit works by means of lubrication cycles (pause and run-time and
read time). A pressure relief valve is fitted to the pump element, ensur-
ing that the pressure in the system does not become too high.
2 1
Control of central lubrication is performed by the control system. Sig-
nals can be monitored with the diagnostic menu, see 9.14 Central Lubr
018547
Pump unit, central lubrication

1. Lubricant nipple for filling
2. Safety valve
9.14.2 Distribution block

Distribution block, description
The number of distribution blocks can vary depending on how many
(and which) lubrication points are selected. However, the first distribu-
tion 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 move-
ment is repeated time after time. Each piston must have complete its
movement before the next piston can move. The pistons are interde-
pendent. It is technically impossible for a connected lubrication point to
be missed.
Example illustration, components central lubrication

1. Central lubrication sensor (B7242)
2. Grease nipple, manual lubrication of system
3. Safety valve
5. Distribution block

9:146 9 Frame, body, cab and accessories – Lines
9.14.3 Lines
Lines, description
The lubricant is carried to the lubrication points through hoses.
Example illustration, components, central lubrication

1. Lines, central lubrication
2. Lubricant nipples
9.14.4 Lubricant nipples

Lubrication points, description
The lubrication points have lubricant nipples with couplings to which
the lines are connected. The couplings can be straight or angled.
Example illustration, components, central lubrication

1. Lines, central lubrication
2. Lubricant nipples

9 Frame, body, cab and accessories – Sensor, central lubrication 9:147
9.14.5 Sensor, central lubrication

Sensor, central lubrication, description
Sensor, central lubrication (B7242), is fitted on one of the system's dis-
tribution blocks and sends signals to the control system. Faults in cen-
tral lubrication are indicated by error codes.
Example illustration, components central lubrication

1. Central lubrication sensor (B7242)
2. Grease nipple, manual lubrication of system
3. Safety valve
5. Distribution block

9:148 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.
Check the machine frequently for stone chips, dents and paint
scratches, repair them at once to prevent corrosion on the metal under-
neath. 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 thor-
oughly cleaned.
Contact Cargotec for information about other surface treatment and

colours.

10:1
Contents 10 Common hydraulics

10 Common hydraulics .......................................................................................... 10:3
10.2 Safety valves................................................................................................... 10:4
10.2.1 Accumulator drain valve............................................................................. 10:4
10.2.3 Pipes and hoses......................................................................................... 10:4
10.2.4 Pressure relief valve................................................................................... 10:5
10.3 Tanks and accumulators ................................................................................. 10:6
10.3.1 Tank ............................................................................................................ 10:6
10.3.2 Pipes and hoses......................................................................................... 10:6
10.4 Pumps ............................................................................................................. 10:7
10.4.1 Gear pump with fixed displacement........................................................... 10:7
10.4.2 Axial piston pump with variable displacement ........................................... 10:8
10.4.3 Pipes and hoses....................................................................................... 10:20
10.4.5 Screw pump with fixed displacement....................................................... 10:21
10.5 Hoses, pipes and valves ............................................................................... 10:23
10.5.1 Pipes and hoses....................................................................................... 10:23
10.5.5 Collecting block, unfiltered returns........................................................... 10:24
10.5.8 Accumulator servo circuit ......................................................................... 10:31
10.6 Temperature control, cleaning and hydraulic oil ........................................... 10:32
10.6.1 Tank heater............................................................................................... 10:34
10.6.2 Hydraulic oil cooler ................................................................................... 10:35
10.6.3 Cooling fan ............................................................................................... 10:37
10.6.4 Sensor hydraulic oil temperature ............................................................. 10:40
10.6.5 Radiator bypass valve.............................................................................. 10:41
10.6.6 Breather filter hydraulic oil tank................................................................ 10:42
10.6.7 Hydraulic oil filter ...................................................................................... 10:42
10.6.9 Fine filter hydraulic oil............................................................................... 10:43
10.6.10 Pipes and hoses....................................................................................... 10:43
10.6.14 Servo filter ................................................................................................ 10:43
10.7 Other ............................................................................................................. 10:44
10.7.1 Hydraulic cylinders ................................................................................... 10:44

10:2

10 Common hydraulics – Common hydraulics 10:3
Common hydraulics, description
Hydraulic functions that are common to several of the machine's main
functions are found under the function common hydraulics. For exam-
ple, the hydraulic oil pumps that supply load handling, steering and cer-
tain cab functions with hydraulic pressure.
The brake system is completely separate and can be found under the
section 4 Brakes, see Brakes, general, page 4:3.
Pressure plate
On the machine there is a pressure plate with the most important pres-
sure information stamped in. The pressure plate is fitted on the left-
hand side of the frame in front of the cab steps.
Pressure levels vary with the equipment and are therefore unique to
each machine. When checking the pressure, pressures must be con-
sistent with the values specified on the pressure plate.
1
3
10
023165
9 8 7 6 5 4
The appearance of the pressure plate may vary, but the symbols are the same.
1. Feed pressure control valve, attachment 6. Gas pressure servo accumulator
2. Feed pressure control valve lift legs 7. Oil pressure steering
3. Gas pressure brake accumulators 8. Max. pressure hydraulic oil pump 1
4. Max. brake pressure 9. Max. pressure hydraulic oil pump 2
5. Servo pressure lift and extension 10. Hydraulic oil pressure accumulators brake system

10:4 10 Common hydraulics – Safety valves
10.2 Safety valves

10.2.1 Accumulator drain valve
Accumulator drain valve, description
Relief valve brake system, drains the stored pressure in the brake sys-
tem's accumulators.
For information about depressurising the machine, see Hydraulic and
The accumulator drain valve is fitted on the accumulator charging valve.
See Accumulator charging valve, description, page 4:20.
016821
Open the drain valve

Relief valve top lift, drains the pressure in the hydraulic line to the at-
tachment's pressure feed. This line is pressurised after the engine has
been switched off due to non-return valves in the hydraulic oil pump.
The valve must be closed during normal operation.
For information about depressurising the machine, see Hydraulic and
The relief valve is fitted on the pressure feed for the attachment. See
Relief valve top lift, description, page 7:57.
022267
The illustration depicts an open valve


10 Common hydraulics – Pressure relief valve 10:5
10.2.4 Pressure relief valve

Pressure limiting valve, description
The pressure relief valve protects the hydraulic system against exces-
A sive feed pressure from the hydraulic oil pumps.
B The pressure limiting valve leads too high pressure in the hydraulic oil
supply to tank, protecting the hydraulic system against excessive
C pressures.
The pressure relief valve is fitted on hydraulic oil pump 2.
022699
A. Pressure relief valve

B. Pressure feed from hydraulic oil pump 2
C. Tank return overpressure

10:6 10 Common hydraulics – Tanks and accumulators
10.3 Tanks and accumulators

10.3.1 Tank
Tank, description
The hydraulic oil tank forms part of the side panel on the right-hand
3 side of the machine. The oil filters for the working hydraulics are fitted
2 inside the tank. These are accessible through hatches on top of the
1 tank.
Hydraulic oil is filled directly into the tank through the filler plugs on the
filter manhole covers. For oil capacity and grade, see section F Techni-
cal data. The whole filter unit can be removed to facilitate access for
cleaning. There is a drain plug located at the bottom of the tank.
The tank is equipped with filtered breather that allows volume changes
in the tank, due to temperature variations and use.
The oil level is checked on the sight glass on the tank's side when all
hydraulic cylinders are in the bottom position.
022485
1. Oil filter cover

2. Sight glass hydraulic oil
3. Breather filter hydraulic oil tank


10 Common hydraulics – Pumps 10:7
10.4 Pumps
Pumps, general
The machine's hydraulics are supplied from five pumps. Three of them
5 are for working hydraulics, one is for cooling and filtering the hydraulic
2
oil and one is for the brake system. Four of the pumps are fitted on the
1 transmission's power take-off while hydraulic oil pump, cooling and
cleaning, is driven by an electric motor.
4
Hydraulic oil pump 1 (position 1) supplies the control valves for lift
and extension, attachment, cab movement, and cab lift.
3
Hydraulic oil pump 2 (position 2), supplies the control valve for lift and
extension. Hydraulic oil pump 2 disengages at boom in. On machines
with support jacks, hydraulic oil pump 2 also supplies the control valve
for support jacks.
Hydraulic oil pump 3 (position 3) supplies the steering.
For information on hydraulic oil pump 1–3, see Axial piston pump with
variable displacement, description, page 10:8.
022700
Hydraulic oil pump, cooling and cleaning (position 4), circulates the
hydraulic oil through the radiator and hydraulic oil filter, see Tempera-
1. Hydraulic oil pump 1 ture control, cleaning and hydraulic oil, description, page 10:32.
2. Hydraulic oil pump 2 Oil pump brake system (position 5) supplies the brake system's brake
3. Hydraulic oil pump 3 and cooling circuit over an accumulator charging valve, see Oil pump
4. Hydraulic oil pump cooling and cleaning brake system, description, page 4:16.
10.4.1 Gear pump with fixed displacement

Gear pump with fixed displacement, description
There is one gear pump with fixed displacement. It supplies the brake
5 system with pressure, see Oil pump brake system, description, page
2
4:16.
1
The gear pump pumps oil via two gear wheels that rotate opposite each
other. One is driven by the pump's input shaft and the other rotates
4
freely. The gear pump's flow is directly dependent on the speed of the
input shaft.
3
Oil pump brake system is fitted in one of the transmission's power
take-offs. The pump's rotation speed is directly dependent on engine
speed. Pump flow increases with the engine speed.
022700


10:8 10 Common hydraulics – Axial piston pump with variable displacement
10.4.2 Axial piston pump with variable

displacement
Axial piston pump with variable displacement,
description
The hydraulic oil pumps are of the type variable axial piston pump, and
5 are controlled by load signals depending on the flow demand from each
2
function.
1
Hydraulic oil pump 1 (position 1) supplies oil to:
4 • Control valve for lift and extension,
• Control valve for attachment,
3 • Pressure reducer in Valve block, servo pressure.
• Cab movement or cab lift.
Hydraulic oil pump 2 (position 2) supplies oil to:
• Control valve for lift and extension,
• Control valve for support jacks.
Hydraulic oil pump 2 disengages at boom in.
A connection block is located on each pump's pressure side with the
022700
following functions:
• Connection to the functions to which the hydraulic oil pump sup-
1. Hydraulic oil pump 1 plies oil.
2. Hydraulic oil pump 2 • A non-return valve to prevent the oil being pumped around be-
3. Hydraulic oil pump 3 tween the pumps instead of out into the hydraulic system.
4. Hydraulic oil pump cooling and cleaning • A test outlet for checking the pump pressure
5. Oil pump brake system Hydraulic oil pump 3 (position 3) supplies the control system.

D7902
11 1 D7911 D7971
Pa D11 7, 13, 20
P P
P1
12 D7
LS PP D13
C16 C27
4,8 14,21
LSM H A
27
2,15,22
P
26
PT
5,18 17 28
24 LSP1 LSP3 LSHY LS P

LS
P
C15
P
C29
C3 C6 10
3,16,23,25 no 1 no 2 6,9,19 29 no 3
022751

10 Common hydraulics – Axial piston pump with variable displacement 10:9

1 Lift/lower and extension See pressure plate Servo Lifting/lowering, function description, page
Control valve lift, lower and extension pressure lift and extension 7:17
sends a load signal to Valve block servo on left frame member.
pressure when a function is activated.
2 The shuttle valve in Valve block servo - Valve block servo pressure, description, page
pressure sends the load signal onward to 10:25
hydraulic oil pump No. 1.
This shuttle valve selects between load
signal from lift, extension or attachment
functions.
3 Hydraulic oil pump 1 increases the flow. See pressure plate Max. Axial piston pump with variable displacement,
pressure hydraulic oil description, page 10:8
pumps on left frame
member.
4 Solenoid valve unloading main pump - Valve block servo pressure, description, page
(Y6093) in rest position forwards the load 10:25
signal to the shuttle valve (position 5).
5 The shuttle valve forwards the load sig- - Valve block servo pressure, description, page
nal to Hydraulic oil pump No. 2. 10:25
This shuttle valve chooses between load
signal from lift, extension, or support
jacks .
6 Hydraulic oil pump 2 increases the flow. See pressure plate Max. Axial piston pump with variable displacement,
pressure hydraulic oil description, page 10:8
pumps on left frame
member.
7 At boom in, Control unit KFU (D7971) ac- U = 24 V KFU control unit (D7971), description, page
tivates Solenoid valve pump unloading 11:34
(Y6093). D7: Diagnostic menu, 10.4 Pumps 2/XX DI-
AGNOSE, page 8:134
8 Solenoid valve, pump unloading (Y6093) - Valve block servo pressure, description, page
opens and routes the load signal from 10:25
Control valve lift, lower, and extension to
the tank.
9 Hydraulic oil pump No. 2 reduces the - Axial piston pump with variable displacement,
flow to standby. description, page 10:8
10 If the feed pressure for Control valve lift, Opening pressure: 25 Pressure limiting valve, description, page
lower and extension, becomes too high, MPa 10:5
the pressure relief valve opens and di-
rects pressure to the hydraulic oil tank.
11 Attachment functions 0.5–4.5 V Sensor, servo pressure attachment (B7668),
Sensor, servo pressure attachment page 7:50
(B7688), detects whether an attachment D11: Diagnostic menu, see 10.4 Pumps 7/XX
function is activated and sends a voltage DIAGNOSE, page 8:134
signal proportional to the oil pressure to
12 Control unit KAU (D7911) forwards infor- Checked by control sys- 11.5.3.8 Control unit KAU (D7911), page
mation on the oil pressure in the attach- tem, error shown with er- 11:40
ment on the CAN bus to Control unit ror code.
KFU (D7971).
13 Control unit KAU (D7971) controls Pro- 0.5–4.5 V 11.5.3.4 Control unit KFU (D7971), page


ment (Y6002), actuates a load signal (Y6002), description, page 10:25
proportional to the pressure require-
ments in the attachment to the shuttle
valve. The size of the load signal is con-
trolled by the voltage signal from Sensor,
oil pressure attachment (B7688).
The load signal is created by a reduction
on the outlet from hydraulic oil pump
No 1, located before connection PT on
Valve block, servo pressure.
15 The shuttle valve in Valve block servo See the pressure plate on Valve block servo pressure, description, page
pressure sends the load signal onward to the left-hand frame beam. 10:25
16 Hydraulic oil pump No. 1 adapts the flow See pressure plate Max. Axial piston pump with variable displacement,
according to the load signal's pressure pressure hydraulic oil description, page 10:8
difference. pumps on left frame
member.
17 Support jacks - Support jacks, function description, page
Control valve support jacks sends load 7:172
signals to Valve block, servo pressure,
when the support jacks are lowered.
18 The shuttle valve in Valve block servo - Valve block servo pressure, description, page
pressure sends the load signal onward to 10:25
member.
20 Cab movement - Manual sliding cab, description, page 9:105
Control unit KFU (D7971) sends a volt- Vertically adjustable cab, function description,
age signal to Proportional valve, load sig- page 9:119
nal attachment (Y6002), when the cab D13: Diagnostic menu, see 10.4 Pumps 6/XX
shall be moved. DIAGNOSE, page 8:134
ment (Y6002), actuates a constant load (Y6002), description, page 10:25
signal to the shuttle valve.
22 The shuttle valve in Valve block, servo - Valve block servo pressure, description, page
pressure, forwards the load signal to hy- 10:25
draulic oil pump 1.
member.
24 Pressure is supplied to the valve for cab - Manual sliding cab, description, page 9:105
movement. Vertically adjustable cab, function description,
page 9:119
25 Servo pressure to control valve - Axial piston pump with variable displacement,
Pressure from Hydraulic oil pump No. 1 description, page 10:8
is routed to Valve block, servo pressure.
26 The pressure reducer in Valve block, ser- See pressure plate servo Valve block servo pressure, description, page
vo pressure, regulates the pressure to pressure, on left frame 10:25
servo pressure and supplies Control member.
valve lift, lower and extension with servo
pressure.
27 The accumulator on Valve block, servo - Valve block servo pressure, description, page
pressure, stores servo pressure for fast- 10:25
er reactions after starting the machine.


28 Steering See pressure plate Steer- Control valve steering, description, page 5:21
Control valve steering sends a load sig- ing pressure, on left frame
nal to Hydraulic oil pump No. 3 when the member.
wheels should be turned.
according to the size of the load signal. pressure hydraulic oil description, page 10:8
pumps on left frame
member.

chine, page E:6.
Axial piston pump, checking
NOTE
Safety.
0:00pm
ches operating temperature, approx. 50 °C.
a
75°C 50% 2. Switch off the engine.
b c
50°C 50°C
016372

3. Connect a pressure gauge to measuring outlet on hydraulic oil
pump 1.
5. Check the stand-by pressure for one pump at a time in the follow-
ing order:
Hydraulic oil pump 1: 2.0 MPa
The settings apply to a standard machine, certain machines may
have higher standby pressure. For correct standby pressure, see
the pressure plate. However, the difference in pressure between
the different pumps must always be maintained.
6. Extension function overflow.
022862
Run out the boom to max. and continue to request max. extension
3 1 2 with the control lever. This will cause the extension function to
overflow.

7. Check the max. pressure on hydraulic oil pump 1, the pressure

should correspond with the value on the pressure plate.
All pumps should give the same max. pressure. The sequence be-
tween the pumps is of no importance.
9. Transfer the pressure gauge to hydraulic oil pump 2 and repeat
steps 3-8.
10. Transfer the pressure gauge to hydraulic oil pump 3 and repeat
steps 3-5.
11. Turn the steering wheel fully and read pump pressure during the
023169
steering wheel movement. Compare this to the steering pressure
on the hydraulics plate.
Pressure plate, max. pressure hydraulic oil pumps The maximum pressure for hydraulic oil pump 3 must be set
slightly lower than the drain valve in the control valve. This is in or-
der to obtain steering without resistance. If the drain valve, for ex-
ample, is at 20.0 MPa, hydraulic oil pump 3 must be set to 19.9
MPa.
To check and adjust the drain valve's pressure, see Control pres-
sure, checking, page 5:25.
Hydraulic oil pump 1, replacement
NOTE
Safety.
1. Park the machine with the cab in the rearmost position and the
boom fully raised, and half extended.
CAUTION
Make sure that the oil level in the hydraulic oil tank is
below the mouth of the axial piston pump's suction
hose.
If there is not enough room to lift the boom, the hydraulic oil tank
must be drained, see Maintenance manual.
2. Switch off the system voltage.
NOTE
4. Mark up and detach the hydraulic hoses from hydraulic oil pump 1.
NOTE
from impurities.
5. Attach hoisting equipment to the axial piston pump.

022701

6. Remove the axial piston pump.

Remove the retaining bolts and lift the pump away.
7. Clean the flange on hydraulic oil pump 2.
8. Transfer the connection adapters to the new axial piston pump.
NOTE
correctly.
022702
9. Fit the axial piston pump in place.
Use the O-ring included with the new pump.
NOTE
Silicone must not be used.
Position the axial piston pump so that the pump shaft engages the
hydraulic oil pump. Fit the attaching bolts.
022702
10. Connect the suction hose to the axial piston pump.
NOTE
correctly.
022703
11. Fill the pump with oil through the connection on the top.
CAUTION
The hydraulic oil pump will seize if the engine is started
before the pump is filled with oil.
Product damage.
Always fill the pump with oil before the upper connec-
tion is fitted.
022704

12. Connect the hydraulic hoses to the axial piston pump in accord-
NOTE
correctly.
13. Bleed the axial piston pump, see Axial piston pump with variable
displacement, venting, page 10:20.
CAUTION
Vent the axial piston pump before starting the engine.
022705
The oil in the axial piston pump may cavitate and cause
product damage.
hydraulic system.
NOTE
the lock ring.

16. Check that the hose connections are sealed tightly.
17. Check the pump pressures, see Axial piston pump, checking, page
10:11.
manual.
NOTE
Safety.
CAUTION
hose.
NOTE
4. Remove hydraulic oil pump 1, Hydraulic oil pump 1, replacement,

page 10:12.

NOTE
from impurities.
022706

8. Clean the flange on the transmission.
CAUTION
Contaminants can damage the transmission.
Product damage.
Be careful and make sure that no gasket remains fall
down into the transmission.

022717
NOTE
correctly.

NOTE
transmission's gearing. Fit the attaching bolts.
022717

NOTE
correctly.
022718
CAUTION
Product damage.
tion is fitted.
022719
NOTE
correctly.
14. Fit hydraulic oil pump 1, Hydraulic oil pump 1, replacement, page
10:12.
CAUTION
022720
product damage.

hydraulic system.
NOTE
the lock ring.

10:11.
manual.
NOTE
Safety.
CAUTION
hose.
NOTE
NOTE
from impurities.

022725


7. Clean the flange on the transmission.
CAUTION
Contaminants can damage the transmission.
Product damage.
Be careful and make sure that no gasket remains fall
down into the transmission.
022724
NOTE
correctly.

NOTE
transmission's gearing. Fit the attaching bolts.
022724
NOTE
correctly.
022721

CAUTION
Product damage.
tion is fitted.
022722
NOTE
correctly.
CAUTION
022723
product damage.
hydraulic system.
NOTE
the lock ring.

10:11.
manual.

10:20 10 Common hydraulics – Pipes and hoses

venting
NOTE
Safety.
1. Remove the hydraulic oil tank breather filter.

2. Connect compressed air at max. pressure max. 10 kPa to the hy-
draulic oil tank's connection for breather filter.
CAUTION
Excessive pressure in the hydraulic tank damages the
hydraulic system.
Product damage.
Ensure that the pressure does not become too high by
adjusting the pressure regulator on the compressed air
before the tank is pressurised.
3. Detach the leak hoses for the hydraulic oil pumps (1, 2 and 3), one
1 2 at a time and allow oil to flow out. Tighten the connections when oil
free of air is flowing out.
4. Remove the compressed air from the tank and fit the breather filter.
6. Let the engine run at idle speed for at least one minute. Check that
all connections are sealed tightly.
7. Lower the boom and raise it again very slowly so that the pump op-
erates under minimum load while air pockets are eliminated.
3
023133
1. Leak hose hydraulic oil pump 1



10 Common hydraulics – Screw pump with fixed displacement 10:21
10.4.5 Screw pump with fixed displacement

Hydraulic oil pump, cooling and cleaning, description
There is one screw pump with fixed displacement. It circulates the hy-
draulic oil for the working hydraulics through the radiator and filter. Hy-
draulic oil pump, cooling and cleaning, is driven by the same electric
motor that drives the hydraulic oil cooler's fan.
022735
Hydraulic oil pump cooling and cleaning
Hydraulic oil pump cooling and cleaning, replacement
NOTE
Safety.
CAUTION
below the mouth of the hydraulic oil pump's suction
hose.
Drain the hydraulic oil tank, see Maintenance manual.
NOTE
4. Mark up and detach the hydraulic hoses from the hydraulic oil
pump.
NOTE
from impurities.
5. Connect the lifting equipment to the hydraulic oil pump.

022736

10:22 10 Common hydraulics – Screw pump with fixed displacement

7. Clean the flange on the electric motor.
8. Transfer the connection adapters to the new hydraulic oil pump.
NOTE
022737
correctly.
9. Fit the hydraulic oil pump.

Position the hydraulic oil pump so that the electric motor's shaft en-
gages in the hydraulic oil pump. Fit the attaching bolts.
022737
10. Connect the hydraulic hoses to the hydraulic oil pump in accord-
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.
022736

manual.

10 Common hydraulics – Hoses, pipes and valves 10:23
10.5 Hoses, pipes and valves

Hoses, pipes and valves, description
• Servo valve load handling and steering, incl. shuttle valves, pres-
sure reducers and solenoid valves. This converts pump pressure
to servo pressure and collects all control signals from the different
functions and prioritises between them in order to control the hy-
draulic oil pumps in the best way.
• Collection block, unfiltered returns. This valve collects return lines
from different hydraulic valves that may not have any back pres-
sure and routes them directly to the tank.

Hoses with ORFS couplings are used almost exclusively. For maximum
service life and function, the following should be observed when replac-
ing hoses.
1. To avoid stresses in the connection, there should be a length of
straight hose after the connection.
2. The hose must not be twisted. (A twist of 7% reduces service life
by 90%.)
3. Minimise the number of bends by using correct couplings.
4. Avoid sharp bends.
5. Keep the hoses clean internally. Leave the plugs in place as long
as possible when installing.
6. Check the position of the O-rings and tighten to the correct torque,
NOTE
Straight coupling requires a counterhold wrench to prevent damage
to the O-ring.
7. O-rings must not be oiled; O-rings must be dry during assembly.

Hose length
C/L
Hose length is measured on a hose laid out between the sealing surfa-
ces. On angled connections, measure from the sealing surface's centre
line [C/L] as illustrated.
Cleanliness
The function and service life of hydraulic components depend to a great
extent on how clean the hydraulic oil is. It is therefore very important to
prevent dirt from entering the brake and hydraulic system.
Some simple advice to keep the hydraulic system clean.
• Always clean the area around a component before starting to work.
• Plug hose connections immediately after disconnecting. If possible,
001015
use correct plugs for the connection type. If plugs are missing, use
clean plastic bags and cable ties or tape to seal the connection.
C/L line for measuring hose length • Never re-use oil that has been drained from the machine.
• When filling hydraulic oil, fill through the tank's filler cover.

10:24 10 Common hydraulics – Collecting block, unfiltered returns
10.5.5 Collecting block, unfiltered returns

Multiblock, unfiltered return lines, description
The block collects several return lines from different valves and leads
these directly back to the tank.
The drain lines are very sensitive to back-pressure, if pressure builds
up in the drain lines the valves will not work properly.
The block is fitted on the rear of the lifting beam in front of the
transmission.
022726

10 Common hydraulics – Valve block servo pressure 10:25

Valve block servo pressure, description
Valve block, servo pressure, handles load signals from Control valve lift,
15 lower and extension and Control valve steering; and load signals to the
hydraulic oil pumps are handled in the servo valve.
14
1 Valve block servo pressure also supplies Control valve lift, lower and
13 extension with servo pressure.
2
12 The following functions are collected in Servo valve load handling and
steering:
11 • Pressure reducer
10 • Solenoid valve pump unloading (Y6093)
3 • Proportional valve, load signal attachment (Y6002)
4 • Shuttle valves
Pressure reducer, description
The pressure reducer reduces the pressure from the hydraulic oil
pumps to servo pressure for the control valve.
Servo pressure is stored in an accumulator. A built-in non-return valve
prevents pressure leakage from the accumulator when the machine is
9 not in use.
8 7 6 5 Solenoid valve pump unloading, description
For boom in, only a small oil flow is required. Solenoid valve pump un-
loading (Y6093) drains the control signal to hydraulic oil pump 2, to
tank. This means that only one pump unit builds up pressure. When the
valve is not activated the control pressure from Control valve lift, lower
and extension is routed through the solenoid valve to hydraulic oil
pump 2.
022727
Solenoid valve pump unloading (Y6093) is supplied with voltage by

1. Connection from fine filter (T) Control unit KFU (D7971) on activation.
2. Load signal to hydraulic oil pump 2 (LSP3)
The signal can be checked with the diagnostic menu, see 10.4 Pumps
3. Load signal from control valve lift, lower and ex-
tension (LSM)
4. Load signal to hydraulic oil pump 1 (LSP1) Proportional valve, load signal attachment (Y6002),
5. Measuring outlet LSP1 (load signal till hydraulic description
oil pump 1) Sensor, servo pressure attachment (B7668), continuously measures
6. Solenoid valve pump unloading extension in the attachment's pressure requirements and controls the load signal to
(Y6093) hydraulic oil pump 1 via Proportional valve, load signal attachment
7. Proportional valve, load signal attachment (Y6002). The size of the load signal depends on the pressure require-
(Y6002) ments of the top lift attachment's functions. When the proportional valve
8. Adjusting screw servo pressure is activated, pressure from the supply for the top lift hydraulics is routed
9. Pressure feed from hydraulic oil pump 1 through a shuttle valve to hydraulic oil pump 1. When the proportional
10. Servo pressure to control valve lift, lower and ex- valve is not activated, the load signal is drained to the tank and the inlet
tension (H) from the supply for the top lift hydraulics is closed.
11. Return to tank (T)
The signal can be checked with the diagnostic menu, see 10.4 Pumps
12. Servo pressure from hydraulic oil pump 2 (PT) 6/XX DIAGNOSE, page 8:134.
13. Return to tank (T)
14. Measuring outlet, servo pressure For information on Sensor, servo pressure attachment (B7668), see
Sensor, servo pressure attachment (B7668), page 7:50.
15. Accumulator servo pressure

10:26 10 Common hydraulics – Valve block servo pressure
Shuttle valve, description

A shuttle valve chooses between two pressure signals and sends the
strongest. The shuttle valves are used to send load signals to the hy-
draulic oil pumps. This means that the pumps are controlled by the
function that requires the highest pressure if several functions are acti-
vated simultaneously. See Axial piston pump with variable displace-
ment, description, page 10:8.
Depending on options, there are two or three shuttle valves. The shuttle
valves choose between the following pressure signals:
1. Shuttle valve pump 2 chooses between the pressure signal from
Control valve lift, lower and extension and the pressure signal from
Control valve support jacks and forwards the strongest pres-
sure signal to hydraulic oil pump 2.
2. Shuttle valve, attachment chooses between the pressure signal
from Control valve lift, lower and extension (through Solenoid valve,
pump unloading (Y6093)), and the pressure requirements from the
attachment (through Proportional valve, load signal attachment
(Y6002)). The shuttle valve sends the strongest pressure signal on
to hydraulic oil pump 1.
Servo pressure, inspection and adjustment
NOTE
Safety.
0:00pm
75°C 50% the oil temperature.
b c
50°C 50°C
016372


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

Servo valve load handling and steering.
022728
4. Start the engine and check the servo pressure. Compare with the
pressure plate.
Turn the steering wheel or activate a load handling function to acti-
vate the hydraulic oil pumps. The servo pressure is higher than the
standby pressure of the hydraulic oil pumps.
022864
The appearance of the pressure plate may vary, but

the symbols are the same.
5. If necessary, adjust the pressure with the adjusting screw. Loosen
the lock nut and turn the adjusting screw.
NOTE
If the servo pressure is too high, a load handling function must
be activated so that servo pressure is used from the accumulator
for a reduction on the adjusting screw to be seen on the pressure
gauge. Sometimes the engine has to be shut off between the
checks.
Clockwise: reduce pressure.
Anticlockwise: increase pressure.
measuring outlet.
022729

Initiation/calibration of proportional valve, checking

and adjusting
NOTE
Safety.
0:00pm
75°C 50% the oil temperature.
2. Park the machine and activate the parking brake.
b c
3. Retract the boom and fully lower the attachment.
4. Let the engine run at idle speed.
50°C 50°C 016372

5. Check that all hydraulic pressures on the machine are correctly ad-
justed. The pressures must correspond to the values specified on
the pressure plate. For checking and adjusting the hydraulic pres-
sure, see Axial piston pump, checking, page 10:11.
023203
6. Check that relief valve, top lift, is closed.

020119
Relief valve for top lift, the figure above shows a

closed valve.

7. Connect a pressure gauge (0–25 MPa) to the measuring MP1.

Measuring outlet MP1 is used for the pressure to hydraulic oil
pump 1. Hydraulic oil pump 1 is used for the attachment's
functions.
020117
Measuring outlet MP1
Low-pressure check
9. Request side shift function without moving to end position.
10. Compare LS-Pressure attachment in the display with the pressure
gauge's display during the movement. The pressure gauge should
show 3-10 bar higher pressure than the display. For an explanation
of the menu, see 10.4 Pumps 10/XX INITIATE, page 8:245.
11. If necessary, adjust the start current so that the function runs
smoothly and at the correct speed. During adjustment, check that
the value changes on the pressure gauge. The standard setting is
100.0 mA.
Change the value in Row 1 with / and store the value with
Save .
The start current is the lowest current that can be actuated. In
practice, it controls how slowly a function can be operated. On
this is the current which is triggered when the lever leaves the zero
position.
High-pressure check
12. Run the side shift function to end position and continue to request
side shift so that the function overflows.
13. Compare LS-Pressure attachment in the display with the pressure
gauge's display during the movement. The pressure gauge should
show 3-10 bar higher pressure than the display. For an explanation
of the menu, see 10.4 Pumps 11/XX INITIATE, page 8:245.
14. If necessary, adjust the end current so that the function runs
smoothly and at the correct speed. During adjustment, check that
the value changes on the pressure gauge. The standard setting is
420.0 mA.
Change the value in Row 1 with / and store the value with
Save .
position.

After completed initiation/calibration

measuring outlet.
Valve block servo pressure, replacement
NOTE
Safety.
1. Machine in service position, see section B Safety.

NOTE
3. Mark and disconnect the cable harness from the valve block.
NOTE
from impurities.
5. Remove the valve block.

6. Transfer the parts to the new valve block.
NOTE
mixed up.
7. Fit the valve block and connect the hydraulic hoses and cable har-
ness in accordance with the marking
hydraulic system.
NOTE
the lock ring.
022730
9. Start the machine and carefully activate all load handling functions
one at a time
CAUTION
product damage.
manual.

10 Common hydraulics – Accumulator servo circuit 10:31

Accumulator servo circuit, description
The accumulator stores pressurised oil and ensures that there is servo
pressure for activating control valve functions. The accumulator is fitted
on Servo valve load handling and steering to the right on the lifting
beam in the engine compartment.
The accumulator is a diaphragm type and is divided into two spaces by
a diaphragm. One side of the diaphragm is pressurised by nitrogen gas.
The other side is pressurised by the hydraulic oil, which compresses
the nitrogen gas.
Furthest up on the accumulator is a test outlet for checking gas pres-
sure and filling gas.
016332
Accumulator servo circuit, replacement
NOTE
Safety.

NOTE
3. Detach the accumulator from its mounting.

4. Replace the accumulator.
hydraulic system.
NOTE
016334
the lock ring.
7. Start the machine and carefully activate all load handling functions
one at a time
CAUTION
product damage.
manual.

10:32 10 Common hydraulics – Temperature control, cleaning and hydraulic oil
10.6 Temperature control, cleaning

and hydraulic oil
Temperature control, cleaning and hydraulic oil,
description
A sensor for the hydraulic oil temperature continuously measures the
hydraulic oil temperature. At a certain temperature, an electric motor
starts that drives both the hydraulic oil pump and the cooling fan. The
hydraulic oil pump pumps oil (from the tank) which is cooled in the hy-
draulic oil cooler and cleaned by the oil filters in the tank. The cooling
fan increases the airflow through the radiator, which reduces the hy-
draulic oil temperature. A bypass valve routes the hydraulic oil past the
cooler directly to the tank if the resistance through the cooler and filters
is too high. The current hydraulic oil temperature is shown in the
display.
Temperature control and cleaning the hydraulic oil consist of hydraulic
oil tank, hydraulic oil pump, hydraulic oil cooler, cooling fan, hydraulic
oil filter, sensor for hydraulic oil temperature, bypass valve, fine filter,
and electric motor to drive the hydraulic oil pump and cooling fan.
The return oil from Valve block, servo pressure, is routed via a fine filter
where it is deep cleaned.
Temperature control, cleaning and hydraulic oil,

10
D7950
D7902
LSP1 T A H
D7971
2,6 LSP2 8
LSPR
LSHY
LSP3
3 PT T P LSM
LSO
D1 D3
5 4 6,7
M 9
11
8
°C
023387
Pos Description Signal value Reference

1 Sensor hydraulic oil temperature (B7760) U = 0.5-4.5 V Sensor, hydraulic oil temperature, descrip-
sends voltage signals proportional to the tion, page 10:40
hydraulic oil temperature to Control unit D1: Diagnostic menu, see 10.6 Oil Temp/
KFU (D7971). Clean 1/XX DIAGNOSE, page 8:135
2 Control unit KFU (D7971) sends tempera- Electric motor active: 11.5.3.4 Control unit KFU (D7971), page
ture on the CAN bus. If the temperature is U = 24 V 11:34
sufficiently high, Control unit KFU
(D7971) supplies voltage to Relay, cool-
ing/circulation (K6680–2).

10 Common hydraulics – Temperature control, cleaning and hydraulic oil 10:33
Pos Description Signal value Reference

3 Relay, cooling/circulation (K6680–2), sup- Electric motor active: 11.5.2.2 Electronic box frame, page 11:26
plies voltage to the electric motor to drive U = 24 V D3: Diagnostic menu, see 10.6 Oil Temp/
the cooling fan and hydraulic oil pump. Clean 1/XX DIAGNOSE, page 8:135
4 Electric motor (M6680–2) drives the hy- - Cooling fan, description, page 10:37
draulic oil pump and cooling fan.
5 The hydraulic oil pump pumps oil from the - Hydraulic oil pump, cooling and cleaning, de-
hydraulic oil tank. scription, page 10:21
6 The hydraulic oil cooler cools the oil. - Hydraulic oil cooler, description, page 10:35
7 The cooling fan increases air flow through - Cooling fan, description, page 10:37
the radiator.
8 The hydraulic oil filters clean the hydraulic - Hydraulic oil filter, description, page 10:42
oil.
9 If resistance through the oil cooler and hy- - Bypass valve, radiator, description, page
draulic oil filter becomes too high, the 10:41
cooler bypass valve opens and directs
the oil to the tank.
10 Control unit KID (D7950) shows hydraulic Checked by control sys- 11.5.3.3 Control unit, KID (D7950), page
oil temperature in the display. tem, error shown with er- 11:32
ror code.
11 Return oil from Valve block, servo pres- - Fine filter hydraulic oil, description, page
sure, is routed through Fine filter, hydraul- 10:43
ic oil, where it is deep cleaned, and then
via the hydraulic oil filters back to the tank.

chine, page E:6.

10:34 10 Common hydraulics – Tank heater
10.6.1 Tank heater

Tank heater, description
The machine can be equipped with electrically-driven tank heater in dif-

1 ferent units together with electrical heater for engine, oil tank brake sys-
tem and preparation for cab fan. The tank heater heats the oil in the
hydraulic oil tank and is intended for use in cold climates.
2 The tank heater is supplied with high voltage from an external mains
3 minal boxes on the left-hand side of the machine. The machine has a
start interlock function that prevents the engine being started when a
4 power cable is connected to the mains power connector. The sensor
for the start interlock function is an optical sensor that can react to ob-
jects other than the connected power cable.
Tank heater output is adapted through different connections and adap-
tation to different operating voltages - 110, 230 or 400 V AC. Higher
voltage generates higher heater output. The tank heater is fitted in a
hole in the connection cover in the hydraulic oil tank.
The tank heater has an adjustable thermostat that keeps the tempera-
5
ture at a constant level. The thermostat is fitted on the heating element
and is adjusted with a knob on the junction box. The recommended
temperature setting is 20-30 °C.
018550
1. Mains power connector high voltage CAUTION

2. Sensor, start interlock function
3. Terminal box, start interlock, engine and cab The tank heater is connected to high voltage (110 - 400
heater V).
4. Terminal box, heater hydraulic oil tank and oil
tank brake system
High voltage.
5. Tank heater, hydraulic oil tank Installation and reconnection of the tank heater may on-
ly be performed by personnel authorised for work with
high voltage.

10 Common hydraulics – Hydraulic oil cooler 10:35
10.6.2 Hydraulic oil cooler

Hydraulic oil cooler, description
The working hydraulics use flow-through cooler with electric cooling fan.
The oil is cooled when it passes through the cooler. The cooler is fitted
inside the side panel on the right-hand side in front of the hydraulic oil
tank.
022738
Hydraulic oil cooler, replacement
NOTE
Safety.

2. Drain the oil from the hydraulic oil tank, see Maintenance manual.
3. Mark up and detach the hydraulic hoses from the cooler. Let the oil
in the cooler drain into the receptacle.
NOTE
from impurities.
022747

10:36 10 Common hydraulics – Hydraulic oil cooler
4. Secure the unit consisting of cooling fan, electric motor, and hy-
draulic oil pump before it is detached.
Loosen the grille's attaching bolts.
022748
5. Loosen the electric motor's mounting.
022749 6. Move aside the cooling fan, electric motor, and hydraulic oil pump.
7. Loosen the hydraulic oil cooler's mounting.

Lift down the hydraulic oil cooler.
8. Fit the new hydraulic oil cooler.
022750
9. Fit the electric motor, grille, and fan in position.

10. Tighten the attaching bolts.
022749

10 Common hydraulics – Cooling fan 10:37
11. Secure the grille to the radiator.
022748
12. Connect the hydraulic hoses to the cooler.
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.
022747
manual.
10.6.3 Cooling fan

The electric cooling fan is suctioning. The cooling fan is located at the
A B rear of the cooler. The fan draws air from the machine's outside through
the cooler. Openings in the side cover allows air to pass through the
cooler.
The electric motor that drives both cooling fan and hydraulic oil pump
for cooling and filtration is supplied with voltage via Relay, cooling/circu-
lation (K6680–2). The electric motor is activated when oil temperature
is 65 °C in the hydraulic oil tank and the fan is deactivated when oil tem-
perature is 55 °C.
The signal can be checked with the diagnostic menu, see 10.6 Oil
Temp/Clean 1/XX DIAGNOSE, page 8:135.
022739
A. Cooling fan
B. Electric motor for cooling fan and hydraulic oil
pump

10:38 10 Common hydraulics – Cooling fan
Electric motor for cooling fan and hydraulic oil pump,

replacement
NOTE
Safety.

2. Release the hydraulic oil pump for cooling and filtration from the
electric motor.
Loosen the hydraulic oil pump's attaching bolts.
3. Hang up the hydraulic oil pump.
4. Protect the connection on the hydraulic oil pump against dirt with a
plastic bag or similar.
022735 5. Connect the lifting equipment to the electric motor.
6. Disconnect the electrical connection to the electric motor.

022742
7. Loosen the grille over the cooling fan.

022741

10 Common hydraulics – Cooling fan 10:39
8. Loosen the electric motor's mounting.

9. Remove the electric motor, grille, and fan.
022740
10. Detach the grille from the electric motor.
11. Fit the grille on the new electric motor.
022743
12. Fit the electric motor, grille, and fan in position.

Check that the motor's shaft engages in the cooling fan.
13. Tighten the attaching bolts.
022740
14. Secure the grille to the radiator.

022741

10:40 10 Common hydraulics – Sensor hydraulic oil temperature
15. Connect the electrical connection to the electric motor.
022742
16. Fit the hydraulic oil pump for cooling and filtration to the electric
motor.
Check that the motor's shaft engages in the hydraulic oil pump.
Tighten the hydraulic oil pump's attaching bolts.
hydraulic system.
NOTE
the lock ring.

022735
19. Check the function of the electric motor.
10.6.4 Sensor hydraulic oil temperature

Sensor, hydraulic oil temperature, description
Hydraulic oil temperature sensor (B7760) detects the temperature of
the hydraulic oil.
The sensor is fitted on the hydraulic oil tank's rear short side.
The sensor detects the oil temperature in the tank, and therefore takes
into account the accumulated heat in the hydraulic oil. This means that
the cooling fan may continue to run after the machine has been parked
and switched off.
Sensor, hydraulic oil temperature (B7760) is supplied with voltage by,
and sends voltage signals proportional to the oil temperature to Control
unit KFU (D7971).
The signal can be checked with the diagnostic menu, see 10.6 Oil
Temp/Clean 1/XX DIAGNOSE, page 8:135.
022744
Sensor, hydraulic oil temperature, (B7760)

10 Common hydraulics – Radiator bypass valve 10:41
Sensor, hydraulic oil temperature, replacement
NOTE
Safety.

2. Drain the oil from the hydraulic oil tank, see Maintenance manual.
3. Disconnect the cable harness from Sensor, hydraulic oil tempera-
ture (B7760).
4. Replace Sensor, hydraulic oil temperature (B7760).
NOTE
correctly.

manual.
022744
Sensor, hydraulic oil temperature, (B7760)
10.6.5 Radiator bypass valve

Bypass valve, radiator, description
The bypass valve protects the cooler from overpressure. The valve
opens a passage past the cooler directly to the tank if resistance in the
cooler becomes too high. The bypass valve is built into the hydraulic oil
cooler.

10:42 10 Common hydraulics – Breather filter hydraulic oil tank
10.6.6 Breather filter hydraulic oil tank

Breather filter hydraulic oil tank, description
A breather filter of insert type is mounted on the hydraulic oil tank to
protect the tank from impurities. On the top of the filter housing is an in-
dicator that shows when the filter is clogged and needs to be changed.
016892
10.6.7 Hydraulic oil filter

Hydraulic oil filter, description
The oil in the hydraulic system is cleaned by two return filters fitted in-
side the hydraulic oil tank. The oil is pumped through the cooler and
back through the filters by the cooling pump. Some of the return oil from
the load handling functions also passes through the filters.
016893

10 Common hydraulics – Fine filter hydraulic oil 10:43
Hydraulic oil filter, description (high-pressure filter)
As an option the machine can be equipped with two additional high-

pressure filters that are located directly after the axial piston pumps.
The filters are located in front of the transmission under the lifting beam.
The filters are used together with the hydraulic oil filters in the tank.
003602
10.6.9 Fine filter hydraulic oil

Fine filter hydraulic oil, description
The fine filter is fitted on the inside of the left frame member.
The filter is connected to the tank return line from Valve block, servo
pressure. A 2-bar non-return valve ensures that the oil flows through
the filter.
The fine filter cleans a smaller amount of oil but with a higher degree of
filtration when the machine is running.
022484

10.6.14 Servo filter

Servo filter, general
See Servo filter, description, page 7:22.

10:44 10 Common hydraulics – Other
10.7 Other
10.7.1 Hydraulic cylinders
Fault tracing, leakage
CAUTION
All fault tracing should be carried out with as low a
pressure in the system as possible so that internal leak-
age can be detected. High pressure causes the seals to
close tighter, which prevents detection of internal
leakage.
1. Carefully check the source of the leakage before taking any action.
It may be possible to rectify the fault without disassembly.
2. Check for external leakage:
• At cylinder face end welds
• At sleeve coupling welds
• Between cylinder barrel and cylinder head
This could be due to a defective O-ring or damaged O-ring
sealing surfaces.
• Between cylinder head and piston rod
This could be due to a damaged piston rod or damaged or
worn piston rod seal.
3. Check for internal leakage. Pressurise the cylinder and check
whether the piston sinks back.
This could be due to a worn piston seal.
1. Piston rod
2. Scraper
3. Cylinder head
4. Piston rod seal
5. O-ring with support ring
6. Cylinder barrel
7. Sleeve coupling
8. Welded cylinder end face
9. Piston
10. Piston seal, double-acting
11. Example of weld

10 Common hydraulics – Hydraulic cylinders 10:45
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 im-
pact marks.
Make sure that the chamfer up to the chromium surface
of the piston rod is free from burrs and residual paint.

3. Remove the cylinder from its mounting and undo the connections.
4. Plug the cylinder connections and hoses without delay.
5. If the cylinder is opened - observe the strictest cleanliness!
Inspection of surfaces
Inspect the sealing surfaces. Always bearing mind the function of the
seals and the type of sealing surfaces they have. See the following
descriptions:
• O-ring groove, internal and external
• piston rod seal in the cylinder head
• sealing groove on the piston
• cylinder barrel surface
• piston rod surface. The piston rod is chromium plated with a layer
thickness of 20-50 my. Slight damage to the chromium plating may
not necessarily cause leakage directly.
• all slide surfaces (dynamic surfaces), e.g. cylinder barrel and pis-
ton 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 im-
proper seal. This applies to all types of piston rod seals.

10:46 10 Common hydraulics – Hydraulic cylinders
Function and removal of the seals

Piston rod seal
The piston rod seal is the seal that sits in the groove in the cylinder
2
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
1 moving surface on the piston rod while the sealing surface with the cyl-
inder head is fixed. There are different types of piston rod seals:
• Single V-seal
• Pre-stressed V-seal with support ring
• Compressible seal
3
The single V-seal has a V-shaped section with two lips that seal in op-
posite directions. The hydraulic pressure acts in the V-shape, pressing
the sealing lips out towards the sealing surfaces on the piston rod and
4 in the cylinder barrel. Even minor damage to the sealing lips can gener-
6
ate 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
The pretensioned V-seal also has an O-ring in the seal's V-shaped

2
space. The O-ring creates a strong seal at low hydraulic pressure since
1 the O-ring already presses the sealing lips out toward the sealing surfa-
ces when unloaded. It is just as sensitive to damage as the V-seal. Ex-
amine in the same manner. To remove, use a screwdriver to prise the
seal outward and bend it up (see illustration). It is extremely important
that the screwdriver is always inserted in the V-shape so that it cannot
touch and thereby damage a sealing surface. A mark from a screw-
3 driver on a sealing surface can have a devastating effect and cause
7
major leakage.
6 4
001498
5
6. Screwdriver
7. O-ring

2 The compressible piston rod seal consists of a solid rubber profile

and provides a larger sealing surface than the V-seals. To remove, use
a screwdriver to prise the seal outward and bend it up (see illustration).
1
With this type of seal with sealing surfaces that cover so much of the
3 seal groove, it is particularly important that marks are not made with the
screwdriver.
6
4
001499
5
6. Screwdriver
Support ring and O-ring

The support ring and O-ring combination is used for sealing between
two fixed surfaces, such as between cylinder barrel and cylinder head.
The purpose of the support ring is to lend rigidity to the O-ring so that it
is not deformed. The O-ring is pressed against the support ring and the
sealing surface by the hydraulic pressure in the cylinder.
3 When the cylinder head is mounted in the barrel: Take extreme care
not to damage the O-ring.
4
2
001506
1
2. O-ring
3. Support ring

Scraper
The purpose of the scraper is to scrape the piston rod clean and pre-
øD+10 vent impurities from entering the cylinder barrel.
1 The scraper must be fitted with a special fitting tool. This tool must have
a greater outer diameter than the scraper so that the press force
against the scraper ceases precisely when the scraper is pressed into
its position. If the scraper were to be pressed in further, the metal cap-
sule would be deformed (see lower illustration), which would impair the
2
function of the scraper.
To prevent the scraper from bottoming in its recess in the cylinder head,
4 the recess is slightly deeper than the width of the scraper.
3
øD
6
001496
1. Correct assembly tool

2. Scraper, correctly fitted
3. Cylinder head
4. Clearance between scraper and bottom of cylin-
der head recess
5. Incorrect assembly tool
6. Deformed scraper
A screwdriver can be used for removal. This must always be applied

1 against the outer edge of the scraper (see illustration). Carefully tap the
screwdriver down between the scraper and the cylinder head and then
2 prise out the scraper. Polish away any damage to the cylinder head.
CAUTION
No tool may be applied from the inside. This could give
rise to burrs on the cylinder head which could in turn
damage the piston rod. Burrs may also damage the pis-
3
ton rod seal when fitting the piston.
001551
1. Screwdriver
2. Scraper
3. Cylinder head

2 On the single-acting V-seal it is always the long side that seals

against the fixed surface and the short side that seals against the mov-
ing surface.
1 To remove, use a screwdriver to prise the seal outward and bend it up
(see illustration). It is extremely important that the screwdriver is 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

The double-acting seal functions with pressure from both sides, e.g. in
5 4 3 1 6 a steering cylinder.
All of the interior surface of the cylinder barrel is a sealing surface and it
is therefore extremely important that it is completely free from damage.
Exercise caution when fitting the piston in the cylinder barrel, making
sure that the seal is not damaged by the cylinder barrel threads.
2
002951
1. Variable sealing surface to cylinder barrel

2. Fixed sealing surface with piston
3. Guide ring
4. Support ring
5. Piston
6. Cylinder barrel

Dismantling:
1. Remove guide rings and support rings.
2. Move the seal body over to one side of the sealing groove.
3. Press up the material so that there is a gap between seal and
piston.
4. Without damaging the surface of the piston - cut off the seal with a
knife.
5. Carefully examine the seal to find any damage that could cause
leakage. This will be easier if you bend the seal sharply bit by bit
and feel over the sealing surface with a fingernail.
Assembly:
1. All double-acting piston seals are of similar design: a middle seal
body, then support rings and farthest out guide rings.
2. First fit the seal body, then the support rings and finally the guide
rings - all must be done by hand without tools to avoid damage.

Dismantling the steering cylinders (Wipro)

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

Dismantling the steering cylinders (Hengli)

1. Unscrew the end washer at the cylinder head.
2. Carefully extract the piston rod from the cylinder barrel.
023135

11:1
11 Commonelectrics
Contents 11 Common electrics

11 Common electrics.............................................................................................. 11:3
11.2 Electric protection ............................................................................................11:4
11.2.1 Battery disconnector ...................................................................................11:4
11.2.2 Fuses...........................................................................................................11:4
11.2.6 Control breaker............................................................................................11:9
11.3 Batteries .........................................................................................................11:10
11.3.1 Starter battery............................................................................................11:10
11.3.3 Auxiliary start connector............................................................................11:12
11.4 Alternator........................................................................................................11:13
11.4.1 Alternator...................................................................................................11:13
11.5 Distribution of electricity .................................................................................11:14
11.5.1 Voltage feed ..............................................................................................11:14
11.5.2 Electronic box............................................................................................11:25
11.5.3 Control units ..............................................................................................11:27
11.5.5 Cable harness ...........................................................................................11:44
11.6 Communication ..............................................................................................11:48
11.6.1 CAN bus ....................................................................................................11:48
11.6.2 Redundant CAN bus .................................................................................11:50
11.6.3 CAN bus drive-train ...................................................................................11:54
11.6.6 Communication with the machine .............................................................11:54
11.6.7 Insight ........................................................................................................11:56

11:2

11 Common electrics – Common electrics 11:3
11 Common electrics
Common electrics, general
Electrical functions that are common to several of the machine's main
functions are found under the function common electrics. For example,
voltage feed and CAN bus.

11:4 11 Common electrics – Electric protection
11.2 Electric protection

11.2.1 Battery disconnector
Battery disconnector, description
The starter batteries are connected to the machine's electrical system
via battery disconnector (S1440). The battery disconnector disconnects
all voltage feed from the batteries to the machine's electrical system ex-
cept that connected to the 50 A main fuse, see Fuses, description,
page 11:4.
For more information on the starter batteries, see Starter battery, de-
scription, page 11:10
IMPORTANT
Never switch off the voltage with the battery disconnec-
tor when the engine is running. This could damage the
alternator.
016895
The battery disconnector must not be used as control

breaker!
Battery isolator, replacement

2. Open the battery cover.
3. Disconnect the negative cable and then the positive cable from the
battery.
WARNING
Be careful to keep the positive and negative cables
apart to avoid short circuiting.
4. Replace the battery isolator.

016304
11.2.2 Fuses
Fuses, description
CAUTION
Never use fuses with amperage that is too high.
Risk of damage or fire in cables!
Follow the instructions on the fuse plate for fuse type
and amperage.

11 Common electrics – Fuses 11:5
The electrical system has two main circuits (30 and 15-voltage), see
Voltage feed, general, page 11:14. The main circuits are fuse-protected
several times with main fuses, distribution fuses and circuit fuses.
Main fuses
The main fuses splits the machine\qs voltage feed in smaller parts to
maintain as many functions as possible in case of damage in the
cabling.
The machine has two main fuses, 1 x 100 A that is supplied from the
battery disconnector and 1 x 50 A that is supplied directly from the bat-
tery. Together, these two fuses disconnect all electrical power to the
machine.
F9952-1
016239
1 2
Fuses battery box (F9952-1)
1. Main fuse (100 A) (disconnected with the battery
disconnector)
2. Main fuse (50 A) (direct feed)

11:6 11 Common electrics – Fuses
Distribution fuses
The distribution fuses divide the machine's voltage feed in smaller parts
X500-1 X401-1
in order to maintain as many functions as possible in the event of dam-
age in the cable harness.
The machine's electrical system has distribution fuses in the electronic
box on the frame (6 x 50 A), on the frame (2 x 50 A), at the rear boom
mounting and at the front of the inner boom (2 x 50 A).
F9954-1
F9952-2
016302
F9952-2 Distribution fuses battery voltage

F9954-1 Distribution fuses ignition voltage
X401-1 Distribution fuses attachment
X500-1 Distribution fuses attachment

11 Common electrics – Fuses 11:7
Circuit fuses
The fuses are grouped in fuse holders located in the electronic box in
the cab, which is located behind the rear panel, and in the electronic
1 box on the frame on the left-hand side of the machine.
There is a fuse plate by the electronic box that describes the various
fuses.
3
022734
1. Circuit fuses cab (F9968)

2. Circuit fuses frame (F9958)
3. Fuse, electric motor for hydraulic oil pump, cool-
ing and filtration (50A)

11:8 11 Common electrics – Fuses
Main fuse, replacement

3. Disconnect the negative cables from the negative terminals of the
batteries.
4. Remove the plastic cover.
5. Check and replace the fuses if necessary.
CAUTION
and amperage.
F9952-1 6. Fit the protective cover.

7. Connect the negative cables to the negative terminals of the
batteries.
8. Switch on the system voltage with the battery disconnector
016239
1 2
Fuses battery box (F9952-1)
1. Main fuse (100 A) (disconnected with the battery
disconnector)
2. Main fuse (50 A) (direct feed)
Distribution fuse, replacement

X500-1 X401-1
3. For fuses in the electronic box on the frame: Remove the cover for
the electronic box on the frame.
CAUTION
and amperage.
6. Fit the protective cover.

F9954-1 7. For fuses in the electronic box on the frame: Fit the cover for the
electronic box on the frame.
F9952-2 8. Switch on the system voltage with the battery disconnector
016302
F9952-1 Distribution fuses battery voltage

F9954-1 Distribution fuses ignition voltage
X401 Distribution fuses attachment
X500 Distribution fuses attachment

11 Common electrics – Control breaker 11:9
Circuit fuse, replacement

1 3. For fuses in the electronic box on the frame: Remove the cover for
the electronic box on the frame.
CAUTION
and amperage.
6. Fit the protective cover.

2 7. For fuses in the electronic box on the frame: Fit the cover for the
electronic box on the frame.
8. Switch on the system voltage with the battery disconnector
016303
1. Circuit fuses cab (F9968)

2. Circuit fuses frame (F9958)
11.2.6 Control breaker

Control breaker, description
The control breaker is located in the cab on the right dashboard panel,
front section.
See Control breaker voltage, function description, page 11:20.
When the switch is activated, all hydraulic functions are disconnected
and machine speed is limited.
016150
Control breaker placement

11:10 11 Common electrics – Batteries
11.3 Batteries
11.3.1 Starter battery
Starter battery, description
Two series-connected batteries (G9930) are located behind a hatch on
the machine's rear left-hand side (by the fuel tank).
The battery's negative terminal is connected to the frame and the posi-
tive terminal is connected to the battery isolator.
The batteries are charged by the alternator, see Alternator, description,
page 11:13.
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 doc-
tor immediately.
016304
WARNING
Risk of explosion!
Personal injury!
During charging, hydrogen gas forms around the bat-
teries. Sparks could ignite the hydrogen gas, causing
an explosion. Disconnect the battery with the battery
disconnector.
WARNING
Short-circuiting of battery.
Risk of explosion! Fire hazard! Risk of personal injury!
The battery's terminals must not be connected to each
other or to common grounding point (frame).

11 Common electrics – Starter battery 11:11
Starter battery, replacement

2. Disconnect the cables from the battery terminals. Start with the
negative (minus) cable.
3. Replace the batteries.
016304
4. Fit the tensioning strap back in the buckle in accordance with the
series of figures.
5. Connect the cables to the battery terminals. Connect the negative
cable last of all.
NOTE
Take great care when reconnecting the cables to prevent short
circuiting. Do not over-tighten the cable harness.
018837

11:12 11 Common electrics – Auxiliary start connector
11.3.3 Auxiliary start connector

Auxiliary start connector, description
The auxiliary start connector (X9940) is located on the left-hand side of

the machine. The connector is used to start the machine using starter
batteries or another machine. The connector can also be used for start-
ing assistance for another machine, see chapter Distribution of electric-
ity, general, page 11:14.
Power take-off NATO type 019118
Auxiliary start connector, replacement

2. Disconnect the cables from the battery terminals. Start with the
negative (minus) cable.
3. Disconnect the cables from the grounding point on the chassis and
the manual battery disconnector. Start with the negative (minus)
cable.
016304
4. Release the four fixing screws and remove the auxiliary start con-
nector from the bracket.
5. Install a new connector.
6. Ensure that the plus and minus cables are connected correctly.
NOTE
Take great care when reconnecting the cables to prevent short
circuiting. Do not over-tighten the cable harness.
019118
Power take-off NATO type

11 Common electrics – Alternator 11:13
11.4 Alternator
11.4.1 Alternator
Alternator, description
The alternator (G6600) generates current during operation and sup-
plies this to the batteries. The alternator produces AC current and has
an integrated charge regulator.
The alternator is driven by the engine via a belt. Any errors are indi-
cated by an error code for the charging system's voltage. Low battery
charge is indicated by the event menu for low battery charge.
The signal can be checked with the diagnostic menu, see 1.9 Control
System 2/XX DIAGNOSE, page 8:34 or 11.4 Alternator 1/XX DIAG-
NOSE, page 8:136.
018305
Alternator, replacement
See Supplier documentation, engine.

11:14 11 Common electrics – Distribution of electricity
11.5 Distribution of electricity

Distribution of electricity, general
This section describes the distribution of electric power and communi-
cation between the control units.
System communication has three main sections:
• Dual voltage supply of control units, where one voltage supply can
go down while maintaining the diagnosis function.
• Redundant CAN bus communication (one CAN bus loop can go
down without losing system functionality).
See 11.6.2 Redundant CAN bus, page 11:50.
• CAN bus communication for drive train (the drive train has its own
communication system).
See 11.6.3 CAN bus drive-train, page 11:54.
11.5.1 Voltage feed

Voltage feed, general
The machine's components are supplied with voltage at different times
depending on requirements, the machine has the following voltage
feeds:
• Battery voltage (30): see Battery voltage (30), description, page
11:15.
• Ignition voltage (15): see Ignition voltage (15), description, page
11:18.
• Redundant voltage feed: See Redundant voltage feed of control
units, description, page 11:16.
• Control breaker voltage: See Control breaker voltage, description,
page 11:20.
Start-up of electrical systems, description

When the machine is not in use, and no function is switched on, the
machine's electrical system is in a de-energised state, i.e. neither the
power electronics nor control units are energised. When starting the
machine the voltage supply is activated and the redundant CAN bus is
initiated. Start-up is managed by the KCU control unit (D7901). The first
prerequisite in order for the machine to perform the activity is to first es-
tablish the redundant voltage supply for control units and then establish
CAN bus communication to manage the control signals for functions.
Control units establish communication if any of the following happens.
• Driver's door opens
• Interior lighting comes on
• Warning lamp activates
• Ignition key lock in position I
• Operator in seat
• The diesel-driven engine and cab heater starts at the set time
• Courtesy lighting is switched on

11 Common electrics – Voltage feed 11:15
Start-up
On start-up the following happens.
1. Start-up signal to the KCU control unit (D7901).
2. Control unit KCU (D7901) initiates connection of the redundant
voltage feed, see Redundant voltage feed of control units, function
3. Control unit KCU (D7901) initiates ignition voltage, see Ignition
voltage (15), function description, page 11:18.
4. Control unit KCU (D7901) initiates redundant CAN bus, see Re-
dundant CAN bus, start-up, page 11:52.
5. Control unit KFU (D7971) initiates CAN bus drive-train, see 11.6.3
CAN bus drive-train, page 11:54.
11.5.1.1 Battery voltage (30)

Battery voltage (30), description
The battery voltage is supplied from the starter batteries when the bat-
tery disconnector is in position I.
Red fuse holder contains circuit fuses for battery voltage. Black fuse
holder contains circuit fuses for ignition voltage. Green fuse holder in
electronic box frame contains circuit fuses that are supplied before the
RD1 BK1 GN1 battery disconnector. Green fuse holder in the cab holds fuses for spe-
RD2 BK2 GN2 cial functions and fuses that are supplied with ignition voltage.
RD3 BK3 GN3 Battery power voltage feeds:
RD4 BK4 GN4
• KCU control unit (D7901)
RD5 BK5 GN5 • Starter motor (M6540)
RD6 BK6 GN6 • Relay, ignition key lock (K3150)
RD7 BK7 GN7 • Start-up functions
RD8 BK8 GN8 • Control breaker relay (S2500)
• Engine
• Transmission
• Radio (A9002)
016306
A few functions are also supplied with voltage when the battery discon-
Circuit fuses battery voltage nector is in position 0 (Fuses GN5-GN8), these are:
• Control unit RMI (A9110)
• Timer for diesel-driven engine and cab heater (D7440)
• Fire extinguishing system (A9630)
• Control unit for diesel-driven engine and cab heater (E6690)
• Electric battery disconnector (S1440)
• Switch engine compartment lighting (S1041) and Engine com-
partment lighting (E4380-1 – E4380-5)
For fuse placement, see the fuse plate or Operator’s manual.

11:16 11 Common electrics – Voltage feed
11.5.1.2 Redundant voltage feed of control units

Redundant voltage feed of control units, description
The redundant voltage feed only supplies the control logic and buses
for the control units, and is wholly controlled by Control unit KCU
(D7901). The outputs for the control units remain de-energised and are
only supplied with voltage when the ignition voltage is activated.
The redundant voltage feed for each control unit is independent of oth-
er control units. Control unit KCU (D7901) has four outputs for voltage
feed while other control units have two inputs for redundant voltage
feed. In the event of a malfunction of one voltage feed the control unit is
supplied by the other feed.
When all control units have redundant voltage feed and bus communi-
cation, the system is ready to receive and process signals.
Redundant voltage feed is activated by:
• Switch interior lighting (S1160)
• Switch, flashing hazard lights (S1090)
• Switch, ignition key lock (S1500)
• Seat switch (B2300)
• Break contact (opening switch) driver's door left (S2660-LE) or
Break contact (opening switch) driver's door right (S2660-RI)
• Heater cab (E6690)
Redundant voltage feed of control units, function

description
The redundant voltage feed of control units consists of the special re-
dundant voltage feed and the normal ignition voltage, see 11.5.1.3 Igni-
tion voltage (15), page 11:18.

Battery disconnector In position 1 Battery disconnector, description , page 11:4
1 2 3 4 5 6 7
D1 D2 D3 D4 D7
D5 D6
D8 D11 D12
– +
8 11 12 D14
D7901 D7971 D7972
D9 D10 D13
9 D7902 D7911 D7912

022616
D7950 10 13 14

1 On activation of the Interior lighting switch U = 24 V Lighting system, function description, page
(S1160) a voltage signal is sent to the KCU 9:71
control unit (D7901). D1: Diagnostic menu, see 9.6 Lighting Sys
2 On activation of the Warning light switch U = 24 V Lighting system, function description, page
(S1090) a voltage signal is sent to the KCU 9:71
control unit (D7901). D2: Diagnostic menu, see 9.7 Signalling


3 On turning the ignition key lock switch U = 24 V D3: Diagnostic menu, see 11.5 Distr of
(S1500) to position I a voltage signal is sent Electr 1/XX DIAGNOSE, page 8:137
to the KCU control unit (D7901).
4 On activation of the Seat switch (B2300) a U = 24 V Sensor operator in seat, description, page
voltage signal is sent to the KCU control unit 9:25
(D7901). D4: Diagnostic menu, see 9.3 Seat 1/XX DI-
AGNOSE, page 8:110
5 On activation of the driver's door left break U = 24 V D5: Diagnostic menu, see 9.6 Lighting Sys
contact (S2660-LE) or driver's door right 18/XX DIAGNOSE, page 8:125
break contact (S2660-RI) a voltage signal is
sent to the KCU control unit (D7901).
6 On activation of the Cab heater switch U = 24 V Engine heater, description (electric engine
(E6690) a voltage signal is sent to the KCU heater), page 1:28
control unit (D7901). D6: Diagnostic menu, see 9.4 Climate Sys-
tem 19/XX DIAGNOSE, page 8:115
7 On activation of the Instep lighting switch U = 24 V D7: Diagnostic menu, see 9.6 Lighting Sys
(S1410) a voltage signal is sent to the KCU 6/XX DIAGNOSE, page 8:122
8 Control unit KCU (D7901) activates the out- U = 24 V 11.5.3.1 KCU control unit (D7901), page
put for CPU voltage supplying all the control 11:27
units. D8: Diagnostic menu, see 11.5 Distr of
9 Control unit KID (D7950) is supplied with - 11.5.3.3 Control unit, KID (D7950), page
CPU voltage and the control unit starts. 11:32
D9: Diagnostic menu, see 11.5 Distr of
10 Control unit KPU (D7902) is supplied with - 11.5.3.2 KPU control unit (D7902), page
11 Control unit KFU (D7971) is supplied with - 11.5.3.4 Control unit KFU (D7971), page
12 Signal to Control unit KFU-2 (D7972) acti- - 11.5.3.5 Control unit KFU-2 (D7972), page
vates CPU power input. 11:36.
13 Control unit KAU (D7911) is supplied with - 11.5.3.8 Control unit KAU (D7911), page
14 Control unit KAU-2 (D7912) is supplied with - 11.5.3.9 Control unit KAU-2 (D7912), page
CPU voltage and the control unit starts. 11:42.
Electr 41/XX DIAGNOSE, page 8:147.

11.5.1.3 Ignition voltage (15)

Ignition voltage (15), description
The ignition voltage supplies most of the functions in the machine, ex-
cept for the components in the working hydraulics.
The ignition voltage is supplied by Relay ignition voltage (K3150) that
routes voltage from the battery on activation. Relay ignition voltage
(K3150) is controlled by Control unit KCU (D7901)
RD1 BK1 GN1
The green fuse holder in the cab is divided between fuses GN1-GN4,
RD2 BK2 GN2
which are fuses for special functions, and fuses GN5-GN8, which are
RD3 BK3 GN3 supplied with ignition voltage.
RD4 BK4 GN4
Ignition voltage is activated by:
RD5 BK5 GN5
• Switch, ignition key lock (S1500) to position I
RD6 BK6 GN6
• Switch, flashing hazard lights (S1090)
RD7 BK7 GN7
• Heater cab (E6690) (diesel-driven engine and cab heater)
RD8 BK8 GN8
016307
Circuit fuses ignition voltage
Ignition voltage (15), function description

Battery disconnector In position 1 Battery disconnector, description , page 11:4
Redundant voltage feed Activated Redundant voltage feed of control units, function description,
page 11:16
Redundant CAN bus Communication established Redundant CAN bus, description, page 11:50
D16
D7940
– + 1 2 3
D7 16
D3 D15
D1 5 D7930
6 15
D2
D10 D11
D7901 D7971 D7972
4, 7 10, 14 11
9 12 13
D7902 D7911 D7912
D9 D12 D13
D8 8
022617
D7950


1 Ignition key lock switch (S1500) is turned to U = 24 V Cab overview, page 9:5
position I where after a voltage signal is sent D1: Diagnostic menu, see 11.5 Distr of
to KCU control unit (D7901). Electr 1/XX DIAGNOSE, page 8:137
2 Warning lamp activates where after a voltage U = 24 V Lighting system, function description, page
signal is sent to the KCU control unit 9:71
(D7901). D2: Diagnostic menu, see 9.7 Signalling
3 Heater cab (E6690) (diesel-driven engine U = 24 V D3: Diagnostic menu, see 9.4 Climate Sys-
and cab heater) is activated, at which a volt- tem 19/XX DIAGNOSE, page 8:115
age signal is sent to Control unit, KCU
(D7901).
4 Control unit KCU (D7901) supplies voltage U = 24 V 11.5.3.1 KCU control unit (D7901), page
to the Ignition voltage relay (K3150). 11:27
5 Ignition voltage relay (K3150) supplies volt- U = 24 V -
age to fuse holder in the cab electronic box
and in the frame electronic box.
6 The fuses feed voltage to control units, re- U = 24 V -
lays, solenoid valves and other electronic
components.
7 Control unit KCU (D7901) is supplied with U = 24 V 11.5.3.1 KCU control unit (D7901), page
ignition voltage and activates outputs for re- 11:27
quested functions. D8: Diagnostic menu, see 11.5 Distr of
8 Control unit KID (D7950) is supplied with U = 24 V 11.5.3.3 Control unit, KID (D7950), page
ignition voltage and shows information from 11:32
the machine's subsystems. D8: Diagnostic menu, see 11.5 Distr of
9 Control unit KPU (D7902) is supplied with U = 24 V 11.5.3.2 KPU control unit (D7902), page
10 Control unit KFU (D7971) is supplied with U = 24 V KFU control unit (D7971), description, page
11 Control unit KFU-2 (D7972) is supplied with U = 24 V 11.5.3.5 Control unit KFU-2 (D7972), page
ignition voltage and activates outputs for re- 11:36.
quested functions.. D11: Diagnostic menu, see 11.5 Distr of
12 Control unit KAU (D7911) is supplied with U = 24 V 11.5.3.8 Control unit KAU (D7911), page
13 Control unit KAU-2 (D7972) is supplied with U = 24 V 11.5.3.9 Control unit KAU-2 (D7912), page
ignition voltage and activates outputs for re- 11:42.
Electr 41/XX DIAGNOSE, page 8:147.
14 Control unit KFU (D7971) sends signals for U = 24 V KFU control unit (D7971), description, page
ignition voltage to Control unit engine 11:34
(D7940) and Control unit transmission
(D7930)
15 Control unit transmission (D7930) is started U = 24 V 11.5.3.7 Control unit, transmission (D7930),
and establishes communication on CAN bus page 11:39
drive-train D15: Diagnostic menu, see 2.8 Control Sys-
16 Control unit engine (D7940) is started and U = 24 V 11.5.3.6 Control unit, engine (D7940), page
establishes communication on CAN bus 11:38
drive-train D16: Diagnostic menu, see 2.8 Control Sys-

11.5.1.4 Control breaker voltage

Control breaker voltage, description
Control breaker voltage supplies functions that require control breakers
e.g. working hydraulics.
Control breaker voltage is disconnected with Switch control breaker
(S2500). Control breaker voltage is controlled via the CAN bus by Con-
trol unit KPU (D7902).
Conditions for activating control breaker voltage are:
• Start key in position I.
• Ignition voltage (15) activated.
• Switch control breaker (S2500) is not activated.
016314
Switch safety switch (S2500)
Control breaker voltage, function description

Redundant voltage feed Activated Redundant voltage feed of control units, function description,
page 11:16
Ignition voltage Activated Ignition voltage (15), function description, page 11:18
Redundant CAN bus communication 11.6.2 Redundant CAN bus, page 11:50
established
1, 4
D1
17
D7950
2, 5
D7901 D7902
D7971 D7972 D7911 D7912

3, 6, 14 3, 8 3, 10 3, 12
D7940
15
022618
D7930 7 9 11 13
16

1 Control breaker passive Control breaker in Control breaker, description, page 11:9
Switch, control breaker (S2500) sends volt- home position U = 24 V D1: Diagnostic menu see 11.5 Distr of
age signals to Control unit KPU (D7902). Electr 87/XX DIAGNOSE, page 8:158
2 Control unit KPU (D7902) sends Control Checked by the control 11.5.3.2 KPU control unit (D7902), page
breaker passive on the CAN bus. system; error shown 11:30
with error code.
3 Control unit KFU (D7971), Control unit KFU- Checked by the control 11.5.3.4 Control unit KFU (D7971), page
2 (D7972) , Control unit KAU (D7911) and system; error shown 11:34
Control unit KAU-2 (D7912) , allow the with error code. 11.5.3.8 Control unit KAU (D7911), page
connections for PWM safety group 1 and 11:40
PWM safety group 2 to be activated. 11.5.3.9 Control unit KAU-2 (D7912), page
11:42
4 Control breaker activated Control breaker de- Control breaker, description, page 11:9
Switch, control breaker (S2500) stops send- pressed: U = 0 V D1: Diagnostic menu see 11.5 Distr of
ing voltage signals to Control unit KPU Electr 87/XX DIAGNOSE, page 8:158
(D7902).


5 Control unit KPU (D7902) sends Control Checked by the control 11.5.3.2 KPU control unit (D7902), page
breaker activated via the CAN bus. At the system; error shown 11:30
same time, Control unit KPU (D7902) sends with error code.
a request for the functions that are acted on
by the control breaker.
6 Control unit KFU (D7971) interrupts activa- Checked by the control 11.5.3.4 Control unit KFU (D7971), page
tion of connections connected to PWM system; error shown 11:34
safety group 1, PWM safety group 2 and with error code. D6: Diagnostic menu, see:
PWM safety group 3.
• 11.5 Distr of Electr 7/XX DIAGNOSE,
7 Functions connected to one of the safety I = 0 mA page 8:138
groups are interrupted: • 11.5 Distr of Electr 8/XX DIAGNOSE,
page 8:138
• Joystick control/mini-wheel
• Lift or lower page 8:139
• Extension • 11.5 Distr of Electr 17/XX DIAGNOSE,
• Support jacks page 8:141
• Hydraulic sliding cab • 11.5 Distr of Electr 18/XX DIAGNOSE,
page 8:141
• Hydraulic cab lift
page 8:141
page 8:141
page 8:142
8 Control unit KFU-2 (D7972), interrupts acti- Checked by the control 11.5.3.4 Control unit KFU (D7971), page
vation of connections connected to PWM system; error shown 11:34
safety group 1, PWM safety group 2 and with error code. D8: Diagnostic menu, see:
PWM safety group 3.
9 Functions connected to one of the safety I = 0 mA page 8:143
page 8:143
• Support jacks
page 8:143
page 8:144
page 8:144
page 8:144
page 8:144
page 8:145
page 8:145
page 8:145
page 8:145
page 8:146
page 8:146
page 8:146


10 Control unit KAU (D7911) interrupts activa- I = 0 mA 11.5.3.8 Control unit KAU (D7911), page
tion of connections connected to PWM 11:40
safety group 1, PWM safety group 2 and D10: Diagnostic menu, see:
PWM safety group 3.
11 Functions connected to one of the safety page 8:153
page 8:153
• Side shift
page 8:153
• Rotation
• Tilt lock page 8:153
• Controllable tilt • 11.5 Distr of Electr 69/XX DIAGNOSE,
• Levelling page 8:154
• Twistlocks • 11.5 Distr of Electr 70/XX DIAGNOSE,
• Functions on accessory attachment page 8:154
page 8:154
page 8:154
page 8:155
page 8:155
page 8:155
page 8:155
page 8:156
page 8:156
page 8:156


12 Control unit KAU-2 (D7912) interrupts activa- I = 0 mA 11.5.3.9 Control unit KAU-2 (D7912), page
tion of connections connected to PWM 11:42
safety group 1, PWM safety group 2 and D12: Diagnostic menu, see:
PWM safety group 3.
13 Functions connected to one of the safety page 8:148
page 8:148
• Levelling
• Overheight-legs page 8:148
• Lift legs • 11.5 Distr of Electr 48/XX DIAGNOSE,
page 8:148
• Functions on accessory attachment
page 8:149
page 8:149
page 8:149
page 8:149
page 8:150
page 8:150
page 8:150
page 8:150
page 8:151
page 8:151
page 8:151
14 Control unit KFU (D7971) sends request for Checked by the control 11.5.3.4 Control unit KFU (D7971), page
speed limitation on CAN bus drive-train. system; error shown 11:34
with error code.
15 Control unit, engine (D7940) limits the en- Checked by the control 11.5.3.6 Control unit, engine (D7940), page
gine speed. system; error shown 11:38
with error code.
16 Control unit transmission (D7930) limits the Checked by the control 11.5.3.7 Control unit, transmission (D7930),
gear range. system; error shown page 11:39
with error code.
17 Control unit KID (D7950) shows Event menu, Checked by the control 11.5.3.3 Control unit, KID (D7950), page
control breaker. system; error shown 11:32
with error code.

11.5.1.5 Voltage converter

Voltage converter, description
The voltage converter (U9010) is located under a protective cover to
the left behind the operator's seat.
The voltage converter converts 24 V to 12 V. 12 V power is available
for accessories through a connector in the cab electrical distribution
box and through two outlets in the cab.
The voltage converter is connected via four flat-pin terminals
XU9010:1, 24V primary side.
XU9010:2, ground.
XU9010:3, ground.
XU9010:4, 12V secondary side.
016013
Placement of the voltage converter, access from in-

side the cab.
, and
016167
Placement voltage outlet in the cab

11 Common electrics – Electronic box 11:25
Voltage converter, replacement

2. Remove the covers behind the driver's seat.
1 2
015796

3. Mark up and disconnect the cable harness from the converter.
4. Replace the voltage converter.
5. Connect the cable harness in accordance with the marking.
016166
Placement of the voltage converter
11.5.2 Electronic box

11.5.2.1 Electronic box, cab
Electronic box, cab, description
Electronic box, cab, is mounted on the rear wall of the cab, on the left-
1 2 hand side. Located there are:
• KCU control unit (D7901).
• Fuses.
• Connectors
8 3 • Relays.
• Voltage converter 24 V to 12 V
4 • Connector service contact (X050), see Communication with the
machine, description, page 11:54.
• Connector customer accessories (X046) see below.
016132
7 6 5
1. Terminal, frame-ground connections
2. Fuses
3. Connector X046
4. Connector X050
5. Connectors KCU control unit (D7901)
6. Power connection to KCU control unit (D7901)
7. KCU control unit (D7901)
8. Connectors

11:26 11 Common electrics – Electronic box
Customer accessory connector (X046)

Connector customer accessories (X046) is intended for connecting the
3 2 1 customer's own accessories so that they can be connected safely and
so that they do not interfere with other functions on the machine. The
4 connector is the type 9-pin Universal Mate-n-lock. For part number see
Spare parts catalogue.
5 The connector X046 contains the following connections:

1. 24 V ignition voltage 10 A
016916
6 9 8 7 2. 24 V, battery voltage 10 A
9-pin Universal Mate-n-lock, pin numbers 3. Ground
4. 12 V, ignition voltage 20 A, when the machine is equipped with a
voltage converter
5. Ground
6. Ground
7. Empty
8. Empty
9. 24 V, battery voltage before the main power switch 10 A
11.5.2.2 Electronic box frame

Electronic box, description
1. Circuit fuses battery voltage (F9958-RD)
1 2 3 4 2. Circuit fuses ignition voltage (F9958-BK)
5 3. Circuit fuses ignition voltage (F9958-GN)
6 4. Diagnostic outlet J1939/Cummins
7 5. Diagnostic outlet Volvo
11 6. Diagnostic socket, transmission Dana
7. Control unit, transmission (D7930)
8. Distribution fuses ignition voltage (F9954-1)
9. Distribution fuses battery voltage (F9952-2)
10 10. Relay ignition voltage (K3150)
11. Fuse (50A), electric motor for cooling/circulation (F9951–1)
9
12. Relay, cooling/circulation (K6680–2)
8
The electronic box is fitted on the side of the machine. Also located
there are:
• Fuses
• Outlet for programming Control unit, transmission (D7930)
• Distribution fuses
• Transmission control unit
12
• Power relays for voltage feed to the machine's functions
022745

11 Common electrics – Control units 11:27
11.5.3 Control units

Control units, location
1 2 3 4
10
022883
9 8 7 6
1. 11.5.3.8 Control unit KAU (D7911), page 11:40 7. 11.5.3.6 Control unit, engine (D7940), page 11:38
2. 11.5.3.3 Control unit, KID (D7950), page 11:32 8. 11.5.3.5 Control unit KFU-2 (D7972), page 11:36
3. 11.5.3.2 KPU control unit (D7902), page 11:30 9. 11.5.3.4 Control unit KFU (D7971), page 11:34
4. 11.5.3.1 KCU control unit (D7901), page 11:27 10. 11.5.3.9 Control unit KAU-2 (D7912), page 11:42
5. 11.5.3.7 Control unit, transmission (D7930), page 11:39
6. Control unit, after-treatment system (ACM). Only applies to
Volvo TAD873VE and Volvo TAD883VE.
11.5.3.1 KCU control unit (D7901)

KCU control unit (D7901), description
KCU control unit (D7901) is the central control unit of the control sys-
tem. KCU control unit (D7901) sends activation signals to other units,
and controls and monitors their functions. It administrates work in the
control unit network.
KCU control unit (D7901) controls the redundant power supply and
manages communication via the redundant CAN bus. The KCU control
unit (D7901) receives, via KPU control unit (D7902), signals from the
4 switches in the cab.
The cab control unit has two LEDs that indicate the control unit's
function.
LED Status Description
3 Green Short flash The control unit is voltage fed by CPU

(1 Hz, 0.1 s) power.
2
017412
1 Long flash Ignition key lock switch is in position I

(1 Hz, 0.5 s) and the Ignition voltage is switched on.
1. Red LED
Alternating short If both CPU power and ignition power
2. Green LED flash/long flash are switched on the LED flashes with
3. Power supply connections both short and long pulses
4. Connectors simultaneously.

11:28 11 Common electrics – Control units

Lit The control unit is voltage fed.
Ignition key lock switch is in position I.
The display is lit and the system is ready
for the start of machine functions.
Red Short flash RedCAN wiring error on the unit.
(1 Hz, 0.1 s)
Long flash In the event of active error.
(1 Hz, 0.5 s)
Lit No CAN communication with other con-
trol units, BusOff or Driver Error.
Green/red LED microcomputer start-up program

Green Flashes (2.5 Hz)
Unit with interrupted download.
Red Flashes (2.5 Hz)
Green Flashes (10 Hz) Unit has initiation error in the flash loader
Red Flashes (10 Hz) and no application software is loaded.
Green Flashes
Download of HEX file (program flash).
Red Out
Green Lit
Download in progress (erase sector).
Red Out
Green Out Download in progress (erase sector
Red Out ready).
Green Out
Download in progress (download ready).
Red Out
KCU control unit (D7901), replacement

1. Connect Kalmar Service Tool to the machine and select "Create
Machine Image". This saves the machine's settings and operating
data.
022888
Connection Kalmar Service Tool

3. Remove the plastic covers over the door pillar and rear panel.
1 2
4. Carefully fold out the rear panel.
015796
1. Rear panel
5. Disconnect the cable harness from the control unit.
4 The two power cables are fitted with screws under the cable seals.
The multi-pole connectors are fitted with a screw in the centre of
each connector.
6. Remove the attaching bolts and the control unit.
7. Fit in the reverse order. Make sure that the correct torque is used
when tightening screws and nuts, take special care with the fasten-
ing of power cables, which can break with a too large torque.
015797
1 2 3
1. Power cables
2. Connectors
3. KCU control unit (D7901)
4. Screws
8. Connect Kalmar Service Tool to the machine and select "Repair
Machine Wizard". This programs the new control unit and resets
the settings.
9. Calibrate the following functions:
• Hydraulic sliding cab, see Hydraulic sliding cab, calibration,
page 9:109.
• Vertically adjustable cab, see Vertically adjustable cab, calibra-
tion, page 9:121.
022888

11.5.3.2 KPU control unit (D7902)

KPU control unit (D7902), description
KPU control unit (D7902) manages the functions of most switches in
the cab, such as the multi-function lever, direction indicator switches,
start button. It also manages the key panel for the control system and
its panel for warning and indicator lights.
function.
1
2 LED Status Description
Green Short flash The control unit is voltage fed by CPU
022897
Long flash Ignition key lock switch is in position I
1. Green LED (1 Hz, 0.5 s) and the Ignition voltage is switched on.
2. Red LED Alternating short If both CPU power and ignition power
flash/long flash are switched on the LED flashes with
both short and long pulses
simultaneously.
Lit The control unit is voltage fed.
(1 Hz, 0.1 s)
(1 Hz, 0.5 s)

Green Flashes
Red Out
Green Lit
Red Out
Red Out ready).
Green Out
Red Out

KPU control unit (D7902), replacement

data.
022888
4. Open the cover lid.
1
015799
2
1. Screws
2. Cover
5. Mark up and detach the cable harness from the control unit.
6. Replace the control unit.
7. Fit in the reverse order. Check that all connectors are properly in-
serted and all the pins are fitted in place in the connectors.
The space is narrow and restricted. Therefore, exercise caution
1 when fitting the control unit in place.
Tighten the screws for the control unit with care.
015798
2 3
1. Nut
2. KPU control unit (D7902)
3. Connectors
the settings.
• Joystick control, see Lever steering, calibration, page 5:7.
022888

11.5.3.3 Control unit, KID (D7950)

KID control unit (D7950), description
Control unit KID (D7950) displays to the operator information sent by
the control system, such as speed, in the form of messages, status, er-
ror indications, etc.
There is an indicator light for active errors on the steering panel, which
comes on when serious errors exist in the control system. Error codes,
event menus and information are shown on the display.
See the operator's manual for detailed information about the display.
022889
KID control unit (D7950), replacement

data.
022888

3. Loosen the clamp and angle out Control unit KID.
022890
Clamp


5. Separate the display casing carefully, both the display section and
the rear part loosen from the bracket when the screws are
loosened.
022891
6. Disconnect the cable harnesses from the control unit.

7. Replace the control unit.
8. Fit in the reverse order. Check that all connectors are connected
and all the pins are fitted in place in the connectors.
022892

the settings.
022888

11.5.3.4 Control unit KFU (D7971)

KFU control unit (D7971), description
KFU control unit (D7971) manages input data from sensors and sends
control signals to relays and solenoid valves for among others start-up,
hydraulic functions, parking brake, fans, central lubrication and lighting.
The control unit also acts as an interface to the CAN bus drive-train.
The control unit is fitted on the inside of the left-hand frame member
above the drive axle.
4 The cab control unit has two LEDs that indicate the control unit's
function.

3
2 (1 Hz, 0.5 s) and the Ignition voltage is switched on.
017412
1
1. Red LED flash/long flash are switched on the LED flashes with
2. Green LED both short and long pulses
simultaneously.
3. Power supply connections
4. Connectors Lit The control unit is voltage fed.
(1 Hz, 0.1 s)
(1 Hz, 0.5 s)

Green Flashes
Red Out
Green Lit
Red Out
Red Out ready).
Green Out
Red Out

KFU control unit (D7971), replacement

data.
3. Remove the hoods over the engine compartment.
022888
The two power cables are fitted with screws under the cable seals.
each connector.

the settings.
• Load sensor, see Load sensors, calibration, page 8:12.
7:21.
022888

11.5.3.5 Control unit KFU-2 (D7972)

Control unit KFU-2 (D7972), description
Control unit KFU-2 (D7972) processes input data from sensors and
sends control signals to relays and solenoid valves for e.g. support
jacks.
The control unit is fitted on the inside of the left-hand frame member
above the drive axle.
4 The cab control unit has two LEDs that indicate the control unit's
function.

3
2
017412

1
1. Red LED flash/long flash are switched on the LED flashes with
2. Green LED both short and long pulses
simultaneously.
3. Power supply connections
4. Connectors Lit The control unit is voltage fed.
(1 Hz, 0.1 s)
(1 Hz, 0.5 s)

Green Flashes
Red Out
Green Lit
Red Out
Red Out ready).
Green Out
Red Out

Control unit KFU-2 (D7972), replacement

data.
3. Remove the hoods over the engine compartment.
022888
each connector.
Control unit KFU-2 (D7972)

the settings.
022888

11.5.3.6 Control unit, engine (D7940)

Control unit, engine (D7940), description (engine
option Volvo)
Control unit, engine (D7940) is part of the drive-train control and han-
1 dles engine function, fuel injection, etc. On engine options with after-
treatment system for the exhaust gases, Control unit, engine (D7940)
is connected with Control unit, after-treatment system (ACM), all com-
2
munication with the machine is handled by Control unit, engine
(D7940).
3 Control unit engine (D7940) is connected to CAN bus drive-train, to-
gether with the Control unit transmission (D7930) that is connected to
Control unit KFU (D7971). In turn, Control unit KFU (D7971) forwards
drive-train information to other units.
007424
The control unit is fitted on the engine has no function keys or display.
All functions are controlled via the CAN bus and an external control
Engine control unit
system.
1. Cooling duct for control unit (fuel)
2. Connector A (black) The diagnostic socket for communication directly with the engine via
3. Connector B (grey) the diagnostic tool is located in electronic box, frame, see Communica-
tion with the machine, description, page 11:54.
The control unit monitors the following values in order to optimise en-
gine performance.
• engine speed
• camshaft position
• charge air pressure
• charge air temperature
• coolant temperature
• oil pressure
• oil temperature
• oil level
• crankcase pressure
• water in fuel
• fuel pressure
• coolant level
• DEF temperature
• Control unit, after-treatment system (ACM) only engine options
TAD117xVE, TAD118xVE
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the cor-
rect fuel volume and to check the condition of the engine.
For more information, see supplier documentation.
Control unit, engine (D7940), replacement

See supplier documentation, engine.

11.5.3.7 Control unit, transmission (D7930)

Transmission control unit (D7930), description
Control unit, transmission (D7930) is part of drive-train control and han-
dles transmission function, selection of gear at load and engine speed,
etc.
Control unit, transmission (D7930) is connected to CAN bus drive-train,
together with the Control unit engine (D7940) that is connected to Con-
trol unit KFU (D7971). In turn, Control unit KFU (D7971) forwards drive-
train information to other units.
The diagnostic socket for communication directly with the transmission
via the diagnostic tool is located in electronic box, frame, see Commu-
nication with the machine, description, page 11:54.
Control unit, transmission (D7930)
Control unit, transmission, replacement

2. Open the cover lid on electronic box, frame.
3. Undo the outer attaching bolts for Control unit transmission
(D7930) and leave the bolts in place.
4. Lift up the intermediate plate so that the rear of the control unit is
visible.
Control unit, transmission (D7930)

5. Disconnect the cable harness from Control unit, transmission
(D7930).
6. Remove the inner attaching bolts and remove the control unit.
7. Fit the new the control unit and fit the rear attaching bolt.
Ensure that the outer screws guide into the grooves on the control
unit.
8. Connect the cable harness to Control unit transmission (D7930).
9. Lift the intermediate wall into place.
10. Tighten the outer attaching bolts for Control unit transmission
(D7930).
11. Calibrate the transmission, see Maintenance manual.

11.5.3.8 Control unit KAU (D7911)

Control unit KAU (D7911), description
Control unit KAU (D7911) processes input data from sensors and
sends control signals to lights and solenoid valves on the attachment.
The control unit is fitted by Control valve attachment on the rear section
of the attachment.
function.

3
2 flash/long flash are switched on the LED flashes with
017412
1 both short and long pulses

simultaneously.
1. Red LED
2. Green LED Lit The control unit is voltage fed.
3. Power supply connections The display is lit and the system is ready
4. Connectors for the start of machine functions.
(1 Hz, 0.1 s)
(1 Hz, 0.5 s)

Green Flashes
Red Out
Green Lit
Red Out
Red Out ready).
Green Out
Red Out

Control unit KAU (D7911), replacement

data.
022888
each connector.
Control unit KAU (D7911)

1. Power cables
2. Multi-pole connectors
3. Attaching bolts
the settings.
•
Damping for attachment close to the load, see Sensor damp-
ing attachment, calibration, page 7:31.
022888

11.5.3.9 Control unit KAU-2 (D7912)

Control unit KAU-2 (D7912), description
Control unit KAU-2 (D7912) processes input data from sensors and
sends control signals to solenoid valves on the attachment for control-
ling the combi attachment.
function.
3
2
017412
flash/long flash are switched on the LED flashes with

1 both short and long pulses
simultaneously.
1. Red LED
2. Green LED Lit The control unit is voltage fed.
3. Power supply connections The display is lit and the system is ready
4. Connectors for the start of machine functions.
(1 Hz, 0.1 s)
(1 Hz, 0.5 s)

Green Flashes
Red Out
Green Lit
Red Out
Red Out ready).
Green Out
Red Out

Control unit KAU-2 (D7912), replacement

data.
022888
each connector.
Control unit KAU-2 (D7912)

the settings.
022888
11.5.3.10 I/O module KEM-2 (A7992)

I/O module KEM-2 (A7992), description
I/O module KEM-2 (Kalmar Extension Module 2) (A7992) is a unit to in-
crease the number of connections that can be read and controlled by
Control unit KAU (D7911). The I/O module does not contain adapted
software but all logic is in Control unit KAU (D7911).
I/O module KEM-2 (A7992) is used for sensors for measuring the ec-
centric load.
The control unit is fitted on the boom nose at the side of Control unit
KAU (D7911).
The signals can be checked with the diagnostic menus 11.5 Distr of
019543
Electr 48/XX DIAGNOSE, page 8:148 and 11.15 I/O A7991 KEM 1–12/

11:44 11 Common electrics – Cable harness
I/O module KEM-2 (A7992), replacement

2. Disconnect the cable harness from the I/O module.
3. Remove the attaching bolts from the I/O module.
019543
11.5.3.11 I/O module KEM-3 (A7993)
I/O module KEM-3 (A7993), description
I/O module KEM-3 (Kalmar Extension Module 3) (A7993) is a unit to in-
crease the number of connections that can be read and controlled by
Control unit KAU (D7911). The I/O module does not contain adapted
software but all logic is in Control unit KAU (D7911).
I/O module KEM-2 (A7992) is used for sensors for measuring the ec-
centric load.
The control unit is fitted by Control valve attachment on the rear section
of the attachment beside Control unit KAU (D7911).
The signals can be checked with the diagnostic menus 11.5 Distr of
019543
Electr 48/XX DIAGNOSE, page 8:148 and 11.15 I/O A7991 KEM 1–12/
I/O module KEM-3 (A7993), replacement

2. Disconnect the cable harness from the I/O module.
3. Remove the attaching bolts from the I/O module.
019543
11.5.5 Cable harness

Cables, description
The cables are drawn in a cable harness along the side of the frame
and held in place with straps, belts and rubber clamps.
There are very few joints in the cables between the consumers and the
fuse box. The intention is to reduce the risk of faults.
When working on the machine, the following points must be followed in
order to maintain the function and safety of the machine:
• Disconnect the voltage with the battery disconnector or by detach-
ing the negative terminal from the batteries before working on the
electrical system. Note that there are functions that are supplied di-
rectly from the battery.
• A cable harness that is exposed or replaced must be routed and
clamped in the same way as from the factory. The routing and
clamping of the cable harness are fully tested, and deviation from
this may result in damage to the machine or cable harness.

11 Common electrics – Cable harness 11:45
• Never clamp a cable harness to fuel pipes, fuel hoses, hydraulic

pipes or hydraulic hoses.
DANGER
Incorrect clamping of a cable harness.
Fire hazard
Never clamp a cable harness to fuel pipes, fuel hoses,
hydraulic pipes or hydraulic hoses. Chafing damage
may result in leakage, short circuit and fire.
• Never route the cable harness so that it runs over sharp edges or
where it is exposed to radiant heat from hot components or ex-
haust gases.
• Make it a habit to inspect the cable harness in conjunction with re-
pairs. Repair damaged cable harnesses immediately to avoid big-
ger problems.
• When repairing the cable harness, use the intended tools for sepa-
rating connectors and crimping the contacts.
IMPORTANT
DEF on wiring.
replaced.
Cable harness, splicing points

Connectors in the machine are numbered in series according to loca-
X001 - X199 X400 - X499 tion in the machine.
017401
X500 - X599
X200 - X399

11:46 11 Common electrics – Cable harness
Connectors that connect to a component are numbered as the compo-

nent but with an X in front, for example XS1500 for the connector that
connects to Ignition switch (S1500).
Location of joints in the cable harness
Shown below is the approximate location of the connectors that join dif-
ferent parts of the cable harness and branching points (splice) in the
cable harness.
All branching points in the cable harness are extended in connectors
with strappings, contact with strappings is unique to each branching
point and must not be mixed up.
DANGER
Each branching point has a contact with strappings
whose coupling is unique. If the contacts are connected
in the wrong location, the machine's functions may be
activated incorrectly.
Extreme danger!
Never use strappings to change round contacts for
troubleshooting purposes, and always ensure that a de-
tached contact is reconnected to the correct connector.
X237 X210, X228, X278

X090R X090L X400A,
X400B,
X401,
X402,
X055, X403
X030-0041
X056
X029 X098
X054, X099
X060, X045-X050 X276
X061
X200, X238-X240 X222, X207, X209
X098, X099
X269, X247, X255 X211, X229,
X272 X256, X273 X241-X243, X246,
X252-X254, X257, X271
X503A, X504, X560-1 X503B,
X567, X571 X560-2 X566
X572
X501A, X501B
X507A, X507B
X500-10, X500-20
X561, X562, X563,
X564, X565, X568, X573
017402
X574 X569

11 Common electrics – Cable harness 11:47
Connectors, marking
-P021 -P030
12 11 10 9 8 7 12 11 10 9 8 7
1 3 2 5 4 6 1 3 2 5 4 6
DEUTSCH DEUTSCH
023251
023252
Deutsch -P030
Deutsch -P021
DEUTSCH
1 6
- EP14
DEUTSCH
1 6
- EP13
2 5
2 5 3 4
3 4
023254
023253
Deutsch -EP14
Deutsch -EP13

11:48 11 Common electrics – Communication
11.6 Communication
Communication, general
The machine communications are managed by a CAN bus system.
The CAN bus system consists of control units connected into a network.
The idea of a network is to share information. Signal values are sent to
the control unit, which for example, is connected to a sensor, other con-
trol units can use the signal for their functions.
The network consists of control units and segments. Segments are the
CAN bus between the control units.
11.6.1 CAN bus

CAN bus, description
Communication between the control units takes place using so-called
1 2 "CAN buses" (Controller Area Network) based on the ISO 11898 stand-
ard and CAN specification 2.0B.
The CAN bus is a fast control bus with logical hardware circuits. A sim-
120 ohm 120 ohm ple technology that is highly reliable (low error frequency), which is a re-
quirement 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 ca-
bles' impedance) so that the pulse train (position 4) should obtain a
4 sharp signal.
2 • that the signal valve is given as the potential difference between
U [V]
the cables, CAN + and CAN - (position 2 and 3).

• form of signal messages.
3
000026
t [S]
Messages are sequential and signal is high (voltage
high) or low (voltage low).
1. Termination resistor (120 ohm)
2. CAN + (voltage high)
3. CAN - (voltage low)
4. Pulse
5. Control unit

11 Common electrics – CAN bus 11:49
Message
There are two types of messages:
A
• CAN Standard, has identity field of 11 bits
• CAN Extended, has identity field of 29 bits
CAN works in messages sent in frames of 8 bytes (64 bits). A complete
B C D E F G message is approx. 100 bits long. The illustration depicts how a mes-
000027
t [S] sage is structured.
Messages are sequential and signal is high (voltage Start bit (B)
high) or low (voltage low).
Indicates that the transmission of a frame, i.e. a message, is now
A. Length message beginning.
B. Start bit
C. Identity field/Priority Identity field (C)
D. Control field (length of data segment) Indicates what kind of information the message contains, e.g. measure-
E. Data segment ment information on engine speed.
F. Checksum for error detection
Does not indicate address to control unit. CAN does not work with ad-
G. Acknowledge bit
dressing. All control units receive messages and send them on.
Control field (D)

Indicates how the length of the data segment that follows.
Data segment (E)

Contains the information to be conveyed to control units in the network.
Checksum for error detection (F)

Calculates a checksum for the message. This makes it possible for the
receiving control unit to detect errors in the sent message.
Acknowledge (G)
The transmitting control unit sets a bit to logical one (1) when the mes-
sage is sent. The first control unit to receive the message sends it on
and sets the bit to logical zero (0).

11:50 11 Common electrics – Redundant CAN bus
Communication
The CAN network consists of control units and segments. The segment
(bus) is a twisted pair cable that leads CAN + and CAN - signal levels
from control unit to control unit.
Each control unit measures the potential difference of its two inputs.
The potential difference generates logical zero and logical one. The il-
3,5 V
lustration depicts an approved interval according to the standard for po-
tential levels. CAN + has a recommended value of 3.5 V and CAN - has
1.5 V. As a worst case scenario, the potential difference can be only 0.5
U [V]
V and still be approved. In practice, a potential difference of 2 V is rec-

0,5 V ommended for reliable communication.
Pulse trains can only be observed using an oscilloscope, not with an
analogue or digital multimeter.
1,5 V
When a message is sent, all control units in the network listen. Mes-
sages are saved in the control unit and relevant information is pro-
cessed. The control unit that receives the message first confirms
receipt (sets an acknowledge bit). The transmitting control unit then
000028
knows that the message has been received by at least one control unit.
t [S]
One control unit at a time sends the message. Other control units listen
Potential levels CAN + and CAN - and wait until the bus is available. If two messages are to be sent simul-
taneously 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
11.6.2 Redundant CAN bus

Redundant CAN bus, description
Redundant CAN bus means that each control unit has two connections
D7901 N R D7971 N R D7972 N for communication, CAN-N (normal) and CAN-R (redundant). The CAN
R Nod 1 Nod 2 Nod 3
bus is connected in series between the control units. This means the
R
D7912 CAN bus can handle the loss of a segment. If several segments fail
N Nod 6 then one or several of the control units lose contact with the network
D7902 and work independently, but usually with limited capacity to perform
N Nod 11 R N D7911 R their function. The signals can be checked with diagnostic menu.
CAN+ CAN- Nod 7
N+ N- The network is based on a node being central, in this case DynRed-

022619
D7950 CAN King KCU D7901, and the governing unit (master). This node has
Nod 12
lowest node number. Other nodes in the network are secondary
(slaves) and manage dedicated areas, e.g. hydraulic unit.
Communication with Control unit KID (D7950) takes place via Control
unit KPU (D7902).
CAN bus faults are indicated with an error code and a warning in the
display. If several CAN bus segments are faulty, the system only shows
an error code for the first faulty out segment. The machine can still be
run, in some cases with a limited function.

11 Common electrics – Redundant CAN bus 11:51
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 commu-
nication is established in the system.
The redundant CAN bus can handle the loss of a segment. The link is
analysed during start-up and continuously during operation. If a seg-
ment is incorrect, the message is sent another way. If several segments
are lost, one or more control units lose communication and work inde-
pendently, often with significantly limited functionality. CAN bus faults
are indicated with an error code and a warning in the display. The com-
munication loop can be disrupted by cable damage for example, and
then communication is established via an alternative route. Open cir-
cuits and errors are shown in the diagnostic menus for RedCAN, diag-
nostic menu 1 – 9
11.6 Communication 1/XX DIAGNOSE, page 8:160, 11.6 Communica-
tion 2/XX DIAGNOSE, page 8:160, 11.6 Communication 3/XX DIAG-
NOSE, page 8:160, 11.6 Communication 4/XX DIAGNOSE, page
8:161, 11.6 Communication 5/XX DIAGNOSE, page 8:161, 11.6 Com-
munication 6/XX DIAGNOSE, page 8:161, 11.6 Communication 7/XX
DIAGNOSE, page 8:161, 11.6 Communication 8/XX DIAGNOSE, page
8:162 and 11.6 Communication 9/XX DIAGNOSE, page 8:162.
Technical specification:
• 11 bit identity field
• 250 kbit/s
• Termination 120 Ohm (in the control units)

11:52 11 Common electrics – Redundant CAN bus
Redundant CAN bus, start-up

Condition Reference Reference
value
Battery disconnector In position 1 Battery disconnector, description , page 11:4.
Redundant voltage feed Activated Redundant voltage feed of control units, function description, page 11:16.
7
D7950
N+ N-
6
1, 8, 9 CAN+ CAN-
D7901 D7902
N R N R X050
2 3 4 5
D7971 D7972 D7912 D7911
R N R N R N R N
022620
The illustration shows two alternatives for how the couplings are changed depending on the number of control units on the
machine:
Solid lines show the CAN-bus with a minimal number of control units.
Dotted lines show the CAN-bus with a maximal number of control units.

1 Control unit KCU (D7901) establishes redun- Checked by control 11.5.3.1 KCU control unit (D7901), page
dant CAN bus communication by sending a system, error shown 11:27
request on the CAN bus via CAN-N to Con- with error code.
trol unit KFU (D7971).
Termination resistor in the control unit pro-
tects against interference in the event of
open circuit in the segment and thereby en-
sures communication on the second CAN
connection.
2 Control unit KFU (D7971) responds with Checked by control 11.5.3.4 Control unit KFU (D7971), page
node number (Node 2) to Control unit KCU system, error shown 11:34
(D7901) via CAN-R and sends the request with error code.
onward via CAN-N.
Depending on the machine's equipment, the
control unit that is next in the loop varies.
connection.
3 Control unit KFU-2 (D7972) responds with Checked by control 11.5.3.5 Control unit KFU-2 (D7972), page
node number (Node 3) to Control unit KFU system, error shown 11:36
onward via CAN-N.
connection.

11 Common electrics – Redundant CAN bus 11:53

4 Control unit KAU-2 (D7912) responds with Checked by control 11.5.3.9 Control unit KAU-2 (D7912), page
node number (Node 6) via CAN-R and sends system, error shown 11:42
the request onward via CAN-N. with error code.
connection.
5 Control unit KAU (D7911) responds with Checked by control 11.5.3.8 Control unit KAU (D7911), page
node number (Node 7) via CAN-R and sends system, error shown 11:40
the request onward to Control unit KPU with error code.
(D7902) via CAN-N.
connection.
6 Control unit KPU (D7902) responds with Checked by control 11.5.3.2 KPU control unit (D7902), page
node number (Nod 11) to Control unit KAU system, error shown 11:30
onward to Control unit KCU (D7901) via
CAN-N.
connection.
7 Control unit KID (D7950) responds with node Checked by control 11.5.3.3 Control unit, KID (D7950), page
number (Node 12). This is sent to Control system, error shown 11:32
unit KPU (D7902), which adds Control unit with error code.
KID (D7950) in the RedCAN loop.
8 Control unit KCU (D7901) receives informa- Checked by control 11.5.3.1 KCU control unit (D7901), page
tion about the control units that responded system, error shown 11:27
and the order in which they responded. The with error code. Diagnostic menu, see 11.6 Communication
information is compared with the set-up file 1/XX DIAGNOSE, page 8:160, 11.6 Com-
and if the information is correct the CAN bus munication 2/XX DIAGNOSE, page 8:160,
is signalled as functioning and the control 11.6 Communication 3/XX DIAGNOSE,
units are allowed to communicate with each page 8:160, 11.6 Communication 4/XX DI-
other. AGNOSE, page 8:161, 11.6 Communication
If a control unit has not responded, then 5/XX DIAGNOSE, page 8:161 and 11.6
Control unit KCU (D7901) uses both CAN-R Communication 6/XX DIAGNOSE, page
and CAN-N to keep communication open 8:161.
and an error code is set.
9 Each time a control unit requests information Checked by control Diagnostic menu, see 11.6 Communication
from another control unit, a response is sent system, error shown 7/XX DIAGNOSE, page 8:161, 11.6 Com-
that the information is received. If a control with error code. munication 8/XX DIAGNOSE, page 8:162
unit is not responding then an error message and 11.6 Communication 9/XX DIAGNOSE,
is sent to Control unit KCU (D7901). page 8:162.
In the event of errors, as the first action, Con-
trol unit KCU (D7901) attempts to re-estab-
lish communication with a new request.

11:54 11 Common electrics – CAN bus drive-train
11.6.3 CAN bus drive-train

CAN bus for drive-train, description
Communication with Control unit engine (D7940) and Control unit
1 2 transmission (D7930) is separated from the redundant CAN bus. Con-
trol unit KFU (D7971) forwards the communication between the ma-
chine's control system and engine and transmission.
3 4 5 The CAN bus for the drive-train is based on the standard SAE J1939
where selected messages are used to control the engine and transmis-
sion. SAE J1939 is a standard from SAE (Society of Automotive Engi-
D7971 D7940 D7930 neers) for data communication in vehicles. The standard regulates
hardware interface, bit times and message composition.
The engine and transmission control units are supplied by respective
engine and transmission suppliers. The machine can be equipped with
different transmission and engine models. Messages from the trans-
mission and engine are built up according to a standard structure.
The signals from Control unit transmission (D7930) can be checked
with the diagnostic menus 2.8 Control System 12/XX DIAGNOSE, page
8:41, 2.8 Control System 13/XX DIAGNOSE, page 8:42 and 2.8 Con-
016151
6 7 trol System 14/XX DIAGNOSE, page 8:42.

The signals from Control unit engine (D7940) can be checked with the
1. Engine
diagnostic menus 1.9 Control System 1/XX DIAGNOSE, page 8:34, 1.9
2. Transmission
Control System 2/XX DIAGNOSE, page 8:34, 1.9 Control System 3/XX
3. Control unit KFU (D7971) DIAGNOSE, page 8:35 and 1.9 Control System 4/XX DIAGNOSE,
4. Control unit, engine (D7940) page 8:35.
5. Control unit, transmission (D7930)
6. Redundant CAN bus
7. CAN bus for drive-train
11.6.6 Communication with the machine

Communication with the machine, description
Diagnostic socket, machine
The machine has an outlet for communication between control units
and a PC.
The rear of the cover on Control unit KID (D7950) includes a USB port
for connecting a computer with Kalmar Service Tool (KST). Kalmar
Service Tool is used for resetting the service interval, upgrading and re-
programming the machine's control units (not engine and transmission).
022888

11 Common electrics – Communication with the machine 11:55
Diagnostic socket, drive-train

Electronic box frame contains diagnostic socket for CAN bus drive-train
(J1939), engine and transmission.
1
016305
1. Diagnostic outlet Volvo

2. Diagnostic outlet J1939/Cummins
3. Diagnostic socket, transmission
Service contact (X050)

Connector service contact (X050) is fitted in electronic box, cab. The
connector can be used for connecting service tools or troubleshooting
the machine.
The connector is the type 9-pin Universal Mate-n-lock. For part number
see Spare parts catalogue.
Connector service contact (X050) contains the following connections:
1. CAN bus option (R+)
2. CAN bus option (R-)
3. Ignition voltage, 24 V 10 A
016169
4. Battery voltage 24 V 10 A
5. Ground
Service contact X050 6. Searchlight (E4370)
, and
7. Searchlight (E4370)
3 2 1 8. Status signal, relay ignition voltage (K3150)
9. Status signal, redundant voltage feed CPU Power
4
5
016916
6 9 8 7
9-pin Universal Mate-n-lock, pin numbers

11:56 11 Common electrics – Insight
Vehicle Data Interface (VDI) (X039)
As an option, the machine can be prepared for connection of external

systems for communication with the machine (for example, Insight and
radio control). Connection of external systems is made to the Vehicle
Data Interface (VDI) connector (X039).
VDI is a connector of the 9-pin Universal mate-n-lock type in the elec-
tronic box in the cab. For part number, see the spare parts catalogue.
Connector VDI (X039) contains the following connections:
1. CAN bus option (R+)
2. CAN bus option (R-)
3 2 1 3. Ignition voltage, 24 V 10 A
4. Battery voltage 24 V 10 A
4 5. Ground
6. Not connected
7. Not connected
5
8. Not connected
019145
9. Battery voltage before battery disconnector, 24 V 10 A

6 9 8 7
11.6.7 Insight
Insight, description
Insight is an option for process automation. Insight reads and sends op-
erating data from the machine and creates advanced functions for sta-
tistics and load data. The information can be sent wirelessly to a central
server for further processing.
The functions for Insight in the machine are handled by the Machine
Telematic Unit (MTU), see Machine Telematic Unit (MTU), description,
page 11:56.
11.6.7.1 Machine Telematic Unit (MTU)

Machine Telematic Unit (MTU), description
Machine Telematic Unit (MTU) is the control unit for Insight functions
and equipment in the machine. MTU handles communication between
machine and other components that are connected to MTU. The Insight
control unit is connected to the machine via Vehicle Data Interface
(VDI) (connector X039 in the wiring diagram).
MTU communicates wirelessly with equipment on the machine and
central servers via antennas on the rear window and an antenna on the
cab's roof.
Equipment is connected to MTU via USB and physical inputs:
Examples of equipment connected to MTU:
• Printer for printout of load receipts, see Printer, description, page
11:57'.
• Keyboard for entering load time on the load receipts, see Key-
board, description, page 11:57.
• RFid reader for operator identification, see RFid reader, descrip-
tion, page 11:57.

11 Common electrics – Insight 11:57
11.6.7.2 Printer
Printer, description
As an option for Insight, the machine can be equipped with a function

for printout of load receipts on a printer in the cab. The printer is con-
nected to the USB port MTU, see Machine Telematic Unit (MTU), de-
For a more detailed description of the load receipt function, see Printout
of load receipts, general, page 8:26.
11.6.7.3 Keyboard
Keyboard, description
As an option for Insight, the machine can be equipped with a function

for printout of load receipts on a printer in the cab. A keyboard is used
to enter load identification on load receipts and to save load receipts.
The keyboard is connected to the USB port on MTU, see Machine Tele-
matic Unit (MTU), description, page 11:56.
For a more detailed description of the load receipt function, see Printout
of load receipts, general, page 8:26
11.6.7.4 RFid reader

RFid reader, description
Insight can connect the operator to stored operating data and save op-
erator-specific settings from the machine, such as speed limitation. The
operator uses an RFid tag to identify him/herself.
The RFid reader is fitted on the left-hand side of the cab’s rear panel.
The RFid reader is connected directly to MTU, see Machine Telematic
Unit (MTU), description, page 11:56.

11:58

D:1
D Errorc odes
Contents D Error codes

Error codes...........................................................................................................D:3
Engine .............................................................................................................D:12
Error codes engine (engine option Volvo TAD853VE,
TAD873VE) ................................................................................................D:12
Error codes engine (engine option Volvo TAD883VE)...............................D:51
Transmission...................................................................................................D:95
Error codes transmission (transmission alternative DRTS HVT
R2)..............................................................................................................D:95
Machine.........................................................................................................D:133
Error codes machine ................................................................................D:133

D:2

D Error codes – Error codes D:3
D Error codes
Error codes, explanation
The error codes are explained in table form for Engine, Transmission
as well as Control system. They are sorted according to error code
number.
The error code table has the following information:
• Code, error code's number, shown in field d on the display.
10:23
ACTIVE ERRORS 1/10 • Node, specifies which control unit generated the error. See Table
Node, explanation, page D:133.
• Description, explanation of the error code and when it\qs
0 d generated.
• Limitation, in case of certain error codes certain functions are im-
paired or limited to protect the machine and operator.
0
• Action, information of what should be checked to find the cause of
the error code.
• Diagnostic menu, reference to suitable diagnostic menu to rectify
016080
0
the problem, read signal value or check the function.
In addition to the explanation of the display figure, the description
Active error codes are shown in Active errors of the diagnostic menus contains reference to circuit diagrams that
are found in section E Schematics and reference to function group
Field d: Error code. for further information about functions and components.
, and
• The reference leads to the function or component that the error
10:23 code is linked to, this field should be used to seek more information
ERROR HISTORY 1/12 if necessary. Various types of information can be located via each
reference.
1 Sections 0-12 contain a description of the function and its compo-
0 d
2012-06-23 10:23 nents, component locations and work instructions for different
tasks.
2
d
0 2012-06-22 14:15
3
d
2012-06-22 13:01
016081
Inactive and active error codes are shown in Error

history
Field d: Error code.

D:4 D Error codes – Error codes
Error code menu, description

The control and monitoring system's display is divided into a number of
fields where the information is shown (see the figures to the left).
• Field a: Error code level. Shown with a symbol.
• Field b: Driver's action. Shown with a symbol.
• Field c: Component that generated the error code. Shown with a
symbol.
• Field d: Error code.
• Field e: Number of errors. For Error history the number is limited to
the last 50 errors.
• Field f: Number of errors on each error code level.
• Field g: Date and time.
Field a: Error code level
10:23
ACTIVE ERRORS e The control and monitoring system gives error code information in three
f levels which are indicated with a symbol on the display unit.
0 d
Symbol Action
STOP
0 a b c Indicates a serious malfunction that may jeopardise
the operator's safety or cause machine failure. The
error code must be attended to immediately.
015229
WARNING
Active error codes are shown in Active errors Indicates malfunction in machine that should be tak-
, and en care of as soon as possible.
10:23
ERROR HISTORY e
f INFORMATION
1 Information to the operator that something should
0 a d c
g be rectified, e.g. broken bulb. Rectify the cause at a
suitable opportunity. Instructions for action are nor-
2 111/ 5160- / 3 mally found in Operator's manual, chapter 6 Inspec-
0 2011-09-19 10:23 tion and maintenance.
3 0/ 0- / 0
0000-00-00 00:00 Field b: Driver's action
015230
0
The control system provides information about what action the driver
should take. The information is indicated by a symbol on the display.
Inactive error codes are shown in Error history
Symbol Action
Carry out action in accordance with daily inspection,
see Operator's manual, chapter 6 Inspection and
maintenance.
Errors that must be repaired by trained personnel.

Any of the machine's functions that do not work fully.
Critical errors.
Errors that may jeopardise the machine or safety,
such as low oil pressure or an overload. Stop the
machine and repair the error.
Read the operator's manual.

Field c: Affected function
Symbol Function Symbol Function Symbol Function

Engine Fuel level DEF level
Temperature electric mo- Temperature electric mo- Combifilter

tor drive tor hydraulics
Exhaust gas temperature Air filter Coolant level engine
Coolant temperature Oil level engine Preheating engine

engine
Transmission Oil temperature torque Lock-up, torque converter

converter
Diff lock Oil level transmission Oil pressure transmission
Oil temperature Driveline/Axle Tyre pressure

transmission
Regulator (inverter) Brakes Brake pressure
Parking brake Oil temperature brake Steering

system
Suspension Load handling Control levers
Lift/lower Lift/lower Extension
Side shift Side shift Spreading (positioning)
Spreading (positioning) Rotation Tilt
Tilt lock Tilt Levelling
Levelling lock Levelling Contact twistlocks
Locked twistlocks Unlocked twistlocks Contact top lift attachment

Symbol Function Symbol Function Symbol Function

Contact side lift Bottom lift attachment Support jacks
attachment
Control system Boom angle Boom length
Scale Overload system Overload system
Height limit Frame, body, cab and Hour meter

accessories
Seat Reversible operator\qs Air conditioning

seat
ECH, ECC Fresh air filter Pause heater
Temperature water heater Recirculation Washer fluid
Wiper Revolving or flashing Lighting

beacon
Horn Heater rear window/rear Length displacement cab

view mirrors
Vertically adjustable cab Tiltable cab Central lubrication
Hydraulic oil filter Hydraulic oil temperature Battery charging
CAN bus CAN bus drive-train

Field d: Error code number

The control system gives error codes from the machine's sub-systems:
Unit number (AAA)
1 2 3
The first part of the error code indicates the unit that generated the er-
10:23 ror. The following units can generate error codes:
ACTIVE ERRORS
Unit number Unit
AAA/ BCCCC-DD E
0 1–99 Units in the RedCAN system
100 Engine
0 110 Transmission
210 Exhaust system
015233
0
Component type (B)
Example illustration error codes A letter before the numbers in the component number indicates the
component in question. There is no component type (B) for error codes
1. Unit number (AAA)
from the engine and transmission.
2. Component number (SPN) (BCCCC-DD)
3. Type of error (FMI) (E) The following component types can be identified:
Prefix Description
A Control panel Drive-train/Wiper
B Converter from non-electric to electric signals or vice versa. Example: inductive sensor.
C Capacitor
D Binary element, delay unit, memory. Example: control unit.
E White light. Example: work lighting.
F Protective device. Example: fuse.
G Alternator, power supply device. Example: battery.
H Signal device. Example: horn, brake lights.
K Relay, contactor. Example: power relay ignition key lock.
M Motor. Example: electric motor.
P Measuring instrument, testing equipment. Example: hour meter.
Q Battery disconnector
R Resistor. Example: potentiometer.
S Electric switch for control circuit, selector. Example: switch.
V Diode
W Antenna
X Outlet/socket, connecting device. Example: connection terminal.
Y Electrically controlled mechanical device. Example: solenoid valve, hydraulic valve.
Component (CCCC)
The numbers are a unique number (SPN) to locate the faulty
component.

Component location (DD)

In cases where multiple components have the same component num-
ber, two letters or the serial number 1-9 are added to make the error
code unique. The letters often specify a location on the machine. There
is no component location (DD) for error codes from the engine and
transmission.
The following placements are used:
Letters Location
10 Left
20 Right
30 Upper
40 Lower
100 Front
110 Left front
120 Right front
200 Rear
210 Left rear
220 Right rear
Type of error (EE)

The FMI code indicates the type of error.
Table Specifications FMI
FMI Description SAE-text

0 Too high value. Data valid, but higher than normal operating range.
1 Value too low. Data valid, but lower than normal operating range.
2 Incorrect data. Intermittent or incorrect data.
3 Electrical problem. Abnormally high voltage or short-circuit to higher voltage.
4 Electrical problem. Abnormally low voltage or short-circuit to lower voltage.
5 Electrical problem. Abnormally low current or open circuit.
6 Electrical problem. Abnormally high current or short-circuit to ground.
7 Mechanical problem. Incorrect response from mechanical system.
8 Mechanical problem or electrical problem. Abnormal frequency.
9 Communication error. Abnormal update rate.
10 Mechanical problem or electrical problem. Abnormally wide variations.
11 Unknown malfunction. Non-identifiable malfunction.
12 Component error. Incorrect unit or component.
13 Incorrect calibration. Values outside calibration values.
14 Unknown malfunction. Special instructions.
15 Too high value. Data valid, but higher than normal operating range: The least serious
level.
16 Too high value. Data valid, but higher than normal operating range. Moderately se-
vere level.
17 Value too low. Data valid, but below normal operating range: The least serious level.
18 Value too low. Data valid, but below normal operating range: Moderately severe
level.
19 Communication error. Received network data in error.

FMI Description SAE-text

20 Data too high. Data valid, but higher than normal value.
21 Data too low. Data valid, but lower than normal value.
22-30 Reserved for SAE assignment.
31 FMI is not available or the condition that Not available or condition exists.
is identified by the SPN exists.
32 Electrical problem. Abnormally high resistance or short-circuit to higher voltage.
33 Electrical problem. Abnormally low resistance or short-circuit to lower voltage.
34 Time exceeded. Time exceeded.
35 Communication error. CAN bus error.
36 Communication error. Drive routine error.
37 Communication error. Overflow.
38 Communication error. Error passive state.
39 Communication error. Baudrate.
40 Communication error. Control unit lost (stops sending messages) after start-up.
41 Communication error. Control unit missing during start-up.
42 Communication error. CAN bus segment after control unit is incorrect. Normal side.
43 Communication error. CAN bus segment after control unit is incorrect. RedCAN side.
44 Communication error. Control unit incorrectly positioned RedCAN circuit.
45 Communication error. Checksum error in the control unit.
Field e: Number of error codes

Specifies the number of menu pages with active error codes in Active
errors and the number of menu pages with inactive error codes in Error
history.
Field f: Number of errors on each error code level
Specifies the number of active error codes on each error code level.
Field g: Date and time
Specifies the date and time when the error code was confirmed.

Reading out error code

NOTE
In the event of an error code, perform the actions recommended
in the error code table to identify the fault.
Error codes are stored as active and inactive. Active errors are
shown in the error code menu.
Always use error code menus for reading error codes, otherwise
there is a risk of missing error codes.
1. Turn the ignition key lock to position I.
WARNING
Risk of machine damage.
In the event of error codes of level "WARNING" and
"STOP", serious machine damage may result if the en-
gine is started.
Do not start the engine until the cause of the error code
has been identified or repaired.
2. Select the menu for ACTIVE ERRORS or ERROR HISTORY with

10:23
CUSTOMER SETTINGS
or and confirm with .
0
014978
10:23
ACTIVE ERRORS e
f
0 d
0 a b c
015229
Active error codes are shown in Active errors

3. The error code list is shown on the display. Error code is shown on
10:23
the display where the field d shows the error code number together
ERROR HISTORY e with field e that shows the number of errors.
f
1 Navigate the error code list with the function keys and . Leave
0 a d c the error code list by pressing the function key .
g
2 111/ 5160- / 3
0 2011-09-19 10:23 NOTE
3 0/ 0- / 0
If the error code is not in the error code list, this may be due to
0000-00-00 00:00 the following:
015230
0
– conditions for error detection are no longer valid, e.g. control
lever has been released or the engine turned off.
Inactive error codes are shown in Error history – loose contact.
Error codes disappear from the list when the cause has been
remedied.

4. Note error code number (field d) to avoid forgetting.

5. Use the error code tables to find more information about the error
code.
6. After the remedial action, check that no active error codes remain
for the function in question.

D:12 D Error codes – Engine
D.1 Engine
Error codes engine (engine option Volvo
TAD853VE, TAD873VE)
The error codes for the engine are sorted in numerical order. The table
contains the following information:
• SPN - Specifies component, SPN is the error code as it is shown in
the machine, in accordance with SAE J1939.
• FMI - Specifies type of fault, see Table Specifications FMI, page
D:8.
• Supplier code - Specifies the error code in accordance with the
supplier's specification.
• Description - Gives a description of the error code as well as any
limitation that may arise in the machine for the error code in
question.
• Action - Specifies recommended action in summarised form with
the troubleshooting action that should be taken first.
• Connection and component - Specifies component number and
connector pin on the control unit and component for additional trou-
bleshooting with the wiring diagram.
• Diagnostic menu - Specifies which diagnostic menu can be used to
show the signal in the display's diagnostic menus.
Note that the engine also shows error codes for Control unit after-treat-
ment system (ACM). Certain components are connected to this control
unit, which is shown by "ACM" being first in the "Connection and com-
ponent" field.

Table Error codes engine (engine option Volvo TAD853VE, TAD873VE)
SPN FMI Supplier Description Limitation Action Connections Diagnostic menu

code and components
28 2 - + switch, no or weak signal. No limitation. Check the cable harness be- - -
tween control unit and
component.
Check the component.
29 2 - Signal from accelerator pedal, no Accelerator pedal con- Check the cable harness be- D7940/A:2 -
or weak signal. nected to A:2 not working tween control unit and
correctly. component.
29 3 - Signal from accelerator pedal, Accelerator pedal con- Check the cable harness be- D7940/A:2 -
abnormally high voltage or short nected to A:2 not working tween control unit and
circuit to higher voltage. correctly. component.
abnormally low voltage or short nected to A:2 not working tween control unit and
circuit to lower voltage. correctly. component.
abnormally low current or open nected to A:2 not working tween control unit and
circuit. correctly. component.
51 3 P02E612 Sensor damper position, abnor- Engine speed limited to idle. Check the cable harness be- D7940/B:24 -
mally high voltage or short circuit tween control unit and
to higher voltage. component.
51 5 P02E613 Sensor damper position, abnor- Engine speed limited to idle. Check the cable harness be- D7940/B:17 -
mally low current or open circuit. tween control unit and D7940/B:18
Workshop Manual DRG420–450 ECOefficient

component. D7940/B:24
51 7 P02E699 Sensor damper position, calibra- Throttle not working. Check that the throttle is not D7940/B:17 -
tion error. binding during opening and D7940/B:18
closing. D7940/B:24
Check that throttle movement
runs smoothly without jerking
during self-calibration which
takes place during ignition.
Check the sensor.
51 12 P02E601 Sensor damper position, general No limitation. Check the cable harness be- D7940/B:17 -
electrical problem. tween control unit and D7940/B:18
VDRG09.01GB
D:13
Table Error codes engine (engine option Volvo TAD853VE, TAD873VE) (continued) D:14

code and components
VDRG09.01GB
51 13 P02E697 Sensor damper position, me- Engine speed limited to idle. Check that the throttle is not D7940/B:17 -
chanical defect. Engine difficult to start or binding during opening and D7940/B:18
does not start at all. closing. D7940/B:24
Check the sensor.
91 0 P012085 Signal from accelerator pedal, Speed limitation. Check error codes for accelerator D7940/A:1 1.1 Controls &
value too high. pedal and CAN communication Instr 1/XX DIAG-
in the machine. NOSE, page 8:29
91 2 - Signal from accelerator pedal, no Accelerator pedal con- Check the cable harness be- D7940/A:1 1.1 Controls &
or weak signal. nected to A:1 not working tween control unit and Instr 1/XX DIAG-
correctly. component. NOSE, page 8:29
91 3 - Signal from accelerator pedal, Accelerator pedal con- Check the cable harness be- D7940/A:1 1.1 Controls &
abnormally high voltage or short nected to A:1 not working tween control unit and Instr 1/XX DIAG-
circuit to higher voltage. correctly. component. NOSE, page 8:29
abnormally low voltage or short nected to A:1 not working tween control unit and Instr 1/XX DIAG-
circuit to lower voltage. correctly. component. NOSE, page 8:29
D Error codes – Engine
abnormally low current or open nected to A:1 not working tween control unit and Instr 1/XX DIAG-
circuit. correctly. component. NOSE, page 8:29

91 9 P012082 Signal from accelerator pedal, No limitation. Check error codes for accelerator D7940/A:1 1.1 Controls &
communication error. pedal and CAN communication Instr 1/XX DIAG-
91 19 P012083 Signal from accelerator pedal, Speed limitation. Check error codes for accelerator D7940/A:1 1.1 Controls &
signal error. pedal and CAN communication Instr 1/XX DIAG-
94 0 P008B97 High fuel pressure. No limitation. Check if: D7940/B:16 -
• fuel filter is clogged.
• fuel pressure sensor is faulty.
• strainer/filter in high-pres-
sure pump fuel inlet (from
fuel filter) is clogged.
Table Error codes engine (engine option Volvo TAD853VE, TAD873VE) (continued)

code and components
94 3 P253912 Sensor fuel pressure, abnormally No limitation. Check the cable harness be- D7940/B:16 -
high voltage or short circuit to tween control unit and
higher voltage. component.
Check the sensor.
low current or open circuit. tween control unit and
component.
Check the sensor.
94 12 P253901 Sensor fuel pressure, general No limitation. Check the cable harness be- D7940/B:16 -
electrical fault. tween control unit and
component.
Check the sensor.
94 18 P008A00 Sensor fuel pressure, low fuel Reduced output and torque. Check the fuel level in the tank. D7940/- -
pressure. Error code for imbalance Troubleshoot the fuel system
between cylinders. after leakage or trapped fuel lines.
Change the fuel filter.
Check sensor fuel pressure.
Remove and clean the safety
valve in the feed pump.
97 0 P226985 Water in fuel. No limitation. Drain water separator. D7940/- -
97 4 P226411 Sensor, water in fuel, abnormally No limitation. Check the cable harness be- D7940/B:8 -
low voltage or short circuit to low- tween control unit and
er voltage. component.
97 12 P226401 Sensor water in fuel, general No limitation. Check the cable harness be- D7940/B:8 -
electrical fault. tween control unit and

component.
98 1 P250F00 Low oil level engine. Warning indication. Check the oil level in the engine. D7940/-
Check that there is no oil leakage.
Check sensor oil level engine.
98 4 P250A11 Sensor oil level engine, abnor- No limitation. Check the cable harness be- D7940/B:4
mally low voltage or short circuit tween control unit and
to lower voltage. component.
98 5 P250A13 Sensor oil level engine, abnor- No limitation. Check the cable harness be- D7940/B:4
mally low current or open circuit. tween control unit and
component.
98 18 P108600 Low oil level engine. Warning for low oil level. Check the oil level in the engine. D7940/-
Check that there is no oil leakage.
VDRG09.01GB
D:15

code and components
VDRG09.01GB
100 1 P052400 Oil pressure in engine too low. Reduced engine power or Check the engine oil level and oil D7940/- 1.8 Lubrication 1/
engine shutdown. quality. XX DIAGNOSE,
Change the engine oil and oil page 8:34
filter.
Check sensor oil pressure.
Replace the pressure control
valve at the oil pump.
Replace oil pump.
100 3 P052012 Sensor oil pressure, abnormally No limitation. Check the cable harness be- D7940/B:11 1.8 Lubrication 1/
high voltage or short circuit to tween control unit and XX DIAGNOSE,
higher voltage. component. page 8:34
low current or open circuit. tween control unit and XX DIAGNOSE,
component. page 8:34
100 18 P109300 Low oil pressure in the engine. Warning for low oil pressure. Check the engine oil level and oil D7940/- 1.8 Lubrication 1/
quality. XX DIAGNOSE,
filter.
Replace oil pump.

102 0 P111800 High charge air pressure. Reduced engine power. Check hoses and connections for D7940/-
the control of charge air pressure.
Leakage causes increased

charge air pressure.
Check the lever movement on
the wastegate valve
Check the charge air pressure
sensor.
Check solenoid valve charge air
pressure control.
Check the turbo.
102 3 P010512 Sensor charge air pressure, ab- Engine power is limited Check the cable harness be- D7940/A:22 -
normally high voltage or short cir- gradually depending on tween control unit and
cuit to higher voltage. measurement values from component.
other sensors. Check the component.
102 5 P010513 Sensor charge air pressure, ab- Engine power is limited Check the cable harness be- D7940/A:22 -
normally low current or open gradually depending on tween control unit and
circuit. measurement values from component.
other sensors. Check the component.

code and components
102 16 P111600 High charge air pressure. No limitation. Check hoses and connections for D7940/-
the control of charge air pressure. 1.7 Cooling sys-
Leakage causes increased tem 8/XX DIAG-
charge air pressure. NOSE, page 8:33
the wastegate valve
sensor.
pressure control.
Check the turbo.
105 0 P111A00 Charge air temperature too high. Reduced engine power. Check that the engine tempera- D7940/-
ture is normal. 1.7 Cooling sys-
Check the coolant level. tem 8/XX DIAG-
Clean the intercooler and radiator. NOSE, page 8:33
Check the charge air tempera-
ture sensor.
105 4 P011011 Sensor charge air temperature, No limitation. Check the cable harness be- D7940/A:47
abnormally high current, low volt- tween control unit and
age or short circuit to ground. component.
Check the sensor.
abnormally low current or open tween control unit and D7940/A:11
circuit. component.
Check the sensor.

105 16 P111900 High charge air temperature. No limitation. Check that the engine tempera- D7940/-
ture is normal. 1.7 Cooling sys-
Check the coolant level. tem 8/XX DIAG-

Clean the intercooler and radiator. NOSE, page 8:33
ture sensor.
107 0 P10F800 Low pressure between air filter No limitation. Change the air filter. D7940/- -
and turbo.
107 3 P100712 Sensor air pressure intake, ab- No limitation. Check the cable harness be- D7940/A:29 -
normally high voltage or short cir- tween control unit and
cuit to higher voltage. component.
Check the sensor.
normally high current, low volt- tween control unit and
VDRG09.01GB
D:17

code and components
VDRG09.01GB
normally low current or open tween control unit and
circuit. component.
Check the sensor.
107 12 P100701 Sensor air pressure intake, gen- No limitation. Check the cable harness be- D7940/A:29 -
eral electrical problem. tween control unit and
component.
Check the sensor.
108 5 P222613 Sensor air pressure (in control No limitation. Replace control unit engine D7940/- -
unit engine), abnormally low cur- (D7940).
rent or open circuit.
110 0 P021700 Coolant temperature too high. Reduced engine power. Check the coolant level. D7940/-
Check the drive of the cooling
fans.
Check that radiator is clean.
Check the condition and tension
of the drive belts.
Bleed the cooling system.
Check or change the thermostat
coolant.
Check sensor coolant
temperature.
Replace the pressure cap on the
expansion tank.
Clean the cooling system.

Replace the coolant pump.
110 4 P011511 Sensor coolant temperature, ab- Engine difficult to start. Check the cable harness be- D7940/B:27 -
normally high current, low volt- Idle control reduced. tween control unit and

Check the sensor.
normally low current or open Idle control reduced. tween control unit and
circuit. component.

code and components
110 16 P111E00 High coolant temperature. No limitation. Check the coolant level. D7940/-
fans.
of the drive belts.
coolant.
temperature.
expansion tank.
111 1 P256000 Low coolant level. No limitation. Check the coolant level; fill if D7940/- -
necessary.
If the coolant level is low, pres-
sure test the cooling system to
find leakage.
Check the cable harness be-
component.
111 3 P255612 Sensor coolant level, abnormally No limitation. Check the cable harness be- D7940/B:23 -


high current, low voltage or short tween control unit and
circuit to ground. component.
component.
111 18 P111D00 Low coolant level. No limitation. Check the coolant level; fill if D7940/- -
necessary.
find leakage.
component.
VDRG09.01GB
D:19

code and components
VDRG09.01GB
131 3 P047012 Pressure sensor exhaust gases, Engine brake, low Check the cable harness be- D7940/B:12 -
abnormally high voltage or short performance. tween control unit and
circuit to higher voltage component.
abnormally low current or open performance. tween control unit and
circuit. component.
131 12 P047001 Pressure sensor exhaust gases, - Check the cable harness be- D7940/B:12 -
general electrical problem. tween control unit and
component.
157 0 P008800 Fuel pressure, too high. Reduced engine power. Check the cable harness be- - -
tween control unit and fuel pres-
sure regulator (MPROP). Check
the fuel pressure regulator's sig-
nal with an oscilloscope.
tween control unit and ePRV.
Check ePRV's signal with an
oscilloscope.
sure sensor. Check the fuel

pressure with VODIA or by meas-
uring the voltage.


code and components
157 1 P008700 Fuel pressure, too low. Engine may be shut down. Check that the fuel inlet valve is - -
The engine turns over but open and that the fuel lines are
does not start. correctly connected. Carry out a
visual inspection of the fuel sys-
tem for trapped hoses/pipes and
for leakage. Check the fuel filters.
Bleed the fuel system.
Run the engine from a separate
stand-alone fuel tank. Check for
inward leakage of air between
the high-pressure pump and the
tank. Check for air leakage.
uring the voltage. P (normal at
idle) = 30-40 MPa, P (start) ap-
proximately 20-30 MPa. If the en-
gine can be started, check at
which fuel pressure the error
code occurs. If the engine cannot
be started, check the fuel pres-
sure when the engine turns over.


oscilloscope.
157 4 P019011 Pressure sensor fuel, abnormally Reduced engine power. Check the cable harness be- D7940/A:19 -
component.
157 7 P019062 Pressure sensor fuel, mechanical Reduced engine power. Check the cable harness be- D7940/A:19 -
problem. tween control unit and
component.
VDRG09.01GB
D:21

code and components
VDRG09.01GB
157 12 P019001 Pressure sensor fuel, general Reduced engine power. Check the cable harness be- D7940/A:19 -
electrical problem. tween control unit and
component.
157 14 P00C600 Pressure sensor fuel, fuel pres- The engine turns over but Check that the fuel inlet valve is - -
sure too low when engine turns does not start. open and that the fuel lines are
over. correctly connected. Carry out a


oscilloscope.

code and components
157 16 P114700 Pressure sensor fuel, fuel pres- Reduced engine power. Check the cable harness be- - -
sure too high. tween control unit and fuel pres-
proximately 20-30 MPa.
oscilloscope.
If the high-pressure pump has
been removed/replaced, check
the installation of the pump.
158 2 P05611F Voltage feed, Control unit engine Uneven torque. Perform a correct shutdown. - -
(D7940). Check the cable harness be-
tween control unit and battery.
Clean the connection points.
Check that there are no voltage
losses between batteries and
control unit.
Check the battery disconnector.
158 3 - Voltage feed, Control unit, engine Voltage feed from the con- Check the cable harness be- - -
(D7940), abnormally high voltage trol unit may be affected. tween the control unit and its

or short circuit to higher voltage. power supply.
Check that the control unit has
the correct power supply.
158 4 - Voltage feed, Control unit, engine Voltage feed from the con- Check the cable harness be- - -
(D7940), abnormally high current, trol unit may be affected. tween the control unit and its
low voltage or short circuit to power supply.
ground. Check that the control unit has
172 4 P00D911 Sensor ambient temperature, ab- Engine difficult to start at Check the cable harness be- D7940/B:31 -
normally high current, low volt- low temperatures. tween control unit and
VDRG09.01GB
D:23

code and components
VDRG09.01GB
normally low current or open low temperatures. tween control unit and
circuit. component.
173 0 P242800 Exhaust gas temperature too Reduced engine power. Check that the exhaust pipe has D7940/- -
high. not been damaged and that there
are no restrictions.
Check the sensor.
Check the exhaust system's back
pressure.
173 16 P112E00 High exhaust gas temperature. No limitation. Check that the exhaust pipe has D7940/- -
not been damaged and that there
Check the sensor.
pressure.
175 0 P029800 Oil temperature too high. Reduced engine power. Check the oil level in the engine D7940/- 1.8 Lubrication 1/
and that there is no leakage. XX DIAGNOSE,
Check the coolant level and en- page 8:34
gine temperature.
Clean the lubrication system.
Replace the drain valve for the oil
cooler.
Check the sensor.

175 4 P019511 Sensor oil temperature, abnor- Speed limitation. Check the cable harness be- D7940/A:31 1.8 Lubrication 1/
mally high current, low voltage or tween control unit and XX DIAGNOSE,
short circuit to ground. component. page 8:34

175 5 P019513 Sensor oil temperature, abnor- No limitation. Check the cable harness be- D7940/A:31 1.8 Lubrication 1/
mally low current or open circuit. tween control unit and XX DIAGNOSE,
175 16 P112500 High oil temperature. No limitation. Check the oil level in the engine D7940/- 1.8 Lubrication 1/
gine temperature.
cooler.
Check the sensor.

code and components
190 0 P021900 Engine speed too high. Engine speed is limited Stop the machine and switch off D7940/- 1.9 Control Sys-
the engine. Investigate the cause tem 1/XX DIAG-
of the high engine speed when NOSE, page 8:34
the engine has been stopped.
190 16 P119D00 Engine speed too high. Engine speed is limited Stop the machine and switch off D7940/- 1.9 Control Sys-
the engine. Investigate the cause tem 1/XX DIAG-
of the high engine speed when NOSE, page 8:34
411 3 P040912 Pressure sensor, exhaust gas re- EGR valve closed. Check the cable harness be- D7940/A:21 -
circulation (EGR), abnormally tween control unit and
high voltage or short circuit to component.
higher voltage. Check the component.
411 5 P040913 Pressure sensor, exhaust gas re- EGR valve closed. Check the cable harness be- D7940/A:21 -
circulation (EGR), abnormally tween control unit and
low current or open circuit. component.
411 12 P040901 Pressure sensor, exhaust gas re- - Check the cable harness be- D7940/A:21 -
circulation (EGR), general electri- tween control unit and
cal problem. component.
412 0 P112100 EGR temperature too high. Reduced engine power. Clean the EGR cooler. - -
412 4 P040A11 Temperature sensor, exhaust gas - Check the cable harness be- D7940/B:48 -
recirculation (EGR), abnormally tween control unit and
high current, low voltage or short component.
circuit to ground. Check the component.

recirculation (EGR), abnormally tween control unit and
low current or open circuit. component.
recirculation (EGR), general elec- tween control unit and
trical problem. component.
412 16 P112200 EGR temperature higher than Reduced engine power. Clean the EGR cooler. - -
normal.
626 2 - Signal from start button, no or Start button has jammed. Check the cable harness be- - 1.11 Start & Stop
weak signal. tween control unit and 2/XX DIAGNOSE,
VDRG09.01GB
D:25

code and components
VDRG09.01GB
626 3 P100212 Relay preheating, abnormally Engine difficult to start at Check the cable harness be- D7940/B:25 -
high voltage or short circuit to low temperatures. tween control unit and
626 4 P100211 Relay preheating, abnormally Engine difficult to start at Check the cable harness be- D7940/B:25 -
high current, low voltage or short low temperatures. tween control unit and
626 5 P100213 Relay preheating, abnormally low Engine difficult to start at Check the cable harness be- D7940/B:25 -
current or open circuit. low temperatures. tween control unit and
component.
628 2 P060741 Memory error in Control unit en- The engine does not start. Reprogram the control unit. D7940/- -
gine (D7940). Replace the control unit.
628 2 - Control unit, engine (D7940), The engine does not start. Reprogram the control unit. D7940/- -
program memory Replace the control unit.

636 7 P001676 Sensor rpm camshaft, incorrect The engine takes longer to Check the cable harness be- D7940/A:45 -
assembly. The signal does not start than normal or does tween control unit and D7940/A:46
correspond with the signal from not start at all. component.
sensor rpm crankshaft. Rough running. Check the component's
High fuel consumption. assembly.
Check the signal from the com-
ponent with an oscilloscope.
Compare the signals from sensor
rpm camshaft and sensor rpm
crankshaft with an oscilloscope.

code and components
636 8 P034038 Sensor speed, camshaft, abnor- The engine takes longer to Check the cable harness be- D7940/A:45 -
mal frequency. start than normal. tween control unit and D7940/A:46
component.
Check the component's
assembly.
636 9 P034031 Sensor rotation speed camshaft, The engine takes longer to Check the cable harness be- D7940/A:45 -
no signal. start than normal. tween control unit and D7940/A:46
component.
637 2 P03351F Sensor rpm crankshaft, no or The engine takes longer to Check the component's D7940/A:37 1.9 Control Sys-
weak signal. start than normal. assembly. D7940/A:38 tem 1/XX DIAG-
Reduced torque. Check the signal from the com- NOSE, page 8:34
Rough running. ponent with an oscilloscope.
High fuel consumption. Check the component.
637 8 P033538 Sensor speed, crankshaft, abnor- The engine takes longer to Check the component's D7940/A:37 1.9 Control Sys-
mal frequency. start than normal. assembly. D7940/A:38 tem 1/XX DIAG-
Reduced torque. Clean the component. NOSE, page 8:34
Rough running. Check the signal from the com-
High fuel consumption. ponent with an oscilloscope.

637 9 P033531 Sensor rotation speed flywheel, The engine takes longer to Check the cable harness be- D7940/A:37 1.9 Control Sys-
no signal. start than normal. tween control unit and D7940/A:38 tem 1/XX DIAG-
Reduced torque. component. NOSE, page 8:34

639 2 U001088 Communication error (Backbone Engine switched off: engine Check all data links between ma- D7940/B:51 -
1) Control unit engine. cannot be started. chine, transmission, engine and D7940/B:55
Engine running: the engine after-treatment system. ACM/B:10
can only be stopped by us- ACM/B:14
ing the emergency stop.
No engine information is
shown in the machine.
VDRG09.01GB
D:27

code and components
VDRG09.01GB
639 2 - Communication error (Backbone Engine switched off: engine Check all data links between D7940/B:51 -
1) Control unit engine. cannot be started. Control unit engine and Back- D7940/B:55
Engine running: the engine bone 1. ACM/B:10
639 9 - Communication error (Backbone Engine switched off: engine Check the fuse on Control unit, D7940/B:51 -
1) Control unit engine. cannot be started. engine. D7940/B:55
Engine running: the engine Check the cable harness be- ACM/B:10
can only be stopped by us- tween the control unit and "smart ACM/B:14
ing the emergency stop. relay" module.
641 0 P004577 Variable turbo geometry, value Reduced engine power. Check the movement of the con- - -
too high. trol lever on the VGT actuator.
Check the VGT actuator.
641 2 P256214 Actuator, variable turbo geometry. Reduced engine power. Replace the VGT unit. - -
641 3 P006E17 Actuator, variable turbo geometry, Reduced engine power. Check the cable harness be- - -
abnormally high voltage or short tween control unit and
circuit to higher voltage. component.
Replace the VGT actuator.
641 5 P004513 Actuator, variable turbo geometry, Reduced engine power. Check the cable harness be- - -
abnormally low amperage or tween control unit and
open circuit. component.

641 6 P004519 Actuator, variable turbo geometry, Reduced engine power. Check the cable harness be- - -
abnormally high current. tween control unit and
component.
641 9 U010C00 Communication error between Reduced engine power. Check the engine's CAN - -
actuator, variable turbo geometry, communication.
and Control unit, engine (D7940). Check the voltage feed to the
VGT unit.
641 11 P004592 Actuator, variable turbo geometry, Reduced engine power. Replace the VGT actuator. - -
no measurement values.
641 17 P112B00 Variable turbo geometry temper- Reduced engine power. Check the heat radiation that - -
ature higher than normal. may affect the VGT unit.
Replace the VGT unit.

code and components
647 3 P048012 Magnetic clutch cooling fan, ab- Cooling fan's drive locked to Check the cable harness be- D7940/B:49 -
normally high voltage or short cir- 100%. tween control unit and
647 4 P048011 Magnetic clutch cooling fan, ab- Cooling fan's drive not work- Check the cable harness be- D7940/B:49 -
normally high current, low volt- ing, risk of overheating. tween control unit and
normally low amperage or open 100%. tween control unit and
circuit. component.
651 3 P020112 Injector cylinder 1, abnormally Engine only runs on 5 cylin- Check the cable harness be- D7940/A:56 -
high voltage or short circuit to ders, sounds rough and has tween control unit and D7940/A:59
higher voltage. reduced power. component.
Protected mode Limp-home Check the component.
on other injectors.
high current, low voltage or short ders, sounds rough and has tween control unit and D7940/A:59
circuit to ground. reduced power. component.
on other injectors.
low current or open circuit. ders, sounds rough and has tween control unit and D7940/A:59
reduced power. component.


on other injectors.
on other injectors.
VDRG09.01GB
D:29

code and components
VDRG09.01GB
on other injectors.
on other injectors.
on other injectors.
on other injectors.

on other injectors.
on other injectors.

code and components
on other injectors.
on other injectors.
677 3 P061512 Starter relay on the starter motor, The engine does not start. Check the cable harness be- D7940/B:29 -
abnormally high voltage or short tween control unit and D7940/B:37
677 4 P061511 Start relay on starter motor, ab- The engine does not start. Check the cable harness be- D7940/B:29 -
normally high current, low volt- tween control unit and D7940/B:37
677 5 P061513 Starter relay on the starter motor, The engine does not start. Check the starter relay on the D7940/B:29 -
abnormally high voltage or short starter motor. D7940/B:37
circuit to higher voltage. Check the cable harness be-

component.
normally high current. tween control unit and D7940/B:37

component.
679 3 P009012 Fuel pressure regulator Reduced engine power. Check the cable harness be- D7940/A:12 -
(MPROP), abnormally high volt- Open ePRV. tween control unit and D7940/A:16
age or short circuit to higher component.
voltage. Check the fuel pressure regulator
(MPROP) with an oscilloscope.
(MPROP), abnormally high cur- Open ePRV. tween control unit and D7940/A:16
rent, low voltage or short circuit component.
to ground. Check the fuel pressure regulator
VDRG09.01GB
D:31

code and components
VDRG09.01GB
679 7 P228D72 Fuel pressure regulator Reduced engine power. Check the cable harness be- D7940/A:12 -
(MPROP), mechanical problem, tween control unit and fuel pres- D7940/A:16
stuck in open position. sure sensor. Check the fuel
idle) = 30-40 MPa. Check at
code occurs.
729 5 P054013 Preheating element, abnormally Engine difficult to start at Check the fuse for the D7940/B:7 -
low current or open circuit. low temperatures. component.
component.
729 6 P054070 Relay preheating, mechanical Engine difficult to start at Check the cable harness be- D7940/B:7 -
problem, locked in engaged low temperatures. tween control unit and D7940/B:25
mode. component.

729 7 P05407F Relay preheating, mechanical Engine difficult to start at Check the cable harness be- D7940/B:7 -
problem, locked in disengaged low temperatures. tween control unit and
mode. component.
729 12 P054001 Preheating element, general Preheating cannot be acti- Check the fuse for the D7940/B:7 -
electrical problem. vated, starting problems in component.
cold weather. Check the cable harness be-
component.
970 3 P100112 Stop button on engine, abnor- The engine is switched off Check the cable harness be- D7940/A:27 -
mally high voltage or short circuit and cannot be started. tween control unit and

code and components
mally high current, low voltage or and cannot be started. tween control unit and
short circuit to ground. component.
mally low current or open circuit. and cannot be started. tween control unit and
component.
970 11 P100192 Stop button on engine, activated. Engine cannot be started. Reset the switch and switch the D7940/A:27 -
ignition on and off.
Check the cable harness to A27
on the control unit.
970 14 P100190 Stop button on engine, mechani- Engine cannot be started. Check the Stop button. D7940/A:27 -
cal problem. Jammed in de- Check the cable harness to A27
pressed position. on the control unit.
1188 3 P024312 Actuator intercooler pressure Reduced engine power. Check the cable harness be- D7940/B:38 -
control, abnormally high voltage tween control unit and
or short circuit to higher voltage. component.
1188 4 P024311 Actuator, intercooler pressure Reduced engine power. Check the cable harness be- D7940/B:38 -
control, abnormally high current, tween control unit and
low voltage or short circuit to component.
ground.
control, abnormally low current or tween control unit and

1239 14 P009400 Less fuel leakage. - Check the high-pressure system - -
for leakage.
Check ePRV's signal with an os-
cilloscope. Check the return line
from ePRV.
uring the voltage.
1347 7 P06279C Fuel pressure pump, low flow Reduced engine power. Check for other error codes that - -
may be the cause.
VDRG09.01GB
D:33

code and components
VDRG09.01GB
1485 7 P068573 Engine relay active. ECM relay activated. Bat- Replace main relay. - -
tery is discharged.
1639 3 P052612 Sensor fan speed, abnormally The cooling fan does not Check the cable harness be- D7940/A:35 -
high voltage or short circuit to disengage. tween control unit and
1668 2 U008088 Communication error (Engine No limitation. Check the cable harness be- - -
subnet) control unit engine, un- tween the control unit and com-
reasonable signal. ponents on Engine subnet.
1761 3 P203A12 Sensor, DEF level, abnormally No limitation. Check the wiring between Con- ACM/B:46 1.6 Intake Ex-
P203A86 high voltage or short circuit to trol unit after-treatment system haust 4/XX DIAG-
higher voltage. (ACM) and the component. NOSE, page 8:31
1761 5 P203A13 Sensor, DEF level, abnormally No limitation. Check the wiring between Con- ACM/B:46 1.6 Intake Ex-
low current or open circuit. May also generate error trol unit after-treatment system ACM/B:51 haust 4/XX DIAG-
code SPN 1761/12 and (ACM) and the component. NOSE, page 8:31
3510/4 Check the component.
1761 12 P203A01 Sensor DEF level, general elec- Reduced engine power. Check the cable harness be- D7940/- 1.6 Intake Ex-
P203A86 trical fault. May also generate error tween control unit and haust 4/XX DIAG-
code SPN 1761/3 and 1761/ component. NOSE, page 8:31
5. Check and rectify other error
codes.
1761 17 P114500 Low DEF level. No limitation. Fill with DEF. D7940/- 1.6 Intake Ex-
haust 4/XX DIAG-
NOSE, page 8:31
1761 18 P203F00 DEF level too low. Reduced engine power. Fill with DEF. D7940/- 1.6 Intake Ex-

No DEF additive. haust 4/XX DIAG-
NOSE, page 8:31
2000 9 U010000 Communication error between No limitation. Check fuses for Control unit ACM/- -
Control unit, after-treatment sys- after-treatment system (ACM).
tem (ACM) and Control unit, en- Check the cable harness be-
gine (D7940). tween Control unit, after-treat-
ment system (ACM) and Control
unit, engine (D7940).
Check that the software corre-
sponds between Control unit,
after-treatment system (ACM)
and Control unit, engine (D7940).
2017 9 U014100 Communication error with No limitation Check the cable harness be- - -
machine. tween engine and machine.

code and components
2659 10 P04007C EGR system, slow response. No limitation. Check the function of the EGR D7940/-
valve.
2659 18 P04009C EGR system, flow too low. No limitation. Check that there are no block- D7940/- -
ages in the EGR system.
Check the function of the EGR
valve.
2791 2 P048613 EGR position sensor, no or weak Reduced engine power. Check the cable harness be- - -
signal. tween control unit and
component.
Check the EGR unit.
2791 3 P041A12 EGR unit, abnormally high volt- Reduced engine power. Replace the EGR unit. - -
age or short circuit to higher
voltage.
2791 4 P041A11 EGR unit, abnormally high cur- Reduced engine power. Replace the EGR unit. - -
rent, low voltage or short circuit
to ground.
2791 5 P040313 EGR unit, abnormally high cur- Reduced engine power. Check the cable harness be- - -
rent, cable open circuit or short tween control unit and EGR unit.
circuit to ground. Replace the EGR unit.
2791 6 P040312 EGR unit, abnormally high Reduced engine power. Check the cable harness be- - -
current. tween control unit and EGR unit.
Replace the EGR unit.
2791 7 P040371 EGR valve, incorrect response Reduced engine power. Check the function of the EGR D7940/- -

from mechanical system. valve.
Replace the EGR control unit.
2791 9 U010A00 Communication error between No limitation. Check the engine's CAN D7940/- -
EGR unit and Control unit, en- communication.
gine (D7940). Check the voltage feed to the
EGR unit.
2791 11 P040392 EGR valve, no measurement Reduced engine power. Check the cable harness be- D7940/- -
values. tween control unit and EGR unit.
2791 12 P040341 EGR valve, general electrical Reduced engine power. Replace the EGR unit. D7940/- -
problem.
2791 17 P114E00 EGR valve, temperature higher Reduced engine power. Check the heat radiation that - -
than normal. may affect the EGR unit.
VDRG09.01GB
D:35

code and components
VDRG09.01GB
3031 0 P24FF00 DEF tank, temperature too high. No limitation. Carry out a test with Vodia in or- - 1.6 Intake Ex-
der to check the function of the haust 4/XX DIAG-
tank's heating valve. NOSE, page 8:31
Check the temperature sensor.
3031 4 P205A11 Sensor, temperature DEF tank, No limitation. Check the cable harness be- D7940/B18 -
abnormally high current, low volt- tween Control unit ACM and the
Check and rectify other error
codes.
3031 5 P205A13 Sensor, temperature DEF tank, No limitation. Check the cable harness be- D7940/B18 -
abnormally low current or open tween Control unit ACM and the
circuit. component.
codes.
3031 12 P205A86 Sensor, temperature DEF tank, Reduced engine power. Check the cable harness be- D7940/- -
P205A01 general electrical fault. May also generate error tween control unit and
code SPN 3519/4 and 3519/ component.
5. Check and rectify other error
codes.
3216 2 P220064 NOx sensor before catalyst, un- No limitation. Replace the component. D7940/- -
reasonable signal.
3216 3 P220012 NOx sensor before catalyst, ab- No limitation. Replace the component. D7940/- -
normally high voltage or short cir-

cuit to higher voltage.
normally low current or open

circuit.
3216 9 U029D00 NOx sensor before catalyst, no Reduced engine power. Check the cable harness be- ACM/B:49 -
signal. May also generate error tween engine and control unit for
code SPN 3226/9 and after-treatment system.
520416/9. Check the cable harness be-
component.
Check all cable harnesses for
Engine subnet.
codes.

code and components
3216 11 P225D00 NOx sensor before catalyst, no Reduced engine power. Check that the sensor is clean. D7940/- -
measurement values. Check that the sensor is fitted
correctly.
component.
Check that the exhaust system
has no leaks.
Check the sensor.
3216 12 P22FB92 NOx sensor before catalyst, un- No limitation. Replace the component. D7940/- -
reasonable measurement values.
3216 13 P220093 NOx sensor before catalyst, in- No limitation. Replace the component. D7940/- -
ternal error during start-up.
3216 14 P22001C NOx sensor before catalyst, in- No limitation. Replace the component. D7940/- -
ternal supply voltage too high.
3226 2 P229E64 NOx sensor after catalyst, unrea- No limitation. Replace the component. D7940/- -
sonable signal.
3226 3 P229E12 NOx sensor after catalyst, abnor- Reduced engine power. Replace the component. D7940/- -
mally high voltage or short circuit
to higher voltage.
3226 5 P229E13 NOx sensor after catalyst, abnor- Reduced engine power. Replace the component. D7940/- -
mally low current or open circuit.

3226 7 P225F00 NOx sensor after catalyst, me- Reduced engine power. Check that the sensor is clean. D7940/- -
chanical problem. Check that the sensor is fitted
correctly.

component.
has no leaks.
Check that the intake system has
no leaks.
Check the sensor.
VDRG09.01GB
D:37

code and components
VDRG09.01GB
3226 9 U029E00 NOx sensor after catalyst, no Reduced engine power. Check the cable harness be- ACM/B:49 -
component.
Engine subnet.
codes.
3226 12 P22FE00 NOx sensor after catalyst, unrea- No limitation. Replace the component. D7940/- -
sonable measurement values.
3226 13 P229E93 NOx sensor after catalyst, inter- No limitation. Replace the component. D7940/- -
nal error during start-up.
3226 14 P229E1C NOx sensor after catalyst, inter- No limitation. Replace the component. D7940/- -
nal supply voltage too high.
3241 4 P054411 Sensor exhaust gas temperature No limitation. Check the wiring between Con- ACM/B:39 -
1, abnormally high current, low trol unit after-treatment system
voltage or short circuit to ground. (ACM) and the component.
1, cable open circuit or short cir- May also generate error trol unit after-treatment system
cuit to ground. code SPN 3241/19. (ACM) and the component.

Check the sensor.
1, general electrical problem. trol unit after-treatment system

(ACM) and the component.
Check the sensor.
3241 19 P054486 Sensor exhaust gas temperature Reduced engine power. Check and rectify other error ACM/B:39 -
1, incorrect value from the after- May also generate error codes.
treatment system. code SPN 3241/5.
3361 12 P204F93 Metering error DEF. Reduced engine power. Check and rectify other error D7940/- -
No DEF additive. codes.
May also generate error Check the injection unit for DEF.
code SPN 4376/4, 4334/4, Check the DEF pump unit.
4334/5, 5394/5, 5394/4 and
520416/9.
3361 12 P208A86 Pump unit DEF, general electrical Reduced engine power. Check and rectify other error D7940/- -
fault. May also generate error codes.
code SPN 4334/4, 4334/5,
5392/31 and 5485/14.

code and components
3363 3 P20B112 Heating valve, DEF tank, abnor- Risk that DEF freezes in the Check the cable harness be- ACM/B:4 -
mally high voltage or short circuit tank. tween Control unit after-treat-
to higher voltage. ment system (ACM) and the
component.
3363 4 P20B111 Heating valve DEF tank, abnor- Risk that DEF freezes in the Check the cable harness be- ACM/B:4 -
mally high current, low voltage or tank. tween Control unit after-treat-
short circuit to ground. ment system (ACM) and the
component.
mally low current or open circuit. tank. tween Control unit after-treat-
ment system (ACM) and the
component.
3364 17 P207F9A Incorrect DEF quality. Reduced conversion of NOx. Check the DEF quality. D7940/- -
3464 3 P02E012 Actuator motor throttle, abnor- The throttle is set in open Check the cable harness be- D7940/B:1 1.1 Controls &
mally high voltage or short circuit position. tween control unit and D7940/B:5 Instr 1/XX DIAG-
to higher voltage. component. NOSE, page 8:29
3464 4 P02E011 Actuator motor, accelerator con- The throttle is set in open Check the cable harness be- D7940/B:1 1.1 Controls &
trol, abnormally high current, low position. tween control unit and D7940/B:5 Instr 1/XX DIAG-
voltage or short circuit to ground. component. NOSE, page 8:29
3464 5 P02E013 Actuator motor accelerator con- The throttle is set in open Check the cable harness be- D7940/B:1 1.1 Controls &
trol, abnormally low current or position. tween control unit and D7940/B:5 Instr 1/XX DIAG-
open circuit. component. NOSE, page 8:29

3464 7 P02E09C Actuator motor accelerator con- - Clean the throttle. D7940/- 1.1 Controls &
trol, flow too low. Check that the throttle is not Instr 1/XX DIAG-
binding during opening and NOSE, page 8:29
closing.
Check sensor damper position.
VDRG09.01GB
D:39

code and components
VDRG09.01GB
3464 10 P02E07C Actuator motor accelerator con- Poor throttle response. Clean the throttle. D7940/- 1.1 Controls &
trol, calibration error. Check that the throttle is not Instr 1/XX DIAG-
closing.
3464 12 P02E09B Actuator motor accelerator con- Low exhaust gas Clean the throttle. D7940/- 1.1 Controls &
trol, flow too high. temperature. Check that the throttle is not Instr 1/XX DIAG-
closing.
3468 2 P018564 Fuel temperature manifold, de- - Check the cable harness be- - -
fective sensor tween control unit and
component.
3468 4 P018511 Fuel temperature sensor, abnor- - Check the cable harness be- - -
mally high current, low voltage or tween control unit and

3468 5 P018513 Fuel temperature sensor, abnor- - Check the cable harness be- - -

component.
3468 12 P018501 Fuel temperature sensor, general - Check the cable harness be- - -
component.

code and components
3468 16 P016800 Fuel temperature too high. Reduced engine power. Check the fuel level, fill the tank - -
with fuel.
NOTE
High temperature due to fast re-
turn flow of fuel to the tank being
reduced if there is a lot of fuel in
the tank.
Check the installation of the fuel
tank and the fuel lines. Check if
anything is radiating heat against
the fuel system.
Check the fuel temperature
sensor.
from ePRV.
3509 3 P06B017 Voltage feed sensor A, abnor- Sensor supplied by output Check the cable harness be- D7940/A:7 -
mally high voltage or short circuit A:7 may show incorrect val- tween the control unit and the
to higher voltage. ues and generate other er- components.
ror codes.
3509 4 P06B016 Voltage feed sensor A, abnor- Sensor supplied by output Check the cable harness be- D7940/A:7 -
mally high current, low voltage or A:7 may show incorrect val- tween the control unit and the
short circuit to ground. ues and generate other er- components.
ror codes.

3510 3 P06B317 Voltage feed sensor B, abnor- Sensor supplied by output Check the cable harness be- D7940/B:17 -
mally high voltage or short circuit B:17 may show incorrect tween the control unit and the
to higher voltage. values. components.
May also generate error
code SPN 100/3.
3510 3 P06B317 Voltage feed sensor B, abnor- No pressure gauge in the Check the cable harness be- ACM/B:51 -
mally high voltage or short circuit DEF pump unit. tween the control unit and the
to higher voltage. components.
mally high current, low voltage or B:17 may show incorrect tween the control unit and the
short circuit to ground. values. components.
code SPN 100/5.
VDRG09.01GB
D:41

code and components
VDRG09.01GB
3510 4 P06B316 Voltage feed sensor B, abnor- No pressure gauge in the Check the cable harness be- ACM/B:51 -
mally high current, low voltage or DEF pump unit. tween Control unit, after-treat-
short circuit to ground. May also generate error ment system (ACM) and pump
code SPN 1761/12 unit DEF.
and1761/5. Check the component.
3511 3 P06E617 Voltage feed sensor C, abnor- Sensor supplied by output Check the cable harness be- D7940/A:1 -
mally high voltage or short circuit A:1 may show incorrect val- tween the control unit and the
to higher voltage. ues and generate other er- components.
ror codes.
3511 4 P06E616 Voltage feed sensor C, abnor- Sensor supplied by output Check the cable harness be- D7940/A:1 -
mally high current, low voltage or A:1 may show incorrect val- tween the control unit and the
short circuit to ground. ues and generate other er- components.
ror codes.
3597 3 P065712 Pump unit, DEF voltage feed A, No DEF additive. Check the cable harness be- ACM/B:62 -
abnormally high voltage or short Pump unit, DEF not working. tween Control unit after-treat-
circuit to higher voltage. ment system (ACM) and the
components.
3597 4 P065711 Pump unit, DEF voltage feed A, No DEF additive. Check the cable harness be- ACM/B:62 -
abnormally high current, low volt- Pump unit, DEF not working. tween Control unit after-treat-
age or short circuit to ground. ment system (ACM) and the
components.
3598 3 P266912 Pump unit, DEF voltage feed B, Risk that DEF freezes. Check the cable harness be- ACM/B:59 -
abnormally high current, low volt- tween Control unit after-treat-

components.
3598 4 P266911 Pump unit, DEF voltage feed B, Risk that DEF freezes. Check the cable harness be- ACM/B:59 -

components.
4334 4 P204A11 Pressure sensor, pump unit, DEF, Reduced engine power. Check the cable harness be- ACM/B:30 -
component.
4334 5 P204A13 Pressure sensor, pump unit, DEF, Reduced engine power. Check the cable harness be- ACM/B:30 -
abnormally low current or open tween Control unit after-treat-
circuit. ment system (ACM) and the
component.

code and components
4354 3 P20B912 Hose heater A DEF, abnormally Risk that DEF freezes in the Check the cable harness be- ACM/B:32 -
high voltage or short circuit to hose. tween Control unit after-treat-
higher voltage. ment system (ACM) and the
component.
4354 4 P20B911 Hose heater A, DEF, abnormally Risk that DEF freezes in the Check the cable harness be- ACM/B:32 -
high current, low voltage or short hose. tween Control unit after-treat-
circuit to ground. ment system (ACM) and the
component.
low current or open circuit. hose. tween Control unit after-treat-
component.
4355 3 P20BD12 Hose heater B DEF, abnormally Risk that DEF freezes in the Check the cable harness be- ACM/B:28 -
component.
4355 4 P20BD11 Hose heater B, DEF, abnormally Risk that DEF freezes in the Check the cable harness be- ACM/B:28 -
component.

component.
4356 3 P20C112 Hose heater C DEF, abnormally Risk that DEF freezes in the Check the cable harness be- ACM/B:24 -

component.
4356 4 P20C111 Hose heater C, DEF, abnormally Risk that DEF freezes in the Check the cable harness be- ACM/B:24 -
component.
component.
VDRG09.01GB
D:43

code and components
VDRG09.01GB
4366 14 P20B992 Hose heater A, DEF, special Risk that DEF freezes in the Check the hose connections from ACM/- -
instructions. hose. and to the engine's cooling
system.
Check the heating valve for the
DEF system.
Check error codes for the pre-
heating element.
4374 0 P202D7A DEF system, pressure leakage. No limitation. Check that the DEF hoses are ACM/- -
not damaged.
Check that the injection unit is
not leaking, see supplier
documentation.
4374 1 P208A92 DEF pump unit, motor speed too No DEF additive. Troubleshoot in accordance with ACM/- -
low. May also generate error supplier documentation.
code SPN 5485/14 and
5392/31.
4375 0 P10AD12 Motor, pump unit, DEF, abnor- No limitation. Check the cable harness be- ACM/B:8 -
mally high voltage or ground con- tween Control unit after-treat-
nection short-circuited to voltage. ment system (ACM) and the
component.
mally low current or ground con- tween Control unit after-treat-
nection short-circuited to ground. ment system (ACM) and the
component.
4375 3 P208A12 Motor, pump unit, DEF, abnor- No limitation. Check the cable harness be- ACM/B:7 -
mally high voltage or short circuit tween Control unit after-treat- ACM/B:8
to higher voltage. ment system (ACM) and the ACM/B:12

component. ACM/B:62
mally high current, low voltage or tween Control unit after-treat-
component.
mally low current or open circuit. tween Control unit after-treat- ACM/B:8
ment system (ACM) and the ACM/B:12
component. ACM/B:62
mally low current or open circuit tween Control unit after-treat-
on ground connection. ment system (ACM) and the
component.

code and components
4375 14 P21CAA1 Pump unit, DEF, incorrect supply No limitation. Check the cable harness be- ACM/- -
voltage. tween Control unit after-treat-
component.
4376 3 P20A012 Directional control valve, pump DEF is not pumped back to Check the cable harness be- ACM/B:12 -
unit, DEF, abnormally high volt- the tank when the engine is tween Control unit after-treat-
age or short circuit to higher switched off. ment system (ACM) and the
voltage. component.
unit, DEF, abnormally high cur- the tank when the engine is tween Control unit after-treat-
rent, low voltage or short circuit switched off. ment system (ACM) and the
to ground. component.
unit, DEF, abnormally low current the tank when the engine is tween Control unit after-treat-
or open circuit. switched off. ment system (ACM) and the
component.
4376 7 P20A007 Directional control valve, DEF, DEF is not pumped back to Test by starting the engine, run it ACM/- -
mechanical fault. the tank when the engine is at idling speed for five minutes
switched off. and then switch off the engine.
Check if the fault remains.
Replace the DEF pump unit.
Note that the DEF system is
pressurised!
4752 7 P245700 EGR cooler, temperature - Clean the EGR cooler. - -

deviation.
5016 4 P26E711 Pump unit, DEF voltage feed D, No limitation. Check the cable harness be- ACM/B:49 -

components.
5392 31 P20E892 Low DEF pressure. Reduced engine power. Check the level in the DEF tank. - -
Troubleshoot in accordance with
supplier documentation.
5394 3 P204712 DEF injection unit, abnormally No DEF additive. Check the cable harness be- ACM/B:40 -
high voltage or short circuit to tween Control unit after-treat- ACM/B:44
component.
VDRG09.01GB
D:45

code and components
VDRG09.01GB
high current, low voltage or short tween Control unit after-treat- ACM/B:44
component.
low current or open circuit. tween Control unit after-treat- ACM/B:44
component.
5394 12 P204786 DEF injection unit, general elec- No limitation. Check the cable harness be- D7940/- -
trical fault. tween the control unit and the
components.
5394 14 P204773 DEF injection unit, jammed in No DEF additive. Troubleshoot in accordance with ACM/B:40 -
closed position. supplier documentation. ACM/B:44
5435 14 P204F94 DEF system, active error codes No limitation. Rectify other error codes for the ACM/- -
generated. after-treatment system.
5485 14 P10CE97 Pump unit, DEF, no return flow. No limitation. Check that the DEF hoses are ACM/- -
not trapped or damaged.
Check that the outlet from pump
unit, DEF, is not clogged.

5765 10 P041A2A EGR temperature sensor, slow Reduced engine power. Replace the EGR unit. - -
response.

520244 3 P009B12 Fuel pressure relief valve, abnor- Reduced engine power. Check the cable harness be- D7940/A:28 -
mally high voltage or short circuit tween control unit and ePRV. D7940/A:62
to higher voltage. Check ePRV's signal with an
oscilloscope.
mally high current, low voltage or tween control unit and ePRV. D7940/A:62
short circuit to ground. Check ePRV's signal with an
oscilloscope.
mally low current or open circuit. tween control unit and ePRV. D7940/A:62
oscilloscope.

code and components
520244 7 P009B73 Fuel pressure relief valve, me- Reduced engine power. Check the cable harness be- - -
chanical problem. tween control unit and ePRV.
oscilloscope.
520244 12 P018F00 Fuel pressure relief valve, gener- Reduced engine power. Check the cable harness be- - -
al electrical problem. tween control unit and fuel pres-
code occurs.
520245 0 P016E00 Fuel pressure, too high. Reduced engine power. Check the cable harness be- - -
code occurs.

from ePRV.
VDRG09.01GB
D:47

code and components
VDRG09.01GB
520245 1 P016F00 Fuel pressure, too low. Reduced engine power. Check the fuel level. Check ho- - -
ses and fuel filter for leakage.
Check that fuel hoses are not
trapped or clogged. Change the
fuel filters. Bleed the fuel system.
idle) = 30-40 MPa. If the engine
can be started, check at which
fuel pressure the error code
occurs.
from ePRV.



code and components
520245 16 P228F00 Fuel pressure, above normal Reduced engine power. Check the cable harness be- - -
level. tween control unit and fuel pres-
occurs.
from ePRV.
520245 18 P228E00 Fuel pressure, below normal - Check the cable harness be- - -


occurs.
from ePRV.
VDRG09.01GB
D:49

code and components
VDRG09.01GB
520335 5 U300001 Control unit engine (D7940), in- The engine does not start. Replace the component. D7940/- -
ternal fault in voltage feed.
520416 9 U116F00 Communication error. Control No DEF additive. Check fuses for Control unit D7940/- -
unit, after-treatment system May also generate error after-treatment system (ACM).
(ACM). code SPN 3216/9 and 3226/ Check the wiring between the
9. control unit and metering valve
DEF.
Engine subnet.
codes.
520688 0 P11A600 Exhaust temperature too high. No limitation. Check that the exhaust pipe is - -
not damaged and that it is not
clogged.
Check sensor exhaust gas
temperature.
Check the back pressure.
520688 3 P11A412 Sensor, exhaust gas temperature, No limitation. Check the cable harness be- D7940/B:44 -
abnormally high voltage or short tween the control unit and the
circuit to higher voltage. components.
520688 4 P11A411 Sensor, exhaust temperature, No limitation. Check the cable harness be- D7940/B:44 -
abnormally high current, low volt- tween the control unit and the
age or short circuit to ground. components.

520688 5 P11A413 Sensor, exhaust gas temperature, No limitation. Check the cable harness be- D7940/B:44 -
abnormally low current or open tween the control unit and the

circuit. components.
520688 16 P11A500 Exhaust temperature higher than No limitation. Check that the exhaust pipe is - -
normal. not damaged and that it is not
clogged.
Check sensor exhaust gas
temperature.
Check the back pressure.
D Error codes – Engine D:51
Error codes engine (engine option Volvo

TAD883VE)
The error codes for the engine are sorted in numerical order. The table
contains the following information:
D:8.
question.
Note that the engine also shows error codes for Control unit after-treat-
ment system (ACM). Certain components are connected to this control
unit, which is shown by "ACM" being first in the "Connection and com-
ponent" field.

Table Error codes engine (engine option Volvo TAD883VE) D:52
SPN FMI Supplier Description Limitation Action Connections and Diagnostic

code components menu
VDRG09.01GB
20 1 P1194 Coolant pressure too low. The Reduction of engine power.
most severe level.
20 3 P05C2 Sensor, coolant pressure. -
20 18 P1193 Coolant pressure. Moderately se- -
vere level.
51 3 P02E6 Sensor, throttle position. - Check the cable harness be- TBD -
tween control unit and D7940/B:24
component.
51 5 P02E6 Sensor, throttle position. - Check the cable harness be- TBD
tween control unit and D7940/B:17
Check the component. D7940/B:24
51 7 P02E6 Sensor, throttle position. - Check that the throttle is not bind- TBD
ing during opening and closing. D7940/B:17
Check that throttle movement D7940/B:18
runs smoothly without jerking D7940/B:24
Check the sensor.
51 12 P02E6 Sensor, throttle position. - Check that the throttle is not bind- TBD
ing during opening and closing. D7940/B:17
Check that throttle movement D7940/B:18

runs smoothly without jerking D7940/B:24
Check the sensor.
51 13 P02E6 Sensor, throttle position. - TBD TBD
D7940/B:17
D7940/B:18
D7940/B:24
91 0 P0120 Signal from accelerator pedal, Speed limitation. Check error codes for accelerator D7940/- 1.1 Controls &
value too high. pedal and CAN communication in Instr 1/XX DIAG-
the machine. NOSE, page 8:29
91 9 P0120 Signal from accelerator pedal, No limitation. Check error codes for accelerator D7940/- 1.1 Controls &
communication error. pedal and CAN communication in Instr 1/XX DIAG-
Table Error codes engine (engine option Volvo TAD883VE) (continued)

91 19 P0120 Signal from accelerator pedal, Speed limitation. Check error codes for accelerator D7940/- 1.1 Controls &
signal error. pedal and CAN communication in Instr 1/XX DIAG-
94 0 P008B Fuel pressure too high. The most No limitation. Check the cable harness be- D7940/B:16 -
severe level. tween control unit and
component.
Check the sensor.
Check the sensor.
low voltage or short-circuit to low- tween control unit and
Check the sensor.
component.
Check the sensor.
94 16 P008B Fuel pressure too high. Moder- No limitation. Check the cable harness be- D7940/B:16 -
ately severe level. tween control unit and
component.
Check the sensor.
94 18 P008A Sensor fuel pressure, low fuel Reduced output and torque. Check the fuel level in the tank. D7940/- -
pressure. Moderately severe Error code for imbalance Troubleshoot the fuel system
level. between cylinders. after leakage or trapped fuel lines.
Change the fuel filter.

Check sensor fuel pressure.
Remove and clean the safety
valve in the feed pump.
97 0 P2269 Water in fuel. No limitation. Drain water separator. D7940/- -
97 4 P2264 Sensor water in fuel. No limitation. Check the cable harness be- D7940/B:8 -
component.
98 1 P250F Low oil level engine. The most Engine unexpectedly shut Check the oil level in the engine. D7940/-
severe level down. Only for low speeds. Check that there is no oil leakage.
VDRG09.01GB
D:53
Table Error codes engine (engine option Volvo TAD883VE) (continued) D:54

VDRG09.01GB
98 4 P250A Sensor oil level engine, abnor- No limitation. Check the cable harness be- D7940/B:4
mally low voltage or short circuit tween control unit and
to lower voltage. component.
98 5 P250A Sensor oil level engine, abnor- No limitation. Check the cable harness be- D7940/B:4
component.
98 18 P1086 Low oil level engine. Moderately Engine unexpectedly shut Check the oil level in the engine. D7940/-
severe level. down. Only for low speeds. Check that there is no oil leakage.
100 1 P0524 Oil pressure in engine too low. Engine unexpectedly shut Check the engine oil level and oil D7940/- 1.8 Lubrication 1/
The most severe level. down. Only for low speeds. quality. XX DIAGNOSE,
filter.
Replace oil pump.
100 2 P0520 Sensor oil pressure. No limitation. Check the cable harness be- D7940/- 1.8 Lubrication 1/
tween control unit and XX DIAGNOSE,
high voltage or short circuit to tween control unit and XX DIAGNOSE,

higher voltage. component. page 8:34

low voltage or short-circuit to low- tween control unit and XX DIAGNOSE,
er voltage. component. page 8:34
100 7 P06DA71 Sensor oil pressure, abnormally No limitation. Check the cable harness be- D7940/B:11 1.8 Lubrication 1/

100 18 P1093 Low oil pressure in the engine. No limitation. Check the engine oil level and oil D7940/- 1.8 Lubrication 1/
quality. XX DIAGNOSE,
filter.
Replace oil pump.
102 0 P1118 High charge air pressure. Reduced engine power. Check hoses and connections for D7940/- -
the wastegate valve
sensor.
pressure control.
Check the turbo.
102 2 P0069 Boost pressure. No limitation. Check the cable harness be- D7940/A:22 -
component.
102 3 P0105 Sensor charge air pressure, ab- No limitation. Check the cable harness be- D7940/A:22 -
normally high voltage or short cir- tween control unit and


normally low voltage or short-cir- tween control unit and
cuit to lower voltage. component.
circuit. component.
102 7 P0105 Charge air pressure. No limitation. Check the cable harness be- D7940/A:22 -
component.
VDRG09.01GB
D:55

VDRG09.01GB
102 16 P1116 High charge air pressure. Reduced engine power. Check hoses and connections for D7940/- -
the wastegate valve
sensor.
pressure control.
Check the turbo.
105 0 P111A Charge air temperature too high. Reduced engine power. Check that the engine tempera- D7940/-
ture is normal.
Check the coolant level.
Clean the intercooler and radiator.
ture sensor.
105 2 P009A Charge air temperature. No limitation. Check the cable harness be- D7940/A:47
component.
Check the sensor.
abnormally low voltage or short- tween control unit and
circuit to lower voltage. component.
Check the sensor.

abnormally low current or open tween control unit and D7940/A:11
circuit. component.

Check the sensor.
105 14 P0110 Sensor, charge air temperature. No limitation. Check the cable harness be- D7940/A:47
tween control unit and D7940/A:11
component.
Check the sensor.
105 16 P1119 High charge air temperature. No limitation. Check that the engine tempera- D7940/-
ture is normal.
Check the coolant level.
Clean the intercooler and radiator.
ture sensor.
107 0 P10F800 Low pressure between air filter No limitation. Change the air filter. D7940/- -
and turbo.

107 3 P100712 Sensor, air pressure intake, ab- No limitation. Check the cable harness be- D7940/A:29 -
Check the sensor.
107 4 P100711 Sensor, air pressure intake, ab- No limitation. Check the cable harness be- D7940/A:29 -
circuit. component.
Check the sensor.
107 12 P100701 Sensor air pressure intake, gen- No limitation. Check the cable harness be- D7940/A:29 -
eral electrical problem. tween control unit and
component.
Check the sensor.
108 2 P222664 Sensor, air pressure. No limitation. Check the cable harness be- D7940/- -
component.
Check the sensor.
108 3 P222612 Sensor, air pressure, abnormally No limitation. Check the cable harness be- D7940/- -
low voltage or short-circuit to low- tween control unit and
Check the sensor.
108 5 P222613 Sensor air pressure (in control No limitation. Replace control unit engine D7940/- -
unit engine), abnormally low cur- (D7940).
rent or open circuit.

110 0 P021700 Coolant temperature too high. Reduced engine power. Check the coolant level. D7940/- -
fans.
of the drive belts.
coolant.
temperature.
expansion tank.
VDRG09.01GB
D:57

VDRG09.01GB
normally high current, low volt- Idle control reduced. tween control unit and
Check the sensor.
normally low current or open Idle control reduced. tween control unit and
circuit. component.
110 10 P01152A Sensor coolant temperature. No limitation. Check the cable harness be- D7940/B:27 -
component.
110 16 P111E00 High coolant temperature. No limitation. Check the coolant level. D7940/- -
fans.
of the drive belts.
coolant.
temperature.
expansion tank.

111 1 P256000 Low coolant level. No limitation. Check the coolant level; fill if D7940/- -
necessary.
find leakage.
component.

component.
111 18 P111D00 Low coolant level. No limitation. Check the coolant level; fill if D7940/- -
necessary.
find leakage.
component.
131 2 P047064 Pressure sensor, exhaust gases. Engine brake, low Check the cable harness be- D7940/B:12 -
performance. tween control unit and
component.
abnormally high voltage or short performance. tween control unit and
abnormally low current or open performance. tween control unit and
circuit. component.

131 7 P047572 Pressure sensor, exhaust gases. Engine brake, low Check the cable harness be- D7940/B:12 -
performance. tween control unit and

component.
131 12 P047001 Pressure sensor exhaust gases, - Check the cable harness be- D7940/B:12 -
general electrical problem. tween control unit and
component.
VDRG09.01GB
D:59

VDRG09.01GB
157 0 P008800 Fuel pressure, too high. Reduced engine power. Check the cable harness be- - -
oscilloscope.
uring the voltage.


157 1 P008700 Fuel pressure, too low. Engine may be shut down. Check that the fuel inlet valve is - -
The engine turns over but open and that the fuel lines are
does not start. correctly connected. Carry out a


oscilloscope.
157 2 P019064 Pressure sensor, fuel. Reduced engine power. Check the cable harness be- D7940/A:19 -
component.
component.
VDRG09.01GB
D:61

VDRG09.01GB
157 10 P01901F Pressure sensor, fuel. Reduced engine power. Check the cable harness be- D7940/A:19 -
component.
157 12 P019001 Pressure sensor fuel, general Reduced engine power. Check the cable harness be- D7940/A:19 -
component.
157 14 P00C600 Pressure sensor fuel, fuel pres- The engine turns over but Check that the fuel inlet valve is - -
sure too low when engine turns does not start. open and that the fuel lines are
over. correctly connected. Carry out a


oscilloscope.

157 16 P114700 Pressure sensor fuel, fuel pres- Reduced engine power. Check the cable harness be- - -
sure too high. tween control unit and fuel pres-
proximately 20-30 MPa.
oscilloscope.
158 0 P056085 Voltage feed, Control unit engine No limitation. Check the cable harness be- - -
(D7940). tween the control unit and its
power supply.
158 1 P056084 Voltage feed, Control unit engine No limitation. Check the cable harness be- - -
power supply.

158 2 P05611F Voltage feed, Control unit engine Uneven torque. Check the cable harness be- - -
power supply.
normally high current, low volt- low temperatures. tween control unit and
normally low current or open low temperatures. tween control unit and
circuit. component.
VDRG09.01GB
D:63

VDRG09.01GB
173 0 P242800 Exhaust gas temperature too Reduced engine power. Check that the exhaust pipe has D7940/- -
high. not been damaged and that there
Check the sensor.
pressure.
173 16 P112E00 High exhaust gas temperature. No limitation. Check that the exhaust pipe has D7940/- -
not been damaged and that there
Check the sensor.
pressure.
174 3 P018012 Sensor, fuel temperature, abnor- No limitation. Check the cable harness be-
mally high voltage or short circuit tween control unit and
mally high current, low voltage or tween control unit and
component.

175 0 P029800 Oil temperature too high. Reduced engine power. Check the oil level in the engine D7940/- 1.8 Lubrication 1/

gine temperature.
cooler.
Check the sensor.
175 2 P019564 Oil temperature sensor. Speed limitation. Check the cable harness be- D7940/A:31 1.8 Lubrication 1/
tween control unit and XX DIAGNOSE,
175 3 P019512 Sensor, oil temperature, abnor- Speed limitation. Check the cable harness be- D7940/A:31 1.8 Lubrication 1/
mally high voltage or short circuit tween control unit and XX DIAGNOSE,
to higher voltage. component. page 8:34

175 4 P019511 Sensor, oil temperature, abnor- Speed limitation. Check the cable harness be- D7940/A:31 1.8 Lubrication 1/
mally low voltage or short-circuit tween control unit and XX DIAGNOSE,
to lower voltage. component. page 8:34
175 5 P019513 Sensor oil temperature, abnor- No limitation. Check the cable harness be- D7940/A:31 1.8 Lubrication 1/
mally low current or open circuit. tween control unit and XX DIAGNOSE,
175 16 P112500 High oil temperature. No limitation. Check the oil level in the engine D7940/- 1.8 Lubrication 1/
gine temperature.
cooler.
Check the sensor.
190 16 P119D00 Engine speed too high. Engine speed is limited Stop the machine and switch off D7940/- -
the engine. Investigate the cause
of the high engine speed when
626 3 P2CE412 Relay preheating, abnormally Engine difficult to start at Check the cable harness be- D7940/B:25 -
high voltage or short circuit to low temperatures. tween control unit and

high current, low voltage or short low temperatures. tween control unit and

low current or open circuit. low temperatures. tween control unit and
component.
628 2 P060741 Memory error in Control unit en- Reduced engine power. Reprogram the control unit. D7940/- -
gine (D7940).
628 14 U1FFF68 Control unit, engine (D7940), Reduced engine power. Reprogram the control unit. D7940/- -
VDRG09.01GB
D:65

VDRG09.01GB
636 7 P001676 Sensor rpm camshaft, incorrect The engine takes longer to Check the cable harness be- D7940/A:45 -
assembly. The signal does not start than normal or does tween control unit and D7940/A:46
correspond with the signal from not start at all. component.
sensor rpm crankshaft. Rough running. Check the component's
High fuel consumption. assembly.
Compare the signals from sensor
rpm camshaft and sensor rpm
crankshaft with an oscilloscope.
636 8 P034038 Sensor speed, camshaft, abnor- The engine takes longer to Check the cable harness be- D7940/A:45 -
mal frequency. start than normal. tween control unit and D7940/A:46
component.
Check the component's
assembly.
636 9 P034031 Sensor rotation speed camshaft, The engine takes longer to Check the cable harness be- D7940/A:45 -
no signal. start than normal. tween control unit and D7940/A:46
component.
637 2 P03351F Sensor rpm crankshaft, no or The engine takes longer to Check the component's D7940/A:37 1.9 Control Sys-
weak signal. start than normal. assembly. D7940/A:38 tem 1/XX DIAG-
Reduced torque. Check the signal from the com- NOSE, page 8:34
Rough running. ponent with an oscilloscope.

High fuel consumption. Check the component.
637 8 P033538 Sensor speed, crankshaft, abnor- The engine takes longer to Check the component's D7940/A:37 1.9 Control Sys-
mal frequency. start than normal. assembly. D7940/A:38 tem 1/XX DIAG-
Reduced torque. Clean the component. NOSE, page 8:34
637 9 P033531 Sensor rotation speed flywheel, The engine takes longer to Check the cable harness be- D7940/A:37 1.9 Control Sys-
no signal. start than normal. tween control unit and D7940/A:38 tem 1/XX DIAG-
Reduced torque. component. NOSE, page 8:34

639 2 U001088 Communication error (Backbone Engine switched off: engine Check all data links between ma- D7940/B:51 -
1) Control unit engine. cannot be started. chine, transmission, engine and D7940/B:55
Engine running: the engine after-treatment system. ACM/B:10
normally high voltage or short cir- 100%. tween control unit and
647 4 P048011 Magnetic clutch cooling fan, ab- Cooling fan's drive not work- Check the cable harness be- D7940/B:49 -
normally high current, low volt- ing, risk of overheating. tween control unit and
normally low amperage or open 100%. tween control unit and
circuit. component.
on other injectors.
low voltage or short-circuit to low- ders, sounds rough and has tween control unit and D7940/A:24
er voltage. reduced power. component.
on other injectors.

reduced power. component. D7940/A:59
D7940/A:62
on other injectors.
er voltage. reduced power. component.
on other injectors.
VDRG09.01GB
D:67

VDRG09.01GB
D7940/A:62
on other injectors.
er voltage. reduced power. component. D7940/A:59
Protected mode Limp-home Check the component. D7940/A:62
on other injectors.
D7940/A:62
on other injectors.

on other injectors.
D7940/A:61
on other injectors.

on other injectors.
D7940/A:61
on other injectors.
on other injectors.
D7940/A:61
677 3 P061512 Starter relay on the starter motor, The engine does not start. Check the cable harness be- D7940/B:29 -
abnormally high voltage or short tween control unit and D7940/B:37

normally high current, low volt- tween control unit and D7940/B:37
677 5 P061513 Starter relay on the starter motor, The engine does not start. Check the starter relay on the D7940/B:29 -
abnormally high voltage or short starter motor. D7940/B:37
circuit to higher voltage. Check the cable harness be-
component.
normally high current. tween control unit and D7940/B:37
component.
VDRG09.01GB
D:69

VDRG09.01GB
(MPROP), abnormally high cur- Open ePRV. tween control unit and D7940/A:16
rent, low voltage or short circuit component.
to ground. Check the fuel pressure regulator
679 7 P228D72 Fuel pressure regulator Reduced engine power. Check the cable harness be- D7940/A:12 -
(MPROP), mechanical problem, tween control unit and fuel pres- D7940/A:16
stuck in open position. sure sensor. Check the fuel
code occurs.


729 5 P054013 Preheating element, abnormally Engine difficult to start at Check the fuse for the D7940/B:7 -
low current or open circuit. low temperatures. component.
component.
729 6 P05407E Relay preheating, mechanical Engine difficult to start at Check the cable harness be- D7940/B:7 -
problem, locked in engaged low temperatures. tween control unit and D7940/B:25
mode. component.
729 7 P05407F Relay preheating, mechanical Engine difficult to start at Check the cable harness be- D7940/B:7 -
problem, locked in disengaged low temperatures. tween control unit and
mode. component.

729 12 P054001 Preheating element, general Preheating cannot be acti- Check the fuse for the D7940/B:7 -
electrical problem. vated, starting problems in component.
cold weather. Check the cable harness be-
component.
mally high voltage or short circuit and cannot be started. tween control unit and
mally high current, low voltage or and cannot be started. tween control unit and
mally low current or open circuit. and cannot be started. tween control unit and
component.
970 11 P100192 Stop button on engine, activated. Engine cannot be started. Reset the switch and switch the D7940/A:27 -
ignition on and off.
970 14 P10019E Stop button on engine, mechani- Engine cannot be started. Check the cable harness be- D7940/A:27 -
cal problem. Jammed in de- tween control unit and
pressed position. component.
1127 7 P00457C Charge air pressure Low engine power. Check the cable harness be-

component.
1127 15 P259F00 Charge air pressure No limitation. Check the cable harness be-

component.
1127 16 P023400 High charge air pressure No limitation. Check the cable harness be-
component.
1127 17 P259E00 Boost pressure low No limitation. Check the cable harness be-
component.
1127 18 P029900 Low engine power. No limitation. Check the cable harness be-
component.
VDRG09.01GB
D:71


VDRG09.01GB
1136 4 P066611 Sensor, temperature, control unit, TBD Check the cable harness be-
engine. tween control unit and
component.
component.
component.
1136 16 P112000 Temperature, control unit, engine. TBD Check the cable harness be-
component.
control, abnormally high voltage tween control unit and
or short circuit to higher voltage. component.
control, abnormally high current, tween control unit and
low voltage or short circuit to component.

ground.
control, abnormally low current or tween control unit and

1231 2 U000188 CAN2 J1939 communication link. Starter motor does not turn Check the cable harness be-
over. tween control unit and
component.

1239 14 P009400 Less fuel leakage. No limitation. Check the high-pressure system - -
for leakage.
from ePRV.
uring the voltage.
1347 7 P06279C Fuel pressure pump, low flow Reduced engine power. Check for other error codes that - -
may be the cause.
1485 7 P068573 Engine relay active. ECM relay activated. Bat- Replace main relay. - -
tery is discharged.
1639 3 P052612 Sensor fan speed, abnormally The cooling fan does not Check the cable harness be- D7940/A:35 -
high voltage or short circuit to disengage. tween control unit and
1659 12 P012800 Thermostat coolant. The engine No limitation. Check the component. - -
does not reach normal operating
temperature.
1668 2 U008088 Communication error (Engine No limitation. Check the cable harness be- - -
subnet) control unit engine, un- tween the control unit and com-
reasonable signal. ponents on Engine subnet.
1675 0 P117600 High temperature, starter motor. Starter motor does not turn Check the component. - -

over.
1761 2 P203A64 Level sensor A DEF tank. No limitation. Check the wiring between Con- ACM/B:46 1.6 Intake Ex-
trol unit after-treatment system haust 4/XX DIAG-
(ACM) and the component. NOSE, page 8:31
1761 7 P203A92 Level sensor A DEF tank. Reduced engine power. Check the wiring between Con- ACM/B:46 1.6 Intake Ex-
trol unit after-treatment system ACM/B:51 haust 4/XX DIAG-
1761 17 P114500 Low DEF level. Reduced engine power. Fill with DEF. D7940/- 1.6 Intake Ex-
haust 4/XX DIAG-
NOSE, page 8:31
VDRG09.01GB
D:73

VDRG09.01GB
1761 18 P203F00 DEF level too low. Reduced engine power. Fill with DEF. D7940/- 1.6 Intake Ex-
No DEF additive. haust 4/XX DIAG-
NOSE, page 8:31
1761 31 P203A86 Level sensor A DEF tank. No limitation. Check the wiring between Con- ACM/B:46 1.6 Intake Ex-
trol unit after-treatment system ACM/B:51 haust 4/XX DIAG-
2659 18 P04009C EGR system, flow too low. No limitation. Check that there are no block- D7940/- -
ages in the EGR system.
Check the function of the EGR
valve.
2791 3 P040312 EGR unit, abnormally high volt- Reduced engine power. Replace the EGR unit. - -
age or short circuit to higher
voltage.
2791 4 P040311 EGR unit, abnormally high cur- No limitation. Replace the EGR unit. - -
rent, low voltage or short circuit
to ground.
2791 5 P040313 EGR unit, abnormally high cur- No limitation. Check the cable harness be- - -
rent, cable open circuit or short tween control unit and EGR unit.
circuit to ground. Replace the EGR unit.

2791 7 P040397 EGR valve, incorrect response No limitation. Check the function of the EGR D7940/- -
from mechanical system. valve.
High fuel consumption.
3031 0 P24FF00 DEF tank, temperature too high. No DEF additive. Check the heating function in ac- ACM/- 1.6 Intake Ex-
cordance with supplier haust 4/XX DIAG-
documentation. NOSE, page 8:31
Check DEF tank temperature
sensor.
3031 2 P205A64 Sensor, temperature DEF tank. No limitation. Check the cable harness be- D7940/B18 -
tween Control unit ACM and the
component.
codes.

3061 6 P06FE00 System for monitoring emission No limitation. Check the cable harness be- - -
reduction during cold starting. tween Control unit ACM and the
component.
codes.
3064 0 P246300 High soot level, particulate filter No limitation. Perform a parked regeneration
after-treatment. Serious level. as soon as possible, see Opera-
tor's manual.
3064 11 P10FE00 High soot level, particulate filter Reduced engine power. Perform a parked regeneration
after-treatment. Serious level. as soon as possible, see Opera-
tor's manual.
3064 16 P24A400 High soot level, particulate filter Reduced engine power. Stop the engine as soon as pos-
after-treatment. The most serious sible and contact Cargotec Serv-
level. ice for regeneration of the
exhaust system.
3216 2 P220064 NOx sensor before catalyst, un- No limitation. Replace the component. D7940/- -
reasonable signal.
normally high voltage or short cir-
cuit to higher voltage.
normally low voltage or short cir-
cuit to lower voltage.

normally low current or open

circuit.
3216 9 U029D00 NOx sensor before catalyst, no No limitation. Check the cable harness be- ACM/B:49 -
component.
Engine subnet.
codes.
VDRG09.01GB
D:75

VDRG09.01GB
3216 10 P22F900 NOx sensor before catalyst. No limitation. Check the cable harness be- ACM/B:49 -
tween engine and control unit for
after-treatment system.
component.
Engine subnet.
codes.
3216 11 P225D00 NOx sensor before catalyst, no No limitation. Check that the sensor is clean. D7940/- -
measurement values. Check that the sensor is fitted
correctly.
component.
has no leaks.
Check the sensor.
3216 12 P22FB92 NOx sensor before catalyst, un- No limitation. Replace the component. D7940/- -
reasonable measurement values.
3216 13 P220093 NOx sensor before catalyst, in- No limitation. Replace the component. D7940/- -
ternal error during start-up.
3216 14 P22001C NOx sensor before catalyst, in- No limitation. Replace the component. D7940/- -
ternal supply voltage too high.
3216 20 P225C00 NOx sensor before catalyst. No limitation. Replace the component. D7940/- -

3216 31 P221A00 NOx sensor before catalyst. No limitation. Replace the component. D7940/- -
3226 2 P229E64 NOx sensor after catalyst, unrea- No limitation. Replace the component. D7940/- -
sonable signal.
3226 3 P229E12 NOx sensor after catalyst, abnor- No limitation. Replace the component. D7940/- -
mally high voltage or short circuit
to higher voltage.
mally low voltage or short circuit
to lower voltage.
mally low current or open circuit.

3226 7 P225F00 NOx sensor after catalyst, me- No limitation. Check that the sensor is clean. D7940/- -
chanical problem. Check that the sensor is fitted
correctly.
component.
has no leaks.
Check that the intake system has
no leaks.
Check the sensor.
3226 9 U029E00 NOx sensor after catalyst, no No limitation. Check the cable harness be- ACM/B:49 -
component.
Engine subnet.
codes.
3226 12 P22FE00 NOx sensor after catalyst, unrea- No limitation. Replace the component. D7940/- -
sonable measurement values.
3226 13 P229E93 NOx sensor after catalyst, inter- No limitation. Replace the component. D7940/- -
nal error during start-up.

3226 14 P229E1C NOx sensor after catalyst, inter- No limitation. Replace the component. D7940/- -
nal supply voltage too high.

3226 20 P225E67 NOx sensor after catalyst. No limitation. Replace the component. D7940/- -
3226 31 P113600 NOx sensor after catalyst. No limitation. Replace the component. D7940/- -
3241 2 P054464 Sensor exhaust gas temperature Manual regeneration not Check the wiring between Con- ACM/B:39 -
1. possible. trol unit after-treatment system
1, cable open circuit or short cir- trol unit after-treatment system
cuit to ground. (ACM) and the component.
Check the sensor.
VDRG09.01GB
D:77

VDRG09.01GB
3241 12 P054401 Sensor exhaust gas temperature No limitation. Check the wiring between Con- ACM/B:39
Check the sensor.
3245 2 P242A64 Sensor exhaust gas temperature No limitation. Check the wiring between Con- TBD -
3. trol unit after-treatment system
Check the sensor.
3245 12 P242A01 Sensor exhaust gas temperature No limitation. Check the wiring between Con- TBD
Check the sensor.
3249 2 P203164 Sensor exhaust gas temperature No limitation. Check the wiring between Con- TBD -
2. trol unit after-treatment system


Check the sensor.
3249 12 P203101 Sensor exhaust gas temperature No limitation. Check the wiring between Con- TBD
Check the sensor.
3251 0 P10E100 High differential pressure, partic- Reduced engine power. TBD TBD
ulate filter, after-treatment. The
most serious level.
3251 2 P245264 Sensor, exhaust back pressure No limitation TBD TBD

3251 16 P10E200 High differential pressure, partic- Reduced engine power. TBD TBD
ulate filter, after-treatment. Mod-
erately severe level.
3353 3 P062012 Alternator 1 status. No limitation. Check the cable harness be- TBD
component.
3353 4 P062011 Alternator 1 status. No limitation. Check the cable harness be- TBD -
component.
3360 9 U02A200 Control unit ACM. TBD Check the cable harness be- TBD -
component.
3361 12 P204F93 Metering error DEF. Reduced engine power. Check and rectify other error D7940/- -
No DEF additive. codes.
May also generate error Check the injection unit for DEF.
code SPN 4376/4, 4334/4, Check the DEF pump.
4334/5, 5394/5, 5394/4 and

520416/9.
mally high voltage or short circuit tank. tween Control unit after-treat-

to higher voltage. ment system (ACM) and the
component.
3363 4 P20B111 Heating valve DEF tank, abnor- Risk that DEF freezes in the Check the cable harness be- ACM/B:4 -
mally high current, low voltage or tank. tween Control unit after-treat-
component.
mally low current or open circuit. tank. tween Control unit after-treat-
component.
3363 7 P20B197 Heating valve DEF tank. Risk that DEF freezes in the Check the cable harness be- ACM/B:4 -
tank. tween Control unit after-treat-
component.
VDRG09.01GB
D:79

VDRG09.01GB
3364 2 P206A64 Incorrect DEF quality. Reduced conversion of NOx. Check the DEF quality. D7940/- -
3364 17 P207F9A Incorrect DEF quality. Reduced conversion of NOx. Check the DEF quality. D7940/- -
3364 18 P207F00 Incorrect DEF quality. Reduced conversion of NOx. Check the DEF quality. D7940/- -
3364 31 P206A86 Incorrect DEF quality. Reduced conversion of NOx. Check the DEF quality. D7940/- -
mally high voltage or short circuit position. tween control unit and D7940/B:5 Instr 1/XX DIAG-
to higher voltage. component. NOSE, page 8:29
mally high current, low voltage or position. tween control unit and D7940/B:5 Instr 1/XX DIAG-
short circuit to ground. component. NOSE, page 8:29
3464 5 P02E013 Actuator motor accelerator con- The throttle is set in open Check the cable harness be- D7940/B:1 1.1 Controls &
trol, abnormally low current or position. tween control unit and D7940/B:5 Instr 1/XX DIAG-
open circuit. component. NOSE, page 8:29
3464 7 P02E09C Actuator motor accelerator con- - Clean the throttle. D7940/- 1.1 Controls &
trol, flow too low. Check that the throttle is not bind- Instr 1/XX DIAG-
ing during opening and closing. NOSE, page 8:29


3464 10 P02E07C Actuator motor accelerator con- Poor throttle response. Clean the throttle. D7940/- 1.1 Controls &
trol, calibration error. Check that the throttle is not bind- Instr 1/XX DIAG-
3464 12 P02E09B Actuator motor accelerator con- Low exhaust gas Clean the throttle. D7940/- 1.1 Controls &
trol, flow too high. temperature. Check that the throttle is not bind- Instr 1/XX DIAG-

3468 2 P018564 Fuel temperature sensor 2. No limitation. Check the cable harness be-
component.
3468 4 P018511 Sensor, fuel temperature 2, ab- No limitation. Check the cable harness be-
normally high current, low volt- tween control unit and
3468 5 P018513 Sensor, fuel temperature 2, ab- No limitation. Check the cable harness be-
circuit. component.
3468 12 P018501 Fuel temperature sensor 2. No limitation. Check the cable harness be-
component.
3468 16 P016800 High fuel temperature. Reduced engine power. Check the cable harness be-
component.
3509 3 P06B017 Voltage feed sensor A, abnor- Reduced engine power. Check the cable harness be- D7940/A:7 -
mally high voltage or short circuit Sensor supplied by output tween the control unit and the
to higher voltage. A:7 may show incorrect val- components.

ues and generate other er-
ror codes.
3509 4 P06B016 Voltage feed sensor A, abnor- Reduced engine power. Check the cable harness be- D7940/A:7 -

mally high current, low voltage or Sensor supplied by output tween the control unit and the
short circuit to ground. A:7 may show incorrect val- components.
ues and generate other er-
ror codes.
mally high voltage or short circuit B:17 may show incorrect tween the control unit and the
to higher voltage. values. components.
code SPN 101/3 and 100/3.
mally high current, low voltage or B:17 may show incorrect tween the control unit and the
short circuit to ground. values. components.
code SPN 101/5 and 100/5.
VDRG09.01GB
D:81

VDRG09.01GB
3519 3 P205A12 DEF tank temperature sensor, Check the cable harness be- TBD
abnormally high voltage or short tween control unit and
Check the sensor.
3519 5 P205A13 DEF tank temperature sensor, Check the cable harness be- TBD
voltage feed, abnormally high tween control unit and
current, low voltage or short cir- component.
cuit to ground. Check the sensor.
3520 5 P206A13 DEF quality. TBD TBD TBD -
3520 12 P206A96 DEF quality. TBD TBD TBD -
3521 14 U05A300 DEF properties. Unknown fluid in TBD TBD TBD -
tank.
3522 1 P20F49C Low DEF, consumption. No limitation. Check for leakage in the SCR- - -
system.
3522 18 P20F400 Low DEF, consumption. No limitation. Check for leakage in the SCR- - -
system.
3522 31 P20F493 Low DEF, consumption. No limitation. Check for leakage in the SCR- - -
system.
3532 4 P203A11 Sensor, DEF quality. TBD Check the cable harness be- - -
tween Control unit after-treat-

components.

components.
components.
3597 3 P065712 DEF pump unit voltage feed 1, No DEF additive. Check the cable harness be- ACM/B:62 -
abnormally high voltage or short DEF pump unit not working. tween Control unit after-treat-
circuit to higher voltage. ment system (ACM) and the
components.
3597 4 P065711 DEF pump unit voltage feed 1, No DEF additive. Check the cable harness be- ACM/B:62 -
abnormally high current, low volt- DEF pump unit not working. tween Control unit after-treat-
components.

3598 3 P266912 DEF pump unit voltage feed 2, Risk that DEF freezes. Check the cable harness be- ACM/B:59 -
components.
3598 4 P266911 DEF pump unit voltage feed 2, Risk that DEF freezes. Check the cable harness be- ACM/B:59 -
components.
3936 0 P244B00 Differential pressure too high in No limitation. Check the cable harness be- - -
particulate filter, after-treatment tween Control unit after-treat-
system. ment system (ACM) and the
components.
3936 1 P244A00 Differential pressure too high in No limitation. Check the cable harness be- - -
particulate filter, after-treatment tween Control unit after-treat-
system. ment system (ACM) and the
components.
4334 2 P204A64 Pressure sensor DEF pump unit. Reduced engine power. Check the cable harness be- ACM/B:30 -
component.
4334 4 P204A11 Pressure sensor DEF pump unit, Reduced engine power. Check the cable harness be- ACM/B:30 -

component.

4334 5 P204A13 Pressure sensor DEF pump unit, Reduced engine power. Check the cable harness be- ACM/B:30 -
abnormally low current or open tween Control unit after-treat-
circuit. ment system (ACM) and the
component.
4334 12 P204A01 Pressure sensor DEF pump unit. Reduced engine power. Check the cable harness be- ACM/B:30 -
component.
4337 2 P204264 Temperature sensor DEF. Reduced engine power. Check the cable harness be- TBD -
component.
VDRG09.01GB
D:83

VDRG09.01GB
4337 12 P204201 Temperature sensor DEF. Reduced engine power. Check the cable harness be- TBD -
component.
4354 3 P20B912 Hose heater A DEF, abnormally Risk that DEF freezes in the Check the cable harness be- ACM/B:32 -
component.
component.
component.
4355 3 P20BD12 Hose heater B DEF, abnormally Risk that DEF freezes in the Check the cable harness be- ACM/B:28 -
component.
component.

component.
4356 3 P20C112 Hose heater C DEF, abnormally Risk that DEF freezes in the Check the cable harness be- ACM/B:24 -
component.
component.

component.
4364 17 P100400 After-treatment system SCR, Reduced engine power. TBD TBD -
NOx catalytic converter efficiency
below limit value.
4364 31 P103C00 After-treatment system SCR, Reduced engine power. TBD TBD -
NOx catalytic converter efficiency
below limit value.
4366 14 P20B992 Hose heater A, DEF, special Risk that DEF freezes in the Check the hose connections from ACM/- -
instructions. hose. and to the engine's cooling
system.
Check the heating valve for the
DEF system.
Check error codes for the pre-
heating element.
4374 0 P202D7A DEF system, pressure leakage. No limitation. Check that the DEF hoses are ACM/- -
not damaged.
Check that the injection unit is
not leaking, see supplier
documentation.
4374 1 P208A92 DEF pump unit, motor speed too No DEF additive. Troubleshoot in accordance with ACM/- -
low. May also generate error supplier documentation.
code SPN 5485/14 and
5392/31.

4375 0 P10AD12 Motor DEF pump unit, abnor- No limitation. Check the cable harness be- ACM/B:8 -
mally high voltage or ground con- tween Control unit after-treat-
nection short-circuited to voltage. ment system (ACM) and the
component.
mally low current or ground con- tween Control unit after-treat-
nection short-circuited to ground. ment system (ACM) and the
component.
4375 3 P208A12 Motor DEF pump unit, abnor- No limitation. Check the cable harness be- ACM/B:7 -
mally high voltage or short circuit tween Control unit after-treat- ACM/B:8
to higher voltage. ment system (ACM) and the ACM/B:12
component. ACM/B:62
VDRG09.01GB
D:85

VDRG09.01GB
mally high current, low voltage or tween Control unit after-treat-
component.
mally low current or open circuit. tween Control unit after-treat- ACM/B:8
ment system (ACM) and the ACM/B:12
component. ACM/B:62
mally low current or open circuit tween Control unit after-treat-
on ground connection. ment system (ACM) and the
component.
4375 14 P21CAA1 DEF pump unit, incorrect supply No limitation. Check the cable harness be- ACM/- -
voltage. tween Control unit after-treat-
component.
4376 3 P20A012 Directional control valve DEF DEF is not pumped back to Check the cable harness be- ACM/B:12 -
pump unit, abnormally high volt- the tank when the engine is tween Control unit after-treat-
age or short circuit to higher switched off. ment system (ACM) and the
voltage. component.
pump unit, abnormally high cur- the tank when the engine is tween Control unit after-treat-
rent, low voltage or short circuit switched off. ment system (ACM) and the
to ground. component.
pump unit, abnormally low cur- the tank when the engine is tween Control unit after-treat-

rent or open circuit. switched off. ment system (ACM) and the
component.
4376 7 P20A007 Directional control valve, DEF, DEF is not pumped back to Test by starting the engine, run it ACM/- -
mechanical fault. the tank when the engine is at idling speed for five minutes
switched off. and then switch off the engine.
Check if the fault remains.
Replace the DEF pump unit.
Note that the DEF system is
pressurised!
4795 31 P226D00 Particulate filter missing. No limitation. Check the cable harness be- TBD -
components.

4811 2 P055A64 Oil pressure sensor B piston No limitation TBD TBD -
cooling.
4814 3 P260012 Coolant pump. No limitation TBD TBD -
5016 4 P26E711 DEF pump unit voltage feed D, No limitation. Check the cable harness be- ACM/B:49 -
components.
5285 18 P026A00 Intercooler. Efficiency below limit No limitation. TBD - -
value.
5392 31 P20E892 Low DEF pressure. Reduced engine power. Check the level in the DEF tank.
high voltage or short circuit to tween Control unit after-treat- ACM/B:44
component.
high current, low voltage or short tween Control unit after-treat- ACM/B:44
component.

low current or open circuit. tween Control unit after-treat- ACM/B:44
component.
5394 14 P204773 DEF injection unit, jammed in No DEF additive. Troubleshoot in accordance with ACM/B:40 -
closed position. supplier documentation. ACM/B:44
5394 31 P103B00 DEF injection unit, jammed in No DEF additive. Troubleshoot in accordance with ACM/B:40 -
closed position. Reduced engine power. supplier documentation. ACM/B:44
VDRG09.01GB
D:87

VDRG09.01GB
5485 14 P10CE97 DEF pump unit, no return flow. No limitation. Check that the DEF hoses are ACM/- -
not trapped or damaged.
Check that the outlet from the
DEF pump unit is not clogged.
5625 12 P048B01 Engine brake (exhaust) pressure Engine brake, low TBD - -
regulator. performance.
5627 0 P047598 Engine brake (exhaust) high tem- Engine brake, low TBD - -
perature pressure regulator. performance.
mally high voltage or short circuit tween control unit and ePRV. D7940/A:62
to higher voltage. Check ePRV's signal with an
oscilloscope.
mally high current, low voltage or tween control unit and ePRV. D7940/A:62
short circuit to ground. Check ePRV's signal with an
oscilloscope.
mally low current or open circuit. tween control unit and ePRV. D7940/A:62
oscilloscope.
520244 7 P009B73 Fuel pressure relief valve, me- Reduced engine power. Check the cable harness be- - -
chanical problem. tween control unit and ePRV.
oscilloscope.


520245 0 P016E00 Fuel pressure, too high. Reduced engine power. Check the cable harness be- - -
code occurs.
from ePRV.

VDRG09.01GB
D:89

VDRG09.01GB
520245 1 P016F00 Fuel pressure, too low. Reduced engine power. Check the fuel level. Check ho- - -
ses and fuel filter for leakage.
Check that fuel hoses are not
trapped or clogged. Change the
fuel filters. Bleed the fuel system.
occurs.
from ePRV.



520245 16 P228F00 Fuel pressure, above normal Reduced engine power. Check the cable harness be- - -
occurs.
from ePRV.
520245 18 P228E00 Fuel pressure, below normal Reduced engine power. Check the cable harness be- - -


occurs.
from ePRV.
VDRG09.01GB
D:91

VDRG09.01GB
520330 0 P115100 Temperature after-treatment Reduced engine power. TBD TBD -
system.
520335 5 U300001 Control unit engine (D7940), in- The engine does not start. Replace the component. D7940/- -
ternal fault in voltage feed.
520413 9 U114600 Communication error, Control No DEF additive. Check the fuses for Control unit, D7940/- -
unit, engine (D7940). engine (D7940).
520416 9 U116F00 Communication error. Control No DEF additive. Check fuses for Control unit D7940/- -
unit, after-treatment system Reduced engine power. after-treatment system (ACM).
(ACM). May also generate error Check the wiring between the
code SPN 3216/9 and 3226/ control unit and metering valve
9. DEF.
Engine subnet.
codes.
520566 3 P004A12 Charge air pressure B. Reduced engine power. TBD TBD -
520567 0 P119800 Exhaust gas temperature too Reduced engine power. TBD TBD -
high.
520567 3 P119612 Exhaust gas temperature sensor No limitation. Check the cable harness be- TBD -
tween the control unit and the
components.

components.
components.
520567 16 P119700 Exhaust gas temperature too No limitation. TBD TBD -
high.
520568 0 P11A600 Exhaust gas temperature too Reduced engine power. TBD TBD -
high.

520568 3 P11A412 Exhaust gas temperature sensor No limitation. Check the cable harness be- TBD -
components.
components.
components.
520568 16 P11A500 Exhaust gas temperature too No limitation. TBD TBD -
high.
520691 P102C68 Steering, torque speed. No limitations. Check the cable harness be- TBD -
component.
520837 3 P220512 Sensor, NOx upstream inlet SCR No limitations. Check the cable harness be- TBD -
(B7564) tween control unit and
component.
(B7564) tween control unit and
component.

(B7564). tween control unit and
component.
(B7564). tween control unit and
component.
520838 3 P22A312 Sensor, NOx downstream outlet No limitations. Check the cable harness be- TBD -
SCR (B7565) tween control unit and
component.
VDRG09.01GB
D:93

VDRG09.01GB
component.
component.
component.
520843 2 P246E64 Sensor, exhaust gas temperature No limitation. Check the cable harness be- TBD -
SCR outlet (B7563). tween control unit and
component.
520998 9 U02A900 Sensor, intercooler, coolant No limitation. Check the cable harness be- TBD -
pump. tween control unit and
component.
- U300041 Control unit, engine (D7940) or The engine does not start. Reprogram the control unit. D7940/- -
Control unit after-treatment sys- ACM/-
tem (ACM), programming error.

tem (ACM), memory error.

Control unit after-treatment sys- Replace the control unit. ACM/-
- U300049 Control unit, engine (D7940) or The engine does not start. Replace the control unit. D7940/- -
D Error codes – Transmission D:95
D.2 Transmission
Error codes transmission (transmission
alternative DRTS HVT R2)
Error codes for the transmission are sorted in numerical order. The ta-
ble contains the following information:
D:8.
• Supplier code 2 - Specifies the error code in accordance with the
supplier's specification in alternative format.
question.
Depending on error code severity, Control unit transmission (D7930)
limits the functions in order to protect the transmission from serious
faults:
Display Description Action/Service

Shut-down Stop the machine immediately and recti-
The transmission is fully disengaged and the machine rolls freely. fy the problem straight away.
Use the brakes to stop the machine. Do not continue to work. Risk of damag-
In Shut-down, all servo valves are deactivated, which means that ing the transmission or creating a dan-
there is no oil pressure to select a gear. gerous situation.
It may be possible to regain limited drive as follows: stop the ma-
chine using the brakes, switch off the engine and ignition, and re-
start the machine. If drive is regained, drive the machine only to
service.
Limp-home Unload the load and rectify the problem
The transmission is locked to gear 1. If the fault occurs in a higher as soon as possible.
gear the transmission is fully disengaged. Use the brakes to stop The work can be completed.
the machine.
To continue to drive in gear 1, apply and release the parking brake,
and then reselect direction of travel.
It may be possible to restore transmission function as follows: stop
the machine using the brakes, switch off the engine and ignition,
and restart the machine.
No limitations in function. The work shift can be completed.
Plan a service, the problem should be
rectified as soon as possible.

Table Error codes DRTS HVTR2 D:96
SPN FMI Supplier Description Limitation Action Connections and Diagnostic menu
code components
VDRG09.01GB
32768 3 8000/3 Servo valve, hydrostatic Transmission locked in Check the cable harness D7930-1/77 - A4VG_Sol -
pump A (A4VG_Sol A) neutral (Shut-down). between control unit and A
(voltage feed), short cir- servo valve.
cuit to voltage. Check the servo valve.
(grounding), short circuit servo valve.
to voltage. Check the servo valve.
cuit to ground. Check the servo valve.
to ground. Check the servo valve.
Check the cable harness
between control unit and
servo valve.
Check the servo valve.
pump A (A4VG_Sol A), neutral (Shut-down). between control unit and A
open circuit. servo valve. D7930-1/86 - A4VG_Sol
Check the servo valve. A
pump A (A4VG_Sol A), neutral (Shut-down). between control unit and A
error during shut-down servo valve. D7930-1/86 - A4VG_Sol

test. Check the servo valve. A
Check: Control unit, trans-
mission (D7930).
pump B (A4VG_Sol B) neutral (Shut-down). between control unit and B
cuit to voltage. Check the servo valve.
Table Error codes DRTS HVTR2 (continued)
code components
cuit to ground. Check the servo valve.
pump B (A4VG_Sol B), neutral (Shut-down). between control unit and B
open circuit. servo valve. D7930-1/87 - A4VG_Sol
Check the servo valve. B
pump B (A4VG_Sol B), neutral (Shut-down). between control unit and B
error during shut-down servo valve. D7930-1/87 - A4VG_Sol
test. Check the servo valve. B
mission (D7930).
32770 3 8002/3 Servo valve, hydrostatic Transmission locked in Check the cable harness D7930-1/78 - A6VM -
motor (A6VM) (voltage neutral (Shut-down). between control unit and
feed), short circuit to servo valve.
voltage. Check the servo valve.
D Error codes – Transmission
motor (A6VM) (ground- neutral (Shut-down). between control unit and

ing), short circuit to servo valve.

motor (A6VM) (voltage neutral (Shut-down). between control unit and
feed), short circuit to servo valve.
ground. Check the servo valve.
motor (A6VM) (ground- neutral (Shut-down). between control unit and
ing), short circuit to servo valve.
motor (A6VM) (voltage neutral (Shut-down). between control unit and D7930-1/88 - A6VM
feed), or (ground), open servo valve.
circuit. Check the servo valve.
VDRG09.01GB
D:97
Table Error codes DRTS HVTR2 (continued) D:98
code components
VDRG09.01GB
motor (A6VM), error dur- neutral (Shut-down). between control unit and D7930-1/88 - A6VM
ing shut-down test. servo valve.
mission (D7930).
32771 3 8003/3 Servo valve, clutch gear 2 Transmission locked in Check the cable harness D7930-1/52 - Sol C2 -
(Sol C2) (voltage feed), neutral (Shut-down). between control unit and
short circuit to voltage. servo valve.
(Sol C2) (grounding), neutral (Shut-down). between control unit and
short circuit to ground. servo valve.
(Sol C2), open circuit. neutral (Shut-down). between control unit and D7930-1/82 - Sol C2
servo valve.

(Sol C2), error during neutral (Shut-down). between control unit and D7930v/82 - Sol C2
shut-down test. servo valve.
mission (D7930).
32772 3 8004/3 Servo valve, clutch re- Transmission locked in Check the cable harness D7930-1/73 - Sol CR -
verse gear (Sol CR) (volt- neutral (Shut-down). between control unit and
age feed), short circuit to servo valve.
verse gear (Sol CR) neutral (Shut-down). between control unit and
code components
verse gear (Sol CR) (volt- neutral (Shut-down). between control unit and
age feed), short circuit to servo valve.
verse gear (Sol CR) neutral (Shut-down). between control unit and
verse gear (Sol CR), neutral (Shut-down). between control unit and D7930-1/85 - Sol CR
open circuit. servo valve.
verse gear, error during neutral (Shut-down). between control unit and D7930-1/85 - Sol CR
mission (D7930).
32774 3 8006 Servo valve, clutch gear 3 Transmission locked in Check the cable harness D7930-1/75 - Sol C3 -
32774 3 8006 Servo valve, clutch gear 3 Transmission locked in Check the cable harness D7930-1/81 - Sol C3 -


servo valve.
VDRG09.01GB
D:99
code components
VDRG09.01GB
(Sol C3), error during neutral (Shut-down). between control unit and D7930-1/81 - Sol C3
mission (D7930).
servo valve.

(Sol C1), error during neutral (Shut-down). between control unit and D7930-1/84 - Sol C1
mission (D7930).
32776 4 8008/4 Pressure switch, oil filter No limitation. Check the cable harness D7930-2/33 - B7551 -
supply (B7551), open cir- between control unit and D7930-2/48 - B7551
cuit (ignition on and en- the pressure switch.
gine switched off). Check the pressure
switch.
32777 0 8009/0 Oil filter transmission Transmission locked to Change oil filter - See Maintenance manual.
clogged for more than 50 drive range 1 (Limp- transmission.
operating hours. home).
code components
32777 16 8009/16 Oil filter transmission No limitation. Change oil filter - See Maintenance manual.
clogged for 0 - 50 operat- transmission.
ing hours.
32779 0 800B/0 Control unit transmission No limitation. Check the voltage feed F9958–RD/E1 -D7930-2/ 2.8 Control System 12/XX
(D7930) (voltage supply, Check alternator, battery 45 DIAGNOSE, page 8:41
control electronics), volt- and cable harness be- F9958–RD/E1 -D7930-2/
age too high (above 40 V). tween battery and 58
alternator.
(D7930), (voltage supply, Check the cable harness 45 DIAGNOSE, page 8:41
control electronics), volt- to the control unit. F9958–RD/E1 -D7930-2/
age too low (below 17 V). Check alternator, battery 58
and cable harness be-
tween battery and
alternator.
(D7930) (voltage supply, If auxiliary start equipment 45 DIAGNOSE, page 8:41
control electronics), volt- is connected, disconnect F9958–RD/E1 -D7930-2/
age too high (above 30 V). it. 58
32869 16 8065/16 Temperature sensor, No limitation. Check the cable harness D7930-1/21 - T_Leak 2.8 Control System 15/XX
leakage (T_Leak), tem- between control unit and D7930-1/45 - T_Leak DIAGNOSE, page 8:42
perature too high. sensor.
Check the sensor.
32870 0 8066/0 Sensor oil temperature Transmission locked to Check the cable harness D7930-1/16 - B7660 2.8 Control System 15/XX
(B7660), temperature too drive range 1 (Limp- between control unit and D7930-1/45 - B7660 DIAGNOSE, page 8:42
high. home). sensor.
Check the sensor.

32870 16 8066/16 Sensor oil temperature No limitation. Check transmission oil D7930-1/16 - B7660 2.8 Control System 15/XX
(B7660), high cooler. D7930-1/45 - B7660 DIAGNOSE, page 8:42
temperature. Check the cable harness
between control unit and
sensor.
Check the sensor.
VDRG09.01GB
D:101
code components
VDRG09.01GB
32871 0 8067/0 Control unit transmission No limitation. Check the voltage feed F9958–RD/F1 -D7930-2/ 2.8 Control System 12/XX
power electronics), volt- is connected, disconnect F9958–RD/F1 -D7930-2/
F9958–RD/F1 -D7930-2/
3
F9958–RD/F1 -D7930-2/
4
F9958–RD/F1 -D7930-2/
5
F9958–RD/F1 -D7930-2/
6
(D7930) (voltage supply, 1 DIAGNOSE, page 8:41
power electronics), volt- F9958–RD/F1 -D7930-2/
age too low (below 17 V). 2
F9958–RD/F1 -D7930-2/
3
F9958–RD/F1 -D7930-2/
4
F9958–RD/F1 -D7930-2/
5
F9958–RD/F1 -D7930-2/
6
power electronics), volt- is connected, disconnect F9958–RD/F1 -D7930-2/

F9958–RD/F1 -D7930-2/

3
F9958–RD/F1 -D7930-2/
4
F9958–RD/F1 -D7930-2/
5
F9958–RD/F1 -D7930-2/
6
32872 11 8068/11 Emergency switch Transmission locked in Check the cable harness D7930-1/14 - K3990-1/87 -
activated. neutral (Shut-down). between control unit and D7931/14 - K3990-1/87
emergency switch.
32872 12 8068/12 Emergency switch Transmission locked in Check the cable harness D7930-1/14 - K3990-1/87 -
activated. neutral (Shut-down). between control unit and D7931/14 - K3990-1/87
emergency switch.
code components
33024 12 8100/12 Speed sensor, gear 1 Transmission locked in Check the cable harness D7930-1/12 - N1 2.8 Control System 17/XX
(N1), signal error, fre- neutral (Shut-down). between control unit and D7930-1/46 - N1 DIAGNOSE, page 8:43
quency too low. sensor.
Check the sensor.
33025 12 8101/12 Speed sensor, gear 2 Transmission locked to Check the cable harness D7930-1/13 - N2 2.8 Control System 17/XX
(N2), signal error, fre- drive range 1 (Limp- between control unit and D7930-1/46 - N2 DIAGNOSE, page 8:43
quency too low. home). sensor.
Check the sensor.
(N3), signal error, fre- neutral (Shut-down). between control unit and D7930-1/46 - N3 DIAGNOSE, page 8:43
quency too low. sensor.
Check the sensor.
33028 3 8104/3 Temperature sensor, Transmission locked to Check the cable harness D7930-1/21 - T_Leak 2.8 Control System 15/XX
leakage (T_Leak), short drive range 1 (Limp- between control unit and D7930-1/45 - T_Leak DIAGNOSE, page 8:42
circuit to voltage or open home). sensor.
circuit. Check the sensor.
33028 4 8104/4 Temperature sensor, Transmission locked to Check the cable harness D7930-1/21 - T_Leak 2.8 Control System 15/XX
leakage (T_Leak), short drive range 1 (Limp- between control unit and D7930-1/45 - T_Leak DIAGNOSE, page 8:42
circuit to ground. home). sensor.
Check the sensor.
33029 3 8105/3 Sensor, oil temperature Transmission locked to Check the cable harness D7930-1/16 - B7660 2.8 Control System 15/XX
(B7660), short circuit to drive range 1 (Limp- between control unit and D7930-1/45 - B7660 DIAGNOSE, page 8:42
voltage or open circuit. home). sensor.
Check the sensor.
33029 4 8105/4 Sensor, oil temperature Transmission locked to Check the cable harness D7930-1/16 - B7660 2.8 Control System 15/XX
(B7660), short circuit to drive range 1 (Limp- between control unit and D7930-1/45 - B7660 DIAGNOSE, page 8:42
ground. home). sensor.

Check the sensor.
33030 3 8106/3 Sensor, oil pressure A Transmission locked in Check the cable harness D7930-2/17 - P_A 2.8 Control System 15/XX
(P_A), short circuit to neutral (Shut-down). between control unit and DIAGNOSE, page 8:42
voltage. sensor.
Check the sensor.
33030 4 8106/4 Sensor, oil pressure A Transmission locked in Check the cable harness D7930-2/17 - P_A 2.8 Control System 15/XX
(P_A), short circuit to neutral (Shut-down). between control unit and DIAGNOSE, page 8:42
ground or open circuit. sensor.
Check the sensor.
33031 3 8107/3 Sensor, oil pressure B Transmission locked in Check the cable harness D7930-2/31 - P_B 2.8 Control System 15/XX
(P_B), short circuit to neutral (Shut-down). between control unit and DIAGNOSE, page 8:42
voltage. sensor.
Check the sensor.
VDRG09.01GB
D:103
code components
VDRG09.01GB
33031 4 8107/4 Sensor, oil pressure B Transmission locked in Check the cable harness D7930-2/31 - P_B 2.8 Control System 15/XX
(P_B), short circuit to neutral (Shut-down). between control unit and DIAGNOSE, page 8:42
ground or open circuit. sensor.
Check the sensor.
33032 1 8108/1 Sensor, oil pressure A Transmission locked in Check the oil level. Top up - 2.8 Control System 15/XX
(P_A), low feed pressure. neutral (Shut-down). if necessary. DIAGNOSE, page 8:42
Check the pressure
switch for supply filter with
the diagnostic menu. Re-
place the supply filter if
necessary.
Check the boost pressure
and feed pressure.
Check the charge pump.
Replace defective parts
as necessary.
33032 15 8108/15 Sensor, oil pressure A Transmission locked in Check engine speed while - 2.8 Control System 15/XX
(P_A), low feed pressure neutral (Shut-down). manoeuvring. DIAGNOSE, page 8:42
due to a drop in engine Engine speed decreases
power. due to working hydraulics
or steering.
33033 1 8109/1 Sensor, oil pressure B Transmission locked in Check the oil level. Top up - 2.8 Control System 15/XX
(P_B), low feed pressure neutral (Shut-down). if necessary. DIAGNOSE, page 8:42
Check the pressure
switch for supply filter with
the diagnostic menu. Re-

place the supply filter if
necessary.

Check the boost pressure
and feed pressure.
Check the charge pump.
Replace defective parts
as necessary.
33033 15 8109/15 Sensor, oil pressure B Transmission locked in Check engine speed while - 2.8 Control System 15/XX
(P_B), low feed pressure neutral (Shut-down). manoeuvring. DIAGNOSE, page 8:42
(due to a drop in engine Switch off the machine.
power). Restart the machine.
Check the oil level. Top up
if necessary.
(N1), signal error, air gap neutral (Shut-down). between control unit and D7930-1/46 - N1 DIAGNOSE, page 8:43
error, or assembly error. sensor.
Check the sensor.
code components
33041 12 8111/12 Speed sensor, gear 2 Transmission locked to Check the cable harness D7930-1/13 - N2 2.8 Control System 17/XX
(N2), signal error, air gap drive range 1 (Limp- between control unit and D7930-1/46 - N2 DIAGNOSE, page 8:43
error, or assembly error. home). sensor.
Check the sensor.
(N3), signal error, air gap neutral (Shut-down). between control unit and D7930-1/46 - N3 DIAGNOSE, page 8:43
error, or assembly error. sensor.
Check the sensor.
33280 7 8200/7 Clutch gear 2 slipping. Transmission locked in Check the feed pressure - 2.8 Control System 16/XX
neutral (Shut-down). to the transmission DIAGNOSE, page 8:43
control.
Check the control pres-
sure to the clutch.
Check accumulator pres-
sure and accumulator.
Calibrate the transmission.
Check the wear on the
clutch plates.
33281 7 8201/7 Clutch reverse gear Transmission locked in Check the feed pressure - 2.8 Control System 16/XX
slipping. neutral (Shut-down). to the transmission DIAGNOSE, page 8:43
control.
sure to the clutch.

clutch plates.

control.
sure to the clutch.
clutch plates.
VDRG09.01GB
D:105
code components
VDRG09.01GB
control.
sure to the clutch.
clutch plates.
33286 7 8206/7 Unexpected speed devia- Transmission locked in Check the control pres- - 2.8 Control System 16/XX
tion clutch gear 1, fault in neutral (Shut-down). sure to clutch 1. DIAGNOSE, page 8:43
clutch system Check the clutch plate
packages on clutch 1.
Check the clutch cylinder
on clutch 1.
33296 2 8210/2 Pressure sensor, gear 2 No limitation. Check the cable harness D7930-2/55 - P_C2 2.8 Control System 16/XX
(P_C2), unreasonable between control unit and D7930-1/46 - P_C2 DIAGNOSE, page 8:43
signal. sensor. D7930-2/26 - P_C2
Check the sensor.
33296 3 8210/3 Pressure sensor, gear 2 No limitation. Check the cable harness D7930-2/55 - P_C2 2.8 Control System 16/XX
(P_C2), short circuit to between control unit and D7930-1/46 - P_C2 DIAGNOSE, page 8:43
voltage. sensor. D7930-2/26 - P_C2
Check the sensor.
33296 4 8210/4 Pressure sensor, clutch No limitation. Check the cable harness D7930-2/55 - P_C2 2.8 Control System 16/XX
gear 2 (P_C2), short cir- between control unit and D7930-1/46 - P_C2 DIAGNOSE, page 8:43
cuit to ground or open sensor. D7930-2/26 - P_C2

33297 2 8211/2 Pressure sensor, clutch No limitation. Check the cable harness D7930-2/55 - P_CR 2.8 Control System 16/XX
reverse gear (P_CR), un- between control unit and D7930-1/46 - P_CR DIAGNOSE, page 8:43
reasonable signal. sensor. D7930-1/64 - P_CR
Check the sensor.
reverse gear (P_CR), between control unit and D7930-1/46 - P_CR DIAGNOSE, page 8:43
short circuit to voltage. sensor. D7930-1/62 - P_CR
Check the sensor.
reverse gear (P_CR), between control unit and D7930-1/46 - P_CR DIAGNOSE, page 8:43
short circuit to ground or sensor. D7930-1/64 - P_CR
open circuit. Check the sensor.
code components
gear 3 (P_C3), unreason- between control unit and D7930-1/46 - P_C3 DIAGNOSE, page 8:43
able signal. sensor. D7930-1/66 - P_C3
Check the sensor.
cuit to voltage. sensor. D7930-1/66 - P_C3
Check the sensor.
gear 1 (P_C1), unreason- between control unit and D7930-1/46 - P_C1 DIAGNOSE, page 8:43
able signal. sensor. D7930-1/41 - P_C1
Check the sensor.
cuit to voltage. sensor. D7930-1/41 - P_C1
Check the sensor.
33302 1 8216/1 Temperature too high in No limitation. Check the driving behav- - -
clutch gear 1. iour of the operator.
Contact a service techni-

cian accredited Dana Re-
xroth Transmission
Service for further
troubleshooting.
xroth Transmission
Service for further
troubleshooting.
VDRG09.01GB
D:107
code components
VDRG09.01GB
xroth Transmission
Service for further
troubleshooting.
clutch reverse gear. iour of the operator.
xroth Transmission
Service for further
troubleshooting.
33312 7 8220/7 Asynchronous gear Transmission locked to Check operator driving - -
changing 3 - 2 drive range 1 (Limp- behaviour.
deactivated. home). Calibrate the transmission.
xroth Transmission
Service for further
troubleshooting.
33315 7 8223/7 Asynchronous gear Transmission locked to Check operator driving - -
changing 2 - 3 drive range 1 (Limp- behaviour.
deactivated. home). Calibrate the transmission.

xroth Transmission

Service for further
troubleshooting.
33536 2 8300/2 Communication error Transmission locked in Check and rectify error - -
CAN bus drive-train neutral (Shut-down). codes for the machine.
(brake pedal). Note time and contact
Cargotec support.
CAN bus drive-train (ac- neutral (Shut-down). codes for the machine.
celerator pedal). Note time and contact
Cargotec support.
CAN bus drive-train (trav- neutral (Shut-down). codes for the machine.
el direction). Note time and contact
Cargotec support.
code components
33553 2 8311/2 Communication error Transmission locked to Check and rectify error - -
CAN bus drive-train (trav- drive range 1 (Limp- codes for the machine.
el direction, option). home). Note time and contact
Cargotec support.
CAN bus drive-train (acti- drive range 1 (Limp- codes for the machine.
vation of travel direction, home). Note time and contact
option). Cargotec support.
CAN bus drive-train drive range 1 (Limp- codes for the machine.
(downshifting). home). Note time and contact
Cargotec support.
CAN bus drive-train (au- drive range 1 (Limp- codes for the machine.
tomatic gearing). home). Note time and contact
Cargotec support.
CAN bus drive-train drive range 1 (Limp- codes for the machine.
(parking brake). home). Note time and contact
Cargotec support.
33793 1 8401/1 Calibration transmission, No limitation. Switch off the machine. - -
interrupted (start). Restart the machine. Start
calibration of the
transmission.

xroth Transmission
Service for further
troubleshooting.
interrupted (C2). Restart the machine. Start
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
VDRG09.01GB
D:109
code components
VDRG09.01GB
interrupted (CR). Restart the machine. Start
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further

troubleshooting.

calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
code components
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further

troubleshooting.

calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
VDRG09.01GB
D:111
code components
VDRG09.01GB
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further

troubleshooting.

calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
code components
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further

troubleshooting.

calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
VDRG09.01GB
D:113
code components
VDRG09.01GB
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further

troubleshooting.
33794 13 8402/13 Transmission not Transmission locked to Calibrate the transmission. - -

calibrated. drive range 1 (Limp-
home).
code components
33796 12 8404/12 Control unit transmission Transmission locked in Check the voltage feed F9958–RD/E1 -D7930-2/ 2.8 Control System 12/XX
(D7930), internal hard- neutral (Shut-down). Check the cable harness 45 DIAGNOSE, page 8:41
ware monitoring (error to the control unit. F9958–RD/E1 -D7930-2/
during start-up). Replace the control unit. 58
F9958–RD/F1 -D7930-2/
1
F9958–RD/F1 -D7930-2/
2
F9958–RD/F1 -D7930-2/
3
F9958–RD/F1 -D7930-2/
4
F9958–RD/F1 -D7930-2/
5
F9958–RD/F1 -D7930-2/
6
interrupted (HyPAmin). Restart the machine. Start
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
Check the servo valves
for pump control.

interrupted (HyPAmax). Restart the machine. Start

calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
for pump control.
VDRG09.01GB
D:115
code components
VDRG09.01GB
interrupted (HyMmax). Restart the machine. Start
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
for pump control.
interrupted (HyMmin). Restart the machine. Start
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
for pump control.
interrupted (HyPBmin). Restart the machine. Start
calibration of the
transmission.
xroth Transmission

Service for further
troubleshooting.
for pump control.
interrupted (HyPBmax). Restart the machine. Start
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
for pump control.
code components
calibration of the
transmission.
Check the servo valve for
the clutch.
xroth Transmission
Service for further
troubleshooting.
Check the clutch package.
calibration of the
transmission.
the clutch.
xroth Transmission
Service for further
troubleshooting.

calibration of the
transmission.

the clutch.
xroth Transmission
Service for further
troubleshooting.
VDRG09.01GB
D:117
code components
VDRG09.01GB
calibration of the
transmission.
the clutch.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
the clutch.
xroth Transmission
Service for further
troubleshooting.

calibration of the
transmission.

the clutch.
xroth Transmission
Service for further
troubleshooting.
code components
calibration of the
transmission.
the clutch.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
the clutch.
xroth Transmission
Service for further
troubleshooting.

calibration of the
transmission.

the clutch.
xroth Transmission
Service for further
troubleshooting.
VDRG09.01GB
D:119
code components
VDRG09.01GB
calibration of the
transmission.
the clutch.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
the clutch.
xroth Transmission
Service for further
troubleshooting.

calibration of the
transmission.

the clutch.
xroth Transmission
Service for further
troubleshooting.
code components
calibration of the
transmission.
the clutch.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
the clutch.
xroth Transmission
Service for further
troubleshooting.

calibration of the
transmission.

the clutch.
xroth Transmission
Service for further
troubleshooting.
VDRG09.01GB
D:121
code components
VDRG09.01GB
calibration of the
transmission.
the clutch.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
for pump control.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
for pump control.

xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
for pump control.
xroth Transmission
Service for further
troubleshooting.
code components
calibration of the
transmission.
for pump control.
xroth Transmission
Service for further
troubleshooting.
interrupted (HyPA). Restart the machine. Start
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.

xroth Transmission
Service for further
troubleshooting.

calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
VDRG09.01GB
D:123
code components
VDRG09.01GB
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further

troubleshooting.

calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
code components
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further

troubleshooting.

calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
VDRG09.01GB
D:125
code components
VDRG09.01GB
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further

troubleshooting.

calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
code components
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
calibration of the
transmission.
xroth Transmission
Service for further

troubleshooting.

calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
VDRG09.01GB
D:127
code components
VDRG09.01GB
calibration of the
transmission.
xroth Transmission
Service for further
troubleshooting.
33800 1 8408/1 Calibration transmission, No limitation. Apply the parking brake. - -
not permitted or interrup- Switch off the machine.
ted (parking brake Restart the machine. Start
released). calibration of the
transmission.
33800 2 8408/2 Calibration transmission, No limitation. Select neutral position. - -
not permitted or interrup- Switch off the machine.
ted (travel direction Restart the machine. Start
selected). calibration of the
transmission.
33800 3 8408/3 Calibration transmission, No limitation. Allow the machine to idle - -
not permitted (high oil with the transmission in
temperature). neutral until the oil tem-
perature for the transmis-
sion is below 69 °C.
Switch off the machine.
Wait for 5 minutes. Re-

start the machine. Start
calibration of the

transmission.
33800 4 8408/4 Calibration transmission, No limitation. Allow the machine to idle - -
interrupted (high oil with the transmission in
temperature). neutral until the oil tem-
perature for the transmis-
sion is below 69 °C.
Wait for 5 minutes. Re-
start the machine. Start
calibration of the
transmission.
Check the cooling system.
code components
33800 5 8408/5 Calibration transmission, No limitation. Check that no large power - -
interrupted (high engine consumer has been shut
speed). down during calibration.
Restart the machine. Start
calibration of the
transmission.
33800 6 8408/6 Calibration transmission, No limitation. Check that no large power - -
interrupted (low engine consumer has been
speed). switched on during cali-
bration. Switch off the ma-
chine. Restart the
machine. Start calibration
of the transmission.
33801 13 8409/13 Calibration transmission, No limitation. Change oil and oil filter for - See Maintenance manual.
interrupted (calibration the transmission. Start
period too long). calibration of the
transmission.
34049 19 8028/19 Communication error Transmission locked to Check the cable harness - -
CAN bus drive-train drive range 1 (Limp- between the control units
(EEC1). home). as well as termination.
Check communications
on the CAN bus.
Note time and contact
Cargotec support.
(HMI1). home). as well as termination.

on the CAN bus.
Cargotec support.
(HMI2). home). as well as termination.
on the CAN bus.
Cargotec support.
VDRG09.01GB
D:129
code components
VDRG09.01GB
(PTIN). home). as well as termination.
on the CAN bus.
Cargotec support.
34054 19 8506/19 CAN bus 2, open circuit No limitation. Check the cable harness - -
between the control units
as well as termination.
on the CAN bus.
Cargotec support.
(VEH1). home). as well as termination.
on the CAN bus.
Cargotec support.
34056 19 8508/19 Communications error No limitation. Note time and contact - -
CAN bus drive-train Cargotec support.
(TRQ_LIM_REQ).
34057 19 8509/19 Communications error No limitation. Note time and contact - -

(TRQ_BRK_ACT).

34058 19 850A/19 Communications error No limitation. Note time and contact - -
(TOT_VEH_WGT).
34059 2 850B/2 Communications error No limitation. Note time and contact - -
CAN bus drive-train (ID_ Cargotec support.
CFG_SET).
34059 19 850B/19 Communications error No limitation. Note time and contact - -
CAN bus drive-train (ID_ Cargotec support.
CFG_SET).
code components
34304 7 8600/7 Differential pressure in Transmission locked to Check operator driving - -
transmission too high. drive range 1 (Limp- behaviour.
Relief valve unable to home). Contact a service techni-
protect the transmission. cian accredited Dana Re-
xroth Transmission
Service for further
troubleshooting.
34305 7 8601/7 Incorrect gear ratio. Servo Transmission locked in Calibrate the transmission. - -
valve, hydrostatic pump, neutral (Shut-down). Contact a service techni-
wrong direction. cian accredited Dana Re-
xroth Transmission
Service for further
troubleshooting.
34306 7 8602/7 Rotation speed of hydro- Transmission locked to Check operator driving - -
static motor too high (R3> drive range 1 (Limp- behaviour.
5000 rpm, R2> 5500 rpm). home). Calibrate the transmission.
34307 7 8603/7 Hydrostatic pump, unde- Transmission locked to Calibrate the transmission. - -
sired pump flow. Hydro- drive range 1 (Limp- Contact a service techni-
static motor runs when home). cian accredited Dana Re-
not requested. xroth Transmission
Service for further
troubleshooting.
34308 7 8604/7 Hydrostatic pump, no Transmission locked in Calibrate the transmission. - -
pump flow. Hydrostatic neutral (Shut-down). Contact a service techni-
motor does not run when cian accredited Dana Re-

requested. xroth Transmission
Service for further

troubleshooting.
34309 7 8605/7 Outgoing torque too high. Transmission locked to Check operator driving - -
drive range 1 (Limp- behaviour.
home). Contact a service techni-
xroth Transmission
Service for further
troubleshooting.
34311 7 8607/7 The inputs for the Transmission locked in Check the control pres- - 2.8 Control System 16/XX
clutches are blocked neutral (Shut-down). sure to clutch R, 2 and 3. DIAGNOSE, page 8:43
(StartLock). Check the clutch plate
packages on clutch R, 2
and 3.
Check the clutch cylinder
on clutch R, 2 and 3.
VDRG09.01GB
D:131
code components
VDRG09.01GB
34312 7 8608/7 Status, neutral position, No limitation. Check that the machine - -
logical error. does not move when neu-
tral is selected.
Check and rectify any oth-
er error codes.
34313 7 8609/7 Status, travel direction, No limitation. Check that the machine - -
logical error. does not move towards
the selected travel
direction.
er error codes.
34320 7 8610/7 Status, parking brake, No limitation. Check that the parking - -
logical error. brake has been released
before the travel direction
is selected.
er error codes.
34321 7 8611/7 Status, calibration and No limitation. Check that the parking - -
heating, logical error. brake is applied during
calibration.
Check that the machine is
stationary during
calibration.
er error codes.
34322 12 8612/12 Monitoring, two clutches Transmission locked in Check the driving behav- - -
engaged simultaneously. neutral (Shut-down). iour of the operator.
Select the travel direction

and gear range again.
D Error codes – Machine D:133
D.8 Machine
Error codes machine
The error codes for the machine are sorted in numerical order. The ta-
ble contains the following information:
• Type - Specifies type of component, see Component type (B),
page D:7.
D:8.
• Node - Specifies which control unit set the error code, see below.
• Location - Specifies code for component location if there are sev-
eral with the same component number, see Component location
(DD), page D:8.
• Description - Gives a description of the error code.
• Limitation - Gives any limitation which may exist on the machine
for the current error code.
• Reference - Specifies which section of the workshop manual it is
that contains information relating to the error code.
Table Node, explanation
Node Control unit

1 KCU (D7901)
2 KFU (D7971)
3 KFU-2 (D7972)
6 KAU-2 (D7912)
7 KAU (D7911)
11 KPU (D7902)
12 KID (D7950)
100 Engine
110 Transmission Dana
210 Exhaust system

Table Error codes machine D:134
Type SPN FMI Node Location Description Limitation Action Connections Diagnostic Reference
and menu
components
VDRG09.01GB
114 1 1 Overcurrent will cause The battery is shut Search for abnormal current - -
BMS to shut down and down after timeout consumption.
open the contactor. and error code.
114 2 1 Error on current sensor, - - - -
battery cell.
114 6 1 The current is above the - Search for short circuit or - -
configured alarm level abnormal current
for a configured time. consumers.
114 6 1 The current is above the - Search for short circuit or - -
configured alarm level abnormal current
168 3 1 Warning of overvoltage. - - - - -
168 3 1 Cell voltage is above - BMS service tool is needed - - -
configured alarm level to find defective cell or mod-
4.0V. ule. Contact Cargotec
support.
H 1037 6 11 2 Indicator light Levelling Light not working. Check the cable harness be- H1037 Control lever
lock (H1037) in switch tween control unit control D7902/C4:2 (Ego), descrip-
on control lever. lever. tion, page 7:6
S 1310 7 11 Travel direction selector Selection of gear or Check cabling between the S1310 2.1 Controls & Travel direction
(S1310), logical error activation of park- control unit and the compo- Instr 1/XX DI- selector and
ing brake not nent with diagnostic menu. AGNOSE, parking brake,
working. Check the travel direction page 8:39 description,
selector. page 2:11

S 1500 31 1 0 Ignition is missing at Machine speed is Check cabling between the S1500 11.5 Distr of Ignition key
speeds above 3 km/h. limited to 10 km/h control unit and the compo- D7901/C1:49 Electr 1/XX DI- lock, descrip-
If the speed is < 1 km/h, and engine speed nent with diagnostic menu. AGNOSE, tion, page 1:1
the parking brake will be to 1200 rpm. Check the component. page 8:137
activated.
If the speed is >1 km/h,
the parking brake will
not be activated if the
control breaker is not
activated.
H 1753 6 1 2 Indicator light wide twist- Indicator light not Check cabling between the H1753-2 7.9 Load Car-
locks (WTP), outer posi- working. control unit and the compo- D7901/C2:34 rier 132/XX DI-
tion (H1753-2), short nent with diagnostic menu. AGNOSE,
circuit to ground. Check the travel direction page 8:95
selector.
Table Error codes machine (continued)
and menu
components
H 1753 6 7 1 Indicator light wide twist- Indicator light not Check cabling between the H1753-1 7.9 Load Car-
locks (WTP), outer posi- working. control unit and the compo- D7911/C1:20 rier 131/XX DI-
tion (H1753-1), short nent with diagnostic menu. AGNOSE,
circuit to ground. Check the travel direction page 8:95
selector.
1800 0 1 Battery temperature is - Allow the battery to cool - -
above configured warn- down.
ing level 55 °C.
1800 0 1 Battery temperature is - Allow the battery to cool - -
above configured alarm down.
level 65 °C.
1800 1 1 Battery temperature is - Warm up the battery by op- - -
below configured warn- erating or park the machine
ing level -6 °C. in warm premises.
1800 1 1 Battery temperature is - Warm up the battery by op- - -
below configured alarm erating or park the machine
level -11 °C. in warm premises.
1800 1 1 Temperature in battery The battery is shut Park the machine in warm - -
too low and BMS con- down after timeout premises.
tactor open. and error code.
1800 2 1 The temperature sensor - - - -
D Error codes – Machine
in the battery module

registers temperatures
above 250 °C or lower
than -100 °C

B 2070 3 2 Differential lock contact Differential lock not Check cabling between the B2070
(B2070), position signal working. control unit and the compo- D7971/C1:5
nent with diagnostic menu.
B 2190 2 1 Sensor cab filter B2190, Poor air flow to the Replace the cab filter. B2190 9.4 Climate Fresh air filter,
pressure drop over cab cab. Check the sensor. D7901/C1:15 System 6/XX description,
filter too high. DIAGNOSE, page 9:31
page 8:112
VDRG09.01GB
D:135
Table Error codes machine (continued) D:136
and menu
components
VDRG09.01GB
B 2460 2 1 Pressure sensor Cooling function for Check the drive belt for the B2460 9.4 Climate Pressure
(B2460) for low or high air conditioning unit compressor for air D7901/C1:1 System 6/XX switch, descrip-
pressure in refrigerant not working. conditioning. DIAGNOSE, tion, page 9:43
circuit. Check that compressor for page 8:112
air conditioning is activated.
Check cabling between the
control unit and the compo-
Pressure test the air condi-
tioning unit.
K 3150 6 1 Relay ignition (K3150), Check cabling between the K3150 11.7 I/O D7901 Ignition voltage
short circuit to ground. control unit and the compo- D7901/C2:11 KCU 1-48/XX (15), descrip-
nent with diagnostic menu. DIAGNOSE, tion, page
Check the component. page 8:166 11:18
K 3312 6 2 Driving forwards relay Driving forwards Check the cable harness be- D7971/C1:22 11.1 Controls &
(K3312), signal status not working. tween control unit and Instr 3/XX DI-
component. AGNOSE,
Check the component. page 8:136
component. AGNOSE,
component. AGNOSE,

component. AGNOSE,
K 3320 6 2 Reversing relay (K3320), Reversing not Check the cable harness be- D7971/C1:23 11.1 Controls &
signal status working. tween control unit and Instr 4/XX DI-
component. AGNOSE,
component. AGNOSE,
and menu
components
component. AGNOSE,
component. AGNOSE,
3509 2 1 Voltage sensor, battery - Contact Cargotec support. - - -
cell, detects an incorrect
voltage due to poor con-
nection of sensor cables.
K 3600 5 2 Starter relay engine The engine does Check the cable harness be- K3600/86 1.11 Start &
(K3600) short circuit to not start. tween control unit and D7971/C1:43 Stop 1/XX DI-
ground. component. AGNOSE,
Only engine option Check the component. page 8:37
Cummins.
K 3600 6 2 Starter relay engine The engine does Check the cable harness be- K3600/86 1.11 Start &
(K3600) short circuit to not start. tween control unit and D7971/C1:43 Stop 1/XX DI-
ground. component. AGNOSE,
G 3621 2 1 Internal RS485 commu- Battery contactor Contact Cargotec support.
nication error. open. No power.

G 3621 12 1 Control unit BMS cannot Speed limitation. Contact Cargotec support.
communicate with at The battery is shut

least one battery cell at down after timeout
the moment. and error code.
E 4000 5 2 10 Low beam left (E4000), Low beam left not Check bulb. E4000-LE 9.6 Lighting Headlights, de-
open circuit. working. Check cabling between the D7971/C2:1 Sys 3/XX DI- scription, page
control unit and the compo- AGNOSE, 9:74
nent with diagnostic menu. page 8:121
E 4000 5 3 210 Low beam left rear Low beam left rear Check bulb. E4000-LR Headlights, de-
(E4000), open circuit. not working. Check cabling between the D7972/C2:1 scription, page
At turnable opera- control unit and the compo- 9:74
tor's station. nent with diagnostic menu.
E 4000 6 2 10 Low beam left (E4000) Low beam left not Check cabling between the E4000-LE 9.6 Lighting Headlights, de-
short circuit to ground. working. control unit and the compo- D7971/C2:1 Sys 3/XX DI- scription, page
nent with diagnostic menu. AGNOSE, 9:74
page 8:121
VDRG09.01GB
D:137
and menu
components
VDRG09.01GB
E 4000 6 3 210 Low beam left rear Low beam left rear Check cabling between the E4000-LR Headlights, de-
(E4000), short circuit to not working. control unit and the compo- D7972/C2:1 scription, page
ground. At turnable opera- nent with diagnostic menu. 9:74
tor's station.
E 4000 5 2 20 Low beam right (E4000), Low beam right not Check bulb. E4000-RI 9.6 Lighting Headlights, de-
open circuit. working. Check cabling between the D7971C2:3 Sys 3/XX DI- scription, page
E 4000 5 3 220 Low beam right rear Low beam right Check bulb. E4000-RR Headlights, de-
(E4000), open circuit. rear not working. Check cabling between the D7972/C2:3 scription, page
E 4000 6 2 20 Low beam right (E4000), Low beam right not Check cabling between the E4000-RI 9.6 Lighting Headlights, de-
short circuit to ground. working. control unit and the compo- D7971C2:3 Sys 3/XX DI- scription, page
page 8:121
E 4000 6 3 220 Low beam right rear Low beam right Check cabling between the E4000-RR Headlights, de-
(E4000), short circuit to rear not working. control unit and the compo- D7972/C2:3 scription, page
tor's station.
E 4020 5 2 10 High beam left (E4020), High beam left not Check bulb. E4020-LE 9.6 Lighting Headlights, de-
open circuit. working. Check cabling between the D7971/C2:2 Sys 2/XX DI- scription, page

E 4020 5 3 210 High beam left rear High beam left rear Check bulb. E4020-LR Headlights, de-

(E4020), open circuit. not working. Check cabling between the D7972/C2:2 scription, page
E 4020 6 2 10 High beam left (E4020), High beam left not Check cabling between the E4020-LE 9.6 Lighting Headlights, de-
short circuit to ground. working. control unit and the compo- D7971/C2:2 Sys 2/XX DI- scription, page
page 8:120
E 4020 6 3 210 High beam left rear High beam left rear Check cabling between the E4020-LR Headlights, de-
(E4020), short circuit to not working. control unit and the compo- D7972/C2:2 scription, page
tor's station.
E 4020 5 2 20 High beam right High beam right not Check bulb. E4020-RI 9.6 Lighting Headlights, de-
(E4020), open circuit. working. Check cabling between the D7971/C2:4 Sys 2/XX DI- scription, page
and menu
components
E 4020 5 3 220 High beam right rear High beam right Check bulb. E4020-RR Headlights, de-
(E4020), open circuit. rear not working. Check cabling between the D7972/C2:4 scription, page
E 4020 6 3 220 High beam right rear High beam right Check cabling between the E4020-RR Headlights, de-
(E4020), short circuit to rear not working. control unit and the compo- D7972/C2:4 scription, page
tor's station.
E 4020 6 2 20 High beam right High beam right not Check cabling between the E4020-RI 9.6 Lighting Headlights, de-
(E4020), short circuit to working. control unit and the compo- D7971/C2:4 Sys 2/XX DI- scription, page
ground. nent with diagnostic menu. AGNOSE, 9:74
page 8:120
E 4041 5 2 1 Extra working lights Extra working lights Check bulb. E4041 9.6 Lighting Extra working
frame left (E4041-LE-A) frame left not Check cabling between the D7971/C2:5 Sys 17/XX DI- lights frame,
(E4041-LE-B), open working. control unit and the compo- AGNOSE, description,
circuit. nent with diagnostic menu. page 8:124 page 9:78
frame left (E4041-LE-A) frame left not Check cabling between the D7971/C2:5 Sys 17/XX DI- lights frame,
(E4041-LE-B), short cir- working. control unit and the compo- AGNOSE, description,
cuit to ground. nent with diagnostic menu. page 8:124 page 9:78
frame right (E4041-RI- frame right not Check cabling between the D7971/C2:6 Sys 17/XX DI- lights frame,
A) (E4041-RI B), open working. control unit and the compo- AGNOSE, description,

frame right (E4041-RI- frame right not Check cabling between the D7971/C2:6 Sys 17/XX DI- lights frame,
A) (E4041-RI-B), short working. control unit and the compo- AGNOSE, description,
circuit to ground. nent with diagnostic menu. page 8:124 page 9:78
E 4042 5 1 10 Working lights cab left Working lights left Check bulb. E4042-LE 9.6 Lighting Working lights,
(E4042-LE), open circuit. not working. Check cabling between the D7901/C2:22 Sys 11/XX DI- cab, descrip-
control unit and the compo- AGNOSE, tion, page 9:77
E 4042 6 1 10 Working lights cab left Working lights left Check cabling between the E4042-LE 9.6 Lighting
(E4042-LE), short circuit not working. control unit and the compo- D7901/C2:22 Sys 11/XX DI-
to ground. nent with diagnostic menu. AGNOSE,
page 8:123
VDRG09.01GB
D:139
and menu
components
VDRG09.01GB
E 4042 5 1 20 Working lights cab right Working lights right Check bulb. E4042-RI 9.6 Lighting Working lights,
(E4042-RI) open circuit. not working. Check cabling between the D7901/C2:23 Sys 11/XX DI- cab, descrip-
E 4042 6 1 20 Working lights cab right Working lights right Check cabling between the E4042-RI 9.6 Lighting Working lights,
(E4042-RI), short circuit not working. control unit and the compo- D7901/C2:23 Sys 11/XX DI- cab, descrip-
to ground. nent with diagnostic menu. AGNOSE, tion, page 9:77
page 8:123
E 4042 5 1 1 Extra work lights left Extra work lighting Check bulb. E4042-1 9.6 Lighting Working lights,
(E4042-1), open circuit. left not working. Check cabling between the D7901/C2:18 Sys 12/XX DI- cab, descrip-
E 4042 6 1 1 Extra work lights left Extra work lighting Check bulb. E4042-1 9.6 Lighting Working lights,
(E4042-1), short circuit left not working. Check cabling between the D7901/C2:18 Sys 12/XX DI- cab, descrip-
to ground. control unit and the compo- AGNOSE, tion, page 9:77
E 4042 5 1 2 Extra work lights right Extra work lighting Check bulb. E4042-2 9.6 Lighting Working lights,
(E4042-2), open circuit. right not working. Check cabling between the D7901/C2:36 Sys 13/XX DI- cab, descrip-
E 4042 6 1 2 Extra work lights right Extra work lighting Check bulb. E4042-2 9.6 Lighting
(E4042-2), short circuit right not working. Check cabling between the D7901/C2:36 Sys 13/XX DI-
to ground. control unit and the compo- AGNOSE,
E 4043 5 2 10 Working lights boom left Working lights Check bulb. E4043-LE 9.6 Lighting Work light,

(E4043-LE), open circuit. boom left not Check cabling between the D7971/C2:36 Sys 14/XX DI- boom, descrip-
working. control unit and the compo- AGNOSE, tion, page 9:77
E 4043 6 2 10 Working lights boom left Working lights Check bulb. E4043-LE 9.6 Lighting Work light,
(E4043-LE), short circuit boom left not Check cabling between the D7971/C2:36 Sys 14/XX DI- boom, descrip-
to ground. working. control unit and the compo- AGNOSE, tion, page 9:77
E 4043 5 2 20 Working lights boom Working lights Check bulb. E4043-RI 9.6 Lighting Work light,
right (E4043-RI) open boom right not Check cabling between the D7971/C2:36 Sys 14/XX DI- boom, descrip-
circuit. working. control unit and the compo- AGNOSE, tion, page 9:77
and menu
components
E 4043 6 2 20 Working lights boom Working lights Check bulb. E4043-RI 9.6 Lighting Work light,
right (E4043-RI), short boom right not Check cabling between the D7971/C2:36 Sys 14/XX DI- boom, descrip-
circuit to ground. working. control unit and the compo- AGNOSE, tion, page 9:77
E 4044 5 7 10 Working lights attach- Working lights at- Check bulb. E4044-LE-A 9.6 Lighting Working lights,
ment left (E4044-LE-A), tachment left not Check cabling between the D7911/C2:5 Sys 21/XX DI- attachment,
open circuit. working. control unit and the compo- AGNOSE, description,
nent with diagnostic menu. page 8:125 page 9:77
E 4044 6 7 10 Working lights attach- Working lights at- Check cabling between the E4044-LE-A 9.6 Lighting Working lights,
ment left (E4044-LE-A), tachment left not control unit and the compo- D7911/C2:5 Sys 21/XX DI- attachment,
short circuit to ground. working. nent with diagnostic menu. AGNOSE, description,
page 8:125 page 9:77
E 4044 5 7 110 Working lights attach- Working lights at- Check bulb. E4044-LE-B 9.6 Lighting Working lights,
ment left (E4044-LE-B), tachment left not Check cabling between the D7911/C2:3 Sys 22/XX DI- attachment,
E 4044 6 7 110 Working lights attach- Working lights at- Check cabling between the E4044-LE-B 9.6 Lighting Working lights,
ment left (E4044-LE-B), tachment left not control unit and the compo- D7911/C2:3 Sys 22/XX DI- attachment,
E 4044 5 7 20 Working lights attach- Working lights at- Check bulb. E4044-RI-A 9.6 Lighting Working lights,
ment right (E4044-RI-A), tachment right not Check cabling between the D7911/C2:6 Sys 21/XX DI- attachment,
E 4044 6 7 20 Working lights attach- Working lights at- Check cabling between the E4044-RI-A 9.6 Lighting Working lights,

ment right (E4044-RI-A), tachment right not control unit and the compo- D7911/C2:6 Sys 21/XX DI- attachment,
E 4044 5 7 120 Working lights attach- Working lights at- Check bulb. E4044-RI-B 9.6 Lighting Working lights,
ment right (E4044-RI-B), tachment right not Check cabling between the D7911/C2:4 Sys 22/XX DI- attachment,
E 4044 6 7 120 Working lights attach- Working lights at- Check cabling between the E4044-RI-B 9.6 Lighting Working lights,
ment right (E4044-RI-B), tachment right not control unit and the compo- D7911/C2:4 Sys 22/XX DI- attachment,
VDRG09.01GB
D:141
and menu
components
VDRG09.01GB
E 4045 5 6 110 Work lights lift legs at- Work lights lift legs Check bulb. E4045-LF 9.6 Lighting Working lights,
tachment left front attachment left front Check cabling between the D7912/C2:3 Sys 28/XX DI- attachment,
(E4045-LF), open circuit. not working. control unit and the compo- AGNOSE, description,
E 4045 6 6 110 Work lights attachment Work lights lift legs Check cabling between the E4045-LF 9.6 Lighting Working lights,
lift legs left front (E4045- attachment left front control unit and the compo- D7912/C2:3 Sys 28/XX DI- attachment,
LF), short circuit to not working. nent with diagnostic menu. AGNOSE, description,
ground. page 8:127 page 9:77
E 4045 5 6 120 Work lights lift legs at- Work lights lift legs Check bulb. E4045-RF 9.6 Lighting Working lights,
tachment right front attachment right Check cabling between the D7912/C2:4 Sys 28/XX DI- attachment,
(E4045-RF), open front not working. control unit and the compo- AGNOSE, description,
E 4045 6 6 120 Work lights attachment Work lights lift legs Check cabling between the E4045-RF 9.6 Lighting Working lights,
lift legs right front attachment right control unit and the compo- D7912/C2:4 Sys 28/XX DI- attachment,
(E4045-RF), short cir- front not working. nent with diagnostic menu. AGNOSE, description,
cuit to ground. page 8:127 page 9:77
E 4045 5 6 210 Work lights lift legs at- Work lights lift legs Check bulb. E4045-LR 9.6 Lighting Working lights,
tachment left rear attachment left rear Check cabling between the D7912/C2:5 Sys 27/XX DI- attachment,
(E4045-LR), open not working. control unit and the compo- AGNOSE, description,
E 4045 6 6 210 Work lights attachment Work lights lift legs Check cabling between the E4045-LR 9.6 Lighting Working lights,
lift legs left rear (E4045- attachment left rear control unit and the compo- D7912/C2:5 Sys 27/XX DI- attachment,
LR), short circuit to not working. nent with diagnostic menu. AGNOSE, description,
ground. page 8:126 page 9:77
E 4045 5 6 220 Work lights lift legs at- Work lights lift legs Check bulb. E4045-RR 9.6 Lighting Working lights,

tachment right rear attachment right Check cabling between the D7912/C2:6 Sys 27/XX DI- attachment,
(E4045-RR), open rear not working. control unit and the compo- AGNOSE, description,
E 4045 6 6 220 Work lights attachment Work lights lift legs Check cabling between the E4045-RR 9.6 Lighting Working lights,
lift legs right rear attachment right control unit and the compo- D7912/C2:6 Sys 27/XX DI- attachment,
(E4045-RR), short cir- rear not working. nent with diagnostic menu. AGNOSE, description,
cuit to ground. page 8:126 page 9:77
E 4050 6 1 10 Work lights backwards Working lights Check bulb. E4050-LE 9.6 Lighting
left (E4050-LE), short backward left not Check cabling between the D7901/C2:20 Sys 10/XX DI-
circuit to ground. working. control unit and the compo- AGNOSE,
and menu
components
E 4050 6 1 20 Work lights backwards Working lights Check bulb. E4050-RI 9.6 Lighting
right (E4050-RI), short backward right not Check cabling between the D7901/C2:21 Sys 10/XX DI-
circuit to ground. working. control unit and the compo- AGNOSE,
E 4050 6 2 Working lights steering Working lights Check bulb. E4050
(E4050), short circuit to steering not Check cabling between the D7971/C1:45
ground. working. control unit and the compo-
H 4110 5 2 Brake lights (H4110-RI) Brake lights not Check cabling between the H4110 9.6 Lighting Brake lights,
and (H4110-LE), short working. control unit and the compo- D7971/C1:13 Sys 5/XX DI- description,
circuit to ground. nent with diagnostic menu. AGNOSE, page 9:75
Check the lamp. page 8:121
H 4110 6 2 Brake lights (H4110-RI) Brake lights not Check cabling between the H4110 9.6 Lighting Brake lights,
and (H4110-LE), short working. control unit and the compo- D7971/C1:13 Sys 5/XX DI- description,
circuit to ground. nent with diagnostic menu. AGNOSE, page 9:75
H 4110 6 3 100 Brake lights front Brake lights front Check cabling between the H4110 Brake lights,
(H4110-LF) and (H4110- not working. control unit and the compo- D7972/C1:20 description,
RF), short circuit to At revolving driver's nent with diagnostic menu. page 9:75
ground. seat. Check the lamp.
H 4120 5 2 1 Tail lights (H4120-LE) Tail lights not Check cabling between the H4120 9.6 Lighting Tail lights, de-
and (H4120-RI), short working. control unit and the compo- D7971/C1:19 Sys 4/XX DI- scription, page
circuit to ground. nent with diagnostic menu. AGNOSE, 9:74
H 4120 6 2 1 Tail lights (H4120-LE) Tail lights not Check cabling between the H4120 9.6 Lighting Tail lights, de-

and (H4120-RI), short working. control unit and the compo- D7971/C1:19 Sys 4/XX DI- scription, page
circuit to ground. nent with diagnostic menu. AGNOSE, 9:74
H 4120 6 3 100 Tail lights front (H4120- Tail light front not Check cabling between the H4120 Tail lights, de-
LF) and (H4120-RF), working. control unit and the compo- D7972/C1:19 scription, page
short circuit to ground. At revolving driver's nent with diagnostic menu. 9:74
seat. Check the lamp.
H 4160 5 2 Position lights (H4160- Running lights not Check cabling between the H4160-LF 9.6 Lighting Running lights,
LF, H4160-RF, H4160- working. control unit and the compo- H4160-RF Sys 9/XX DI- description,
LR, H4160-RR), short nent with diagnostic menu. H4160-LR AGNOSE, page 9:74
circuit to ground. Check the lamp. H4160-RR page 8:122
D7971/C1:16
VDRG09.01GB
D:143
and menu
components
VDRG09.01GB
H 4160 6 2 Position lights (H4160- Running lights not Check cabling between the H4160-LF 9.6 Lighting Running lights,
LF, H4160-RF, H4160- working. control unit and the compo- H4160-RF Sys 9/XX DI- description,
LR, H4160-RR), short nent with diagnostic menu. H4160-LR AGNOSE, page 9:74
circuit to ground. Check the lamp. H4160-RR page 8:122
D7971/C1:16
H 4220 5 2 10 Direction indicators left Left direction indi- Check cabling between the H4220-FL 9.6 Lighting Direction indi-
(H4220-FL) and cator not working. control unit and the compo- H4220-RL Sys 7/XX DI- cators, descrip-
(H4220-RL), short cir- nent with diagnostic menu. D7971/C1:20 AGNOSE, tion, page 9:75
cuit to ground. Check the lamp. page 8:122
H 4220 6 2 10 Direction indicators left Left direction indi- Check cabling between the H4220-FL 9.6 Lighting Direction indi-
(H4220-FL) and cator not working. control unit and the compo- H4220-RL Sys 7/XX DI- cators, descrip-
(H4220-RL), short cir- nent with diagnostic menu. D7971/C1:20 AGNOSE, tion, page 9:75
H 4220 5 2 20 Direction indicators right Right direction indi- Check cabling between the H4220-FR 9.6 Lighting Direction indi-
(H4220-FR) and cator not working. control unit and the compo- H4220-RR Sys 8/XX DI- cators, descrip-
(H4220-RR), short cir- nent with diagnostic menu. D7971/C1:26 AGNOSE, tion, page 9:75
H 4220 6 2 20 Direction indicators right Right direction indi- Check cabling between the H4220-FR 9.6 Lighting Direction indi-
(H4220-FR) and cator not working. control unit and the compo- H4220-RR Sys 8/XX DI- cators, descrip-
(H4220-RR), short cir- nent with diagnostic menu. D7971/C1:26 AGNOSE, tion, page 9:75
H 4281 6 2 Revolving beacon on Revolving beacon Check bulb. H4281 9.7 Signalling Revolving bea-
frame (H4281), short cir- on frame not Check the bulb holder. D7971/C1:45 Sys 3/XX DI- con, descrip-
cuit to ground. working. Check cabling between the AGNOSE, tion, page 9:76
control unit and the compo- page 8:128

H 4282 6 1 Revolving beacon Revolving beacon Check bulb. H4282 9.7 Signalling Revolving bea-
(H4282), short circuit to not working. Check the bulb holder. D7901/C2:13 Sys 2/XX DI- con, descrip-
ground. Check cabling between the AGNOSE, tion, page 9:76
control unit and the compo- page 8:127
H 4284 6 7 Revolving beacon at- Revolving beacon, Check cabling between the H4284 9.7 Signalling Revolving bea-
tachment (H4284), short attachment, not control unit and the compo- D7911/C1:45 Sys 4/XX DI- con, descrip-
circuit to ground. working. nent with diagnostic menu. AGNOSE, tion, page 9:76
Check the bulb holder. page 8:128
E 4340 6 1 Interior lighting (E4340), Interior lighting in Check cabling between the E4340 9.6 Lighting Interior lighting,
short circuit to ground. cab not working. control unit and the compo- D7901/C2:30 Sys 19/XX DI- description,
nent with diagnostic menu. AGNOSE, page 9:77
Check bulb. page 8:125
and menu
components
H 5001 6 7 30 Indicator light over- Indicator light not Check cabling between the H5001 7.9 Load Car- Overheight-
height-legs up (H5001) working. control unit and the compo- D7911/C1:20 rier 90/XX DI- legs, descrip-
(on inner boom), short nent with diagnostic menu. AGNOSE, tion, page
circuit to ground. Check the lamp. page 8:90 7:130
H 5004 6 7 Indicator light scale po- Indicator light not Check cabling between the H5004 8.2 Monitoring
sition load receipt working. control unit and the compo- D7911/C1:19 31/XX DIAG-
(H5004) (on inner nent with diagnostic menu. NOSE, page
boom), short circuit to Check the lamp. 8:106
ground.
H 5620 6 1 2 Indicator light unlocked Indicator light not Check cabling between the H5620-2 11.7 I/O D7901 Twistlocks, de-
twistlocks (A3720) (on working. control unit and the compo- D7901/C2:1 KCU 1-48/XX scription, page
the roof panel in the nent with diagnostic menu. DIAGNOSE, 7:127
cab), grounded circuit. Check the light panel. page 8:166
H 5620 6 7 1 Indicator light unlocked Indicator light not Check cabling between the H5620 7.9 Load Car- Twistlocks, de-
twistlocks (H5620) (on working. control unit and the compo- D7911/C1:12 rier 9/XX DIAG- scription, page
inner boom), short cir- nent with diagnostic menu. NOSE, page 7:127
cuit to ground. Check the lamp. 8:69
H 5630 6 1 2 Indicator light locked Indicator light not Check cabling between the H5630-2 Twistlocks, de-
twistlocks (A3720) (on working. control unit and the compo- D7901/C2:2 scription, page
the roof panel in the nent with diagnostic menu. 7:127
cab), grounded circuit. Check the light panel.
H 5630 6 7 1 Indicator light locked Indicator light not Check cabling between the H5620 7.9 Load Car- Twistlocks, de-
twistlocks (H5630) (on working. control unit and the compo- D7911/C1:13 rier 8/XX DIAG- scription, page
inner boom), short cir- nent with diagnostic menu. NOSE, page 7:127
cuit to ground. Check the lamp. 8:69

H 5640 6 1 2 Indicator light contact Indicator light not Check cabling between the H5640-2 Twistlocks, de-
(A3720) (on the roof working. control unit and the compo- D7901/C2:3 scription, page
panel in the cab), nent with diagnostic menu. 7:127
grounded circuit. Check the light panel.
H 5640 6 7 1 Indicator light contact Indicator light not Check cabling between the H5640-1 7.9 Load Car- Twistlocks, de-
(H5640-1), short circuit working. control unit and the compo- D7911/C1:16 rier 8/XX DIAG- scription, page
to ground. nent with diagnostic menu. NOSE, page 7:127
Check the lamp. 8:69
H 5640 6 7 30 Indicator light contact Indicator light not Check cabling between the H5640-1
(H5640-1), short circuit working. control unit and the compo- D7911/C1:16
to ground. nent with diagnostic menu.
Check the lamp.
VDRG09.01GB
D:145
and menu
components
VDRG09.01GB
H 5640 6 7 40 Indicator light contact Indicator light not Check cabling between the H5640-2
(H5640-2), short circuit working. control unit and the compo- D7911/C1:20
Check the lamp.
H 5720 6 7 Indicator light height re- Indicator light not Check cabling between the H5720
striction (H5720), short working. control unit and the compo- D7911/C1:20
circuit to ground. nent with diagnostic menu.
Check the light panel.
H 5740 6 1 Indicator light support Indicator light not Check cabling between the H5740 11.7 I/O D7901 Support jacks
jacks down (H5740) (on working. control unit and the compo- D7901/C2:4 KCU 1-48/XX description,
roof panel in cab), short nent with diagnostic menu. DIAGNOSE, page 7:171
circuit to ground. Check the light panel. page 8:166
H 5760 6 6 110 Indicator light contact Indicator light not Check cabling between the H5760-LF 7.9 Load Car-
lifting leg left front working. control unit and the compo- D7912/C1:12 rier 55/XX DI-
(H5760-LF), short circuit nent with diagnostic menu. AGNOSE,
to ground. Check the light panel. page 8:81
H 5760 6 6 120 Indicator light contact Indicator light not Check cabling between the H5760-RF 7.9 Load Car-
lifting leg right front working. control unit and the compo- D7912/C1:13 rier 56/XX DI-
(H5760-RF), short cir- nent with diagnostic menu. AGNOSE,
cuit to ground. Check the light panel. page 8:81
H 5760 6 6 210 Indicator light contact Indicator light not Check cabling between the H5760-LR 7.9 Load Car-
lifting leg left rear working. control unit and the compo- D7912/C1:16 rier 57/XX DI-
(H5760-LR), short cir- nent with diagnostic menu. AGNOSE,
H 5760 6 6 220 Indicator light contact Indicator light not Check cabling between the H5760-RR 7.9 Load Car-

lifting leg right rear working. control unit and the compo- D7912/C1:19 rier 58/XX DI-
(H5760-RR), short cir- nent with diagnostic menu. AGNOSE,
H 5780 6 6 100 Indicator light lifting legs Indicator light not Check cabling between the H5780-FR 7.9 Load Car-
clamping position front working. control unit and the compo- D7912/C1:42 rier 61/XX DI-
(5780-FR), short circuit nent with diagnostic menu. AGNOSE,
H 5780 6 6 200 Indicator light clamping Indicator light not Check cabling between the H5780-RE 7.9 Load Car-
position rear (5780-RE), working. control unit and the compo- D7912/C1:46 rier 62/XX DI-
short circuit to ground. nent with diagnostic menu. AGNOSE,
Check the light panel. page 8:83
and menu
components
H 5800 6 6 30 Indicator light contact Indicator light not Check cabling between the H5800-UP 7.9 Load Car-
lifting legs front up working. control unit and the compo- D7912/C1:20 rier 59/XX DI-
(5800-UP), short circuit nent with diagnostic menu. AGNOSE,
H 5800 6 6 40 Indicator light contact Indicator light not Check cabling between the H5800-UP 7.9 Load Car-
lifting legs front down working. control unit and the compo- D7912/C1:26 rier 60/XX DI-
(5800-LO), short circuit nent with diagnostic menu. AGNOSE,
5981 1 1 Warning for critical state - - - - -
of charge, SOC.
5981 2 1 State of charge, SOC - - - - -
not correct.
5981 4 1 Cell voltage is below - Charge the battery. - - -
configured alarm level
2.3V.
5983 12 1 Control unit BMS cannot - Contact Cargotec support. - -
communicate with at
least one battery cell at
the moment.
H 5991 6 1 Fasten seat belt indica- Indicator light not Check cabling between the H5991 9.3 Seat 1/XX Seat, general,
tor light (H5991), short working. control unit and the compo- D7901/C2:7 DIAGNOSE, page 9:18
circuit to ground. nent with diagnostic menu. page 8:110

H 5992 6 1 Mini-wheel/joystick con- Indicator light not Check cabling between the H5992 5.2 Power As- Joystick con-

trol, indicator light (on/ working. control unit and the compo- D7901/C2:33 sisted 4/XX DI- trol/mini-wheel,
off) (H5992), short cir- nent with diagnostic menu. AGNOSE, function de-
cuit to ground. Check the component. page 8:47 scription, page
5:10
H 5993 6 11 3 Indicator light tilt lock Indicator light not Check the cable harness be- H5993 11.8 I/O D7902 Control lever
(H5993) in the switch on working. tween control unit control D7902/C4:3 KPU 1–41/XX (Ego), descrip-
the control lever, short lever. DIAGNOSE, tion, page 7:6
circuit to ground Check the control lever. page 8:166
Y 6002 5 2 Servo valve load signal The attachment Check cabling between the Y6002 10.4 Pumps 6/
attachment (Y6002), functions work, but control unit and the compo- D7971/C1:38 XX DIAGNOSE,
open circuit. are working under nent with diagnostic menu. page 8:134
full pressure all the Check the component.
time.
VDRG09.01GB
D:147
and menu
components
VDRG09.01GB
Y 6002 6 2 Servo valve load signal The attachment Check cabling between the Y6002 10.4 Pumps 6/
attachment (Y6002), functions work, but control unit and the compo- D7971/C1:38 XX DIAGNOSE,
open circuit. are working under nent with diagnostic menu. page 8:134
full pressure all the Check the component.
time.
Y 6003 5 2 Solenoid valve engage- Attachment func- Check cabling between the Y6003 10.4 Pumps 1/ Proportional
ment of hydraulics top tions not working or control unit and the compo- D7971/C1:15 XX DIAGNOSE, valve, load sig-
lift (Y6003), open circuit. are very slow. nent with diagnostic menu. page 8:133 nal attachment
Check the component. (Y6002), de-
scription, page
10:25
Y 6003 6 2 Solenoid valve engage- Attachment func- Check cabling between the Y6003 10.4 Pumps 1/ Proportional
ment of hydraulics top tions not working or control unit and the compo- D7971/C1:15 XX DIAGNOSE, valve, load sig-
lift (Y6003), short circuit are very slow. nent with diagnostic menu. page 8:133 nal attachment
to ground. Check the component. (Y6002), de-
scription, page
10:25
Y 6004 5 2 Solenoid valve, lower Lower not working Check cabling between the Y6004 7.2 Lifting Low- 7.2.5 Control
(Y6004), open circuit. control unit and the compo- D7971/C1:28 ering 7/XX DI- valve lift, lower
nent with diagnostic menu. AGNOSE, and extension,
Check the component. page 8:56 page 7:23
Y 6004 6 2 Solenoid valve lower Lower not working Check cabling between the Y6004 7.2 Lifting Low- 7.2.5 Control
(Y6004), short circuit to control unit and the compo- D7971/C1:28 ering 7/XX DI- valve lift, lower
ground. nent with diagnostic menu. AGNOSE, and extension,
Y 6004 5 2 2 Solenoid valve, lower 2 Lower not working Check cabling between the Y6004-2

(Y6004-2), open circuit. control unit and the compo- C1p41 D7971
Y 6004 6 2 2 Solenoid valve lower 2 Lower not working Check cabling between the Y6004-2
(Y6004-2), short circuit control unit and the compo- C1p41 D7971
Y 6005 5 2 Solenoid valve, lift Lift not working. Check cabling between the Y6005 7.2 Lifting Low- 7.2.5 Control
(Y6005), open circuit control unit and the compo- D7971/C1:27 ering 6/XX DI- valve lift, lower
nent with diagnostic menu. AGNOSE, and extension,
Y 6005 6 2 Solenoid valve lift Lift not working. Check cabling between the Y6005 7.2 Lifting Low- 7.2.5 Control
(Y6005), short circuit to control unit and the compo- D7971/C1:27 ering 6/XX DI- valve lift, lower
ground. nent with diagnostic menu. AGNOSE, and extension,
and menu
components
Y 6005 5 2 2 Solenoid valve, lift 2 Lift not working. Check cabling between the Y6005-2
(Y6005-2), open circuit control unit and the compo- C1p40 D7971
Y 6005 6 2 2 Solenoid valve lift 2 Lift not working. Check cabling between the Y6005-2
(Y6005-2), short circuit control unit and the compo- C1p40 D7971
Y 6006 5 2 Solenoid valve, boom Boom out not Check cabling between the Y6006 7.3 Extension 7.3.5 Control
out (Y6006), open working. control unit and the compo- D7971/C1:33 1/XX DIAG- valve lift, lower
circuit. nent with diagnostic menu. NOSE, page and extension,
Check the component. 8:57 page 7:38
Y 6006 6 2 Solenoid valve boom Boom out not Check cabling between the Y6006 7.3 Extension 7.3.5 Control
out (Y6006), short circuit working. control unit and the compo- D7971/C1:33 1/XX DIAG- valve lift, lower
to ground. nent with diagnostic menu. NOSE, page and extension,
Y 6007 5 2 Solenoid valve, boom in Boom in not Check cabling between the Y6007 7.3 Extension 7.3.5 Control
(Y6007), open circuit. working. control unit and the compo- D7971/C1:29 2/XX DIAG- valve lift, lower
nent with diagnostic menu. NOSE, page and extension,
Y 6007 6 2 Solenoid valve boom in Boom in not Check cabling between the Y6007 7.3 Extension 7.3.5 Control
(Y6007), short circuit to working. control unit and the compo- D7971/C1:29 2/XX DIAG- valve lift, lower
ground. nent with diagnostic menu. NOSE, page and extension,
Y 6007 5 7 Solenoid valve, side Side shift not Check cabling between the Y6007 -

shift (Y6007), open working. control unit and the compo- D7911/C1:38
circuit. nent with diagnostic menu.
Y 6007 6 7 Solenoid valve, side Side shift not Check cabling between the Y6007 -
shift (Y6007), short cir- working. control unit and the compo- D7911/C1:38
cuit to ground. nent with diagnostic menu.
Y 6008 5 2 Solenoid valve rotation Rotation clockwise Check cabling between the Y6008
clockwise (Y6008), not working. control unit and the compo- D7971/C1:38
open circuit nent with diagnostic menu.
VDRG09.01GB
D:149
and menu
components
VDRG09.01GB
Y 6008 6 2 Solenoid valve rotation Rotation clockwise Check cabling between the Y6008
clockwise (Y6008), not working. control unit and the compo- D7971/C1:38
short circuit to ground. nent with diagnostic menu.
Y 6008 5 7 Solenoid valve rotation Rotation clockwise Check cabling between the Y6008 7.6 Rotation 1/ Attachment
clockwise (Y6008), not working. control unit and the compo- D7911/C1:27 XX DIAGNOSE, control valve,
open circuit nent with diagnostic menu. page 8:63 description,
Y 6008 6 7 Solenoid valve rotation Rotation clockwise Check cabling between the Y6008 7.6 Rotation 1/ Attachment
clockwise (Y6008), not working. control unit and the compo- D7911/C1:27 XX DIAGNOSE, control valve,
short circuit to ground. nent with diagnostic menu. page 8:63 description,
Y 6009 5 2 Solenoid valve rotation Rotation anticlock- Check cabling between the Y6009
anticlockwise (Y6009), wise not working. control unit and the compo- D7971/C1:39
Y 6009 6 2 Solenoid valve rotation Rotation anticlock- Check cabling between the Y6009
anticlockwise (Y6009), wise not working. control unit and the compo- D7971/C1:39
Y 6009 5 7 Solenoid valve rotation Rotation anticlock- Check cabling between the Y6009 7.6 Rotation 2/ Attachment
anticlockwise (Y6009), wise not working. control unit and the compo- D7911/C1:28 XX DIAGNOSE, control valve,
open circuit nent with diagnostic menu. page 8:63 description,
Y 6009 6 7 Solenoid valve rotation Rotation anticlock- Check cabling between the Y6009 7.6 Rotation 2/ Attachment

anticlockwise (Y6009), wise not working. control unit and the compo- D7911/C1:28 XX DIAGNOSE, control valve,
short circuit to ground. nent with diagnostic menu. page 8:63 description,
Y 6010 5 2 Solenoid valve, tilt out Tilt out not working Check cabling between the Y6010
(Y6010), open circuit control unit and the compo- D7971/C1:33
Y 6010 6 2 Solenoid valve tilt out Tilt out not working Check cabling between the Y6010
(Y6010), short circuit to control unit and the compo- D7971/C1:33
ground. nent with diagnostic menu.
and menu
components
Y 6010 5 7 Solenoid valve, tilt out Tilt out not working Check cabling between the Y6010 7.7 Tilt 4/XX Attachment
(Y6010), open circuit control unit and the compo- D7911/C1:37 DIAGNOSE, control valve,
nent with diagnostic menu. page 8:64 description,
Y 6010 6 7 Solenoid valve tilt out Tilt out not working Check cabling between the Y6010 7.7 Tilt 4/XX Attachment
(Y6010), short circuit to control unit and the compo- D7911/C1:37 DIAGNOSE, control valve,
ground. nent with diagnostic menu. page 8:64 description,
Y 6011 5 2 Solenoid valve, tilt in Tilt in not working Check cabling between the Y6011
(Y6011), open circuit. control unit and the compo- D7971/C1:29
Y 6011 6 2 Solenoid valve tilt in Tilt in not working Check cabling between the Y6011
(Y6011), short circuit to control unit and the compo- D7971/C1:29
Y 6011 5 7 Solenoid valve, tilt in Tilt in not working Check cabling between the Y6011 7.7 Tilt 5/XX Attachment
(Y6011), open circuit. control unit and the compo- D7911/C1:36 DIAGNOSE, control valve,
nent with diagnostic menu. page 8:65 description,
Y 6011 6 7 Solenoid valve tilt in Tilt in not working Check cabling between the Y6011 7.7 Tilt 5/XX Attachment
(Y6010), short circuit to control unit and the compo- D7911/C1:36 DIAGNOSE, control valve,
ground. nent with diagnostic menu. page 8:65 description,
Y 6012 5 7 1 Solenoid valve tilt lock 1 Tilt damping not Check cabling between the Y6012-1 7.7 Tilt 6/XX Lock valve tilt,

(Y6012-1), open circuit. working, tilt locked. control unit and the compo- D7911/C1:23 DIAGNOSE, description,
Machine speed nent with diagnostic menu. page 8:65 page 7:111
limited to 5 km/h. Check the component.
(Y6012-1), short circuit working, tilt locked. control unit and the compo- D7911/C1:23 DIAGNOSE, description,
to ground. Machine speed nent with diagnostic menu. page 8:65 page 7:111
(Y6012-2), open circuit. working, tilt locked. control unit and the compo- D7911/C1:24 DIAGNOSE, description,
Machine speed nent with diagnostic menu. page 8:65 page 7:111
VDRG09.01GB
D:151
and menu
components
VDRG09.01GB
(Y6012-2), short circuit working, tilt locked. control unit and the compo- D7911/C1:24 DIAGNOSE, description,
to ground. Machine speed nent with diagnostic menu. page 8:65 page 7:111
Y 6014 5 2 Solenoid valve, differen- Differential lock not Check cabling between the Y6014
tial lock (Y6014), open working control unit and the compo- D7971/C1:15
Y 6014 6 2 Solenoid valve, differen- Differential lock not Check cabling between the Y6014
tial lock (Y6014), short working control unit and the compo- D7971/C1:15
Y 6016 5 2 Solenoid valve cab Hydraulic cab Check cabling between the Y6016 9.10 Cab sus- Control valve
movement out (forward/ movement only control unit and the compo- D7971/C1:41 pension 2/XX cab movement,
up) (Y6016), open moves in one nent with diagnostic menu. DIAGNOSE, description,
circuit. direction. Check the component. page 8:130 page 9:110
Control valve
cab movement,
description,
page 9:123
movement out (forward/ movement only control unit and the compo- D7971/C1:41 pension 2/XX cab movement,
up) (Y6016), short cir- moves in one nent with diagnostic menu. DIAGNOSE, description,
cuit to ground. direction. Check the component. page 8:130 page 9:110
Control valve
cab movement,

description,
page 9:123
Y 6016 5 3 Solenoid valve cab Hydraulic cab Check cabling between the Y6016
movement up (Y6016), movement only control unit and the compo- D7972/C1:35
open circuit. moves in one nent with diagnostic menu.
direction. Check the component.
Y 6016 6 3 Solenoid valve cab Hydraulic cab Check cabling between the Y6016
movement up (Y6016), movement only control unit and the compo- D7972/C1:35
short circuit to ground. moves in one nent with diagnostic menu.
and menu
components
movement in (back/low- movement only control unit and the compo- D7971/C1:40 pension 3/XX cab movement,
er) (Y6017), open circuit. moves in one nent with diagnostic menu. DIAGNOSE, description,
direction. Check the component. page 8:130 page 9:110
Control valve
cab movement,
description,
page 9:123
movement in (back/low- movement only control unit and the compo- D7971/C1:40 pension 3/XX cab movement,
er) (Y6017), short circuit moves in one nent with diagnostic menu. DIAGNOSE, description,
to ground. direction. Check the component. page 8:130 page 9:110
Control valve
cab movement,
description,
page 9:123
Y 6017 5 3 Solenoid valve cab Hydraulic cab Check cabling between the Y6017 -
movement lower movement only control unit and the compo- D7972/C1:34
(Y6017), open circuit. moves in one nent with diagnostic menu.
Y 6017 6 3 Solenoid valve cab Hydraulic cab Check cabling between the Y6017 -
movement lower movement only control unit and the compo- D7972/C1:34
(Y6017), short circuit to moves in one nent with diagnostic menu.
ground. direction. Check the component.

Y 6018 5 2 Solenoid valve, spread- Spreading out not Check cabling between the Y6018
ing out (Y6018), open working control unit and the compo- D7971/c1:37

circuit nent with diagnostic menu.
Y 6018 6 2 Solenoid valve spread- Spreading out not Check cabling between the Y6018
ing out (Y6018), short working control unit and the compo- D7971/c1:37
Y 6018 5 2 10 Solenoid valve, spread- Spreading out left Check cabling between the Y6018-LE
ing out left fork (Y6018- fork not working control unit and the compo- D7971/c1:37
LE), open circuit. nent with diagnostic menu.
Y 6018 6 2 10 Solenoid valve, spread- Spreading out left Check cabling between the Y6018-LE
ing out left fork (Y6018- fork not working control unit and the compo- D7971/c1:37
LE), short circuit to nent with diagnostic menu.
ground. Check the component.
VDRG09.01GB
D:153
and menu
components
VDRG09.01GB
Y 6018 5 2 20 Solenoid valve, spread- Spreading out right Check cabling between the Y6018-RI
ing out right fork fork not working control unit and the compo- D7917/C1:41
(Y6018-RI), open circuit. nent with diagnostic menu.
Y 6018 6 2 20 Solenoid valve, spread- Spreading out right Check cabling between the Y6018-RI
ing out right fork fork not working control unit and the compo- D7917/C1:41
(Y6018-RI), short circuit nent with diagnostic menu.
to ground. Check the component.
Y 6018 5 7 Solenoid valve, spread- Spreading not Check cabling between the Y6018 7.5 Spreading Attachment
ing out (Y6018), open working. control unit and the compo- D7911/C1:29 10/XX DIAG- control valve,
circuit nent with diagnostic menu. NOSE, page description,
Y 6018 6 7 Solenoid valve spread- Spreading not Check cabling between the Y6018 7.5 Spreading Attachment
ing out (Y6018), short working. control unit and the compo- D7911/C1:29 10/XX DIAG- control valve,
circuit to ground. nent with diagnostic menu. NOSE, page description,
Y 6018 5 7 10 Solenoid valve, spread- Spreading left side Check cabling between the Y6018-LE
ing out left (Y6018-LE), not working. control unit and the compo-
open circuit. nent with diagnostic menu.
Y 6018 6 7 10 Solenoid valve spread- Spreading left side Check cabling between the Y6018-LE
ing out left (Y6018-LE), not working. control unit and the compo-
Y 6018 5 7 20 Solenoid valve, spread- Spreading right Check cabling between the Y6018-RI

ing out right (Y6018-RI), side not working. control unit and the compo-
Y 6018 6 7 20 Solenoid valve spread- Spreading right Check cabling between the Y6018-RI
ing out right (Y6018-RI), side not working. control unit and the compo-
Y 6019 5 2 Solenoid valve, spread- Spreading in not Check cabling between the Y6019
ing in (Y6019), open working control unit and the compo- D7971/C1:36
and menu
components
Y 6019 6 2 Solenoid valve spread- Spreading in not Check cabling between the Y6019
ing in (Y6019), short cir- working control unit and the compo- D7971/C1:36
Y 6019 5 2 10 Solenoid valve, spread- Spreading in left Check cabling between the Y6019-LE
ing in left fork (Y6019- fork not working control unit and the compo- D7971/C1:36
LE), open circuit. nent with diagnostic menu.
Y 6019 6 2 10 Solenoid valve, spread- Spreading in left Check cabling between the Y6019-LE
ing in left fork (Y6019- fork not working control unit and the compo- D7971/C1:36
LE), short circuit to nent with diagnostic menu.
Y 6019 5 2 20 Solenoid valve, spread- Spreading in right Check cabling between the Y6019-RI
ing in right fork (Y6019- fork not working control unit and the compo- D7971/C1:40
RI), open circuit. nent with diagnostic menu.
Y 6019 6 2 20 Solenoid valve, spread- Spreading in right Check cabling between the Y6019-RI
ing in right fork (Y6019- fork not working control unit and the compo- D7971/C1:40
RI), short circuit to nent with diagnostic menu.
Y 6019 5 7 Solenoid valve, spread- Spreading not Check cabling between the Y6019 7.5 Spreading Attachment
ing in (Y6019), open working. control unit and the compo- D7911/C1:33 11/XX DIAG- control valve,
circuit. nent with diagnostic menu. NOSE, page description,
Y 6019 6 7 Solenoid valve spread- Spreading not Check cabling between the Y6019 7.5 Spreading Attachment

ing in (Y6019), short cir- working. control unit and the compo- D7911/C1:33 11/XX DIAG- control valve,
cuit to ground. nent with diagnostic menu. NOSE, page description,
ing in left (Y6019-LE), not working. control unit and the compo-
ing in left (Y6019-LE), not working. control unit and the compo-
VDRG09.01GB
D:155
and menu
components
VDRG09.01GB
ing in right (Y6019-RI), side not working. control unit and the compo-
ing in right (Y6019-RI), side not working. control unit and the compo-
Y 6020 5 2 Solenoid valve, side Side shift left not Check cabling between the Y6020
shift left (Y6020), open working control unit and the compo- D7971/C1:34
circuit nent with diagnostic menu.
Y 6020 6 2 Solenoid valve side shift Side shift left not Check cabling between the Y6020
left (Y6020), short circuit working control unit and the compo- D7971/C1:34
Y 6020 5 7 Solenoid valve, side Side shift left not Check cabling between the Y6020 7.4 Side Shift Attachment
shift left (Y6020), open working control unit and the compo- D7911/C1:38 4/XX DIAG- control valve,
circuit nent with diagnostic menu. ELME582: NOSE, page description,
Check the component. Y6020-LE 8:59 page 7:49
D7911/C1:23 ELME582:
Y 6020 6 7 Solenoid valve side shift Side shift left not Check cabling between the Y6020 7.4 Side Shift Attachment
left (Y6020), short circuit working control unit and the compo- D7911/C1:38 4/XX DIAG- control valve,
to ground. nent with diagnostic menu. ELME582: NOSE, page description,
Check the component. Y6020-LE 8:59 page 7:49
D7911/C1:23 ELME582:

Y 6021 5 2 Solenoid valve, side Side shift right not Check cabling between the Y6021
shift right (Y6021), open working control unit and the compo- D7971/C1:35
Y 6021 6 2 Solenoid valve side shift Side shift right not Check cabling between the Y6021
right (Y6021), short cir- working control unit and the compo- D7971/C1:35
Y 6021 5 7 Solenoid valve, side Side shift right not Check cabling between the Y6021 7.4 Side Shift
shift right (Y6021), open working control unit and the compo- D7911/C1:39 3/XX DIAG-
circuit. nent with diagnostic menu. ELME582: NOSE, page
Check the component. Y6021–RI 8:59
D7971/C1:24
and menu
components
Y 6021 6 7 Solenoid valve side shift Side shift right not Check cabling between the Y6021 7.4 Side Shift
right (Y6021), short cir- working control unit and the compo- D7911/C1:39 3/XX DIAG-
cuit to ground. nent with diagnostic menu. ELME582: NOSE, page
Check the component. Y6021–RI 8:59
D7971/C1:24 ELME582:
Y 6022 5 2 Solenoid valve, extra Extra hydraulic Check cabling between the Y6022
hydraulic function out function out not control unit and the compo- D7971/C1:41
(Y6022), open circuit. working nent with diagnostic menu.
Y 6022 6 2 Solenoid valve hydraulic Extra hydraulic Check cabling between the Y6022
function out (Y6022), function out not control unit and the compo- D7971/C1:41
short circuit to ground. working nent with diagnostic menu.
Y 6022 5 7 Solenoid valve open Open container Check cabling between the Y6022 7.9 Load Car- See separate
container door (Y6022), door not working control unit and the compo- D7911/C1:47 rier 137/XX DI- supplement.
open circuit. nent with diagnostic menu. AGNOSE,
Y 6022 6 7 Solenoid valve hydraulic Open container Check cabling between the Y6022 7.9 Load Car- See separate
function out (Y6022), door not working control unit and the compo- D7911/C1:47 rier 137/XX DI- supplement.
Y 6023 5 2 Solenoid valve, extra Extra hydraulic Check cabling between the Y6023
hydraulic function in function in not control unit and the compo- D7971/C1:40
(Y6023), open circuit. working nent with diagnostic menu.

Y 6023 6 2 Solenoid valve, hydraul- Extra hydraulic Check cabling between the Y6023
ic function in (Y6023), function in not control unit and the compo- D7971/C1:40
short circuit to ground. working nent with diagnostic menu.
Y 6023 5 7 Solenoid valve close Close container Check cabling between the Y6023 7.9 Load Car- See separate
open circuit. nent with diagnostic menu. AGNOSE,
Y 6023 6 7 Solenoid valve close Close container Check cabling between the Y6023 7.9 Load Car- See separate
VDRG09.01GB
D:157
and menu
components
VDRG09.01GB
Y 6034 5 7 1 Solenoid valve levelling Levelling locked, Check cabling between the Y6034-1 7.8 Levelling 5/
lock 1 (Y6034-1), open levelling not control unit and the compo- D7911/C1:21 XX DIAGNOSE,
circuit. working. nent with diagnostic menu. page 8:67
lock 1 (Y6034-1), short levelling not control unit and the compo- D7911/C1:21 XX DIAGNOSE,
circuit to ground. working. nent with diagnostic menu. page 8:67
lock 2 (Y6034-2), open levelling not control unit and the compo- D7911/C1:22 XX DIAGNOSE,
circuit. working. nent with diagnostic menu. page 8:67
lock 2 (Y6034-2), short levelling not control unit and the compo- D7911/C1:22 XX DIAGNOSE,
circuit to ground. working. nent with diagnostic menu. page 8:67
Y 6035 5 2 Solenoid valve, levelling Levelling right up/ Check cabling between the Y6035 C1:38
right up/anticlockwise anticlockwise not control unit and the compo- D7971
(Y6035), open circuit. working. nent with diagnostic menu.
Y 6035 6 2 Solenoid valve, levelling Levelling right up/ Check cabling between the Y6035 C1:38
right up/anticlockwise anticlockwise not control unit and the compo- D7971
(Y6035), short circuit to working. nent with diagnostic menu.
Y 6035 5 7 Solenoid valve levelling Levelling not Check cabling between the Y6035 7.8 Levelling 4/ Attachment

anticlockwise (Y6035), working. control unit and the compo- D7911/C1:40 XX DIAGNOSE, control valve,
open circuit. nent with diagnostic menu. ELME582: page 8:66 description,
Check the component. Y6035 ELME582: page 7:122
D7911/C2:36
anticlockwise (Y6035), working. control unit and the compo- D7911/C1:40 XX DIAGNOSE, control valve,
short circuit to ground. nent with diagnostic menu. ELME582: page 8:66 description,
D7911/C2:36
Y 6036 5 2 Solenoid valve, levelling Levelling left up/ Check cabling between the Y6036 C1:39
left up/clockwise clockwise not control unit and the compo- D7971
(Y6036), open circuit. working. nent with diagnostic menu.
and menu
components
Y 6036 6 2 Solenoid valve, levelling Levelling left up/ Check cabling between the Y6036 C1:39
left up/clockwise clockwise not control unit and the compo- D7971
clockwise (Y6036), working. control unit and the compo- D7911/C1:41 XX DIAGNOSE, control valve,
open circuit. nent with diagnostic menu. ELME582: page 8:66 description,
D7911/C2:38
Y 6036 6 7 Solenoid valve levelling Levelling not Check cabling between the Y6036 7.8 Levelling 3/
clockwise (Y6036), working. control unit and the compo- D7911/C1:41 XX DIAGNOSE,
short circuit to ground. nent with diagnostic menu. ELME582: page 8:66
Check the component. Y6036 ELME582:
D7911/C2:38
Y 6039 5 3 Solenoid valve, open Twistlocks not Check cabling between the Y6039 - -
twistlocks (Y6039), working. control unit and the compo- D7972/C1:15
Y 6039 6 3 Solenoid valve open Twistlocks not Check cabling between the Y6039 - -
Y 6039 5 7 Solenoid valve, lock Twistlocks not Check cabling between the Y6039 7.9 Load Car- Attachment
twistlocks (Y6039), working. control unit and the compo- D7911/C1:15 rier 7/XX DIAG- control valve,
open circuit. nent with diagnostic menu. NOSE, page description,

Y 6039 6 7 Solenoid valve lock Twistlocks not Check cabling between the Y6039 7.9 Load Car- Attachment
short circuit to ground. nent with diagnostic menu. NOSE, page description,
Y 6040 5 3 Solenoid valve, lock Twistlocks not Check cabling between the Y6040 - -
Y 6040 6 3 Solenoid valve lock Twistlocks not Check cabling between the Y6040 - -
VDRG09.01GB
D:159
and menu
components
VDRG09.01GB
Y 6040 5 7 Solenoid valve, open Twistlocks not Check cabling between the Y6040 7.9 Load Car- Attachment
open circuit. nent with diagnostic menu. NOSE, page description,
Y 6040 6 7 Solenoid valve open Twistlocks not Check cabling between the Y6040 7.9 Load Car- Attachment
short circuit to ground. nent with diagnostic menu. NOSE, page description,
Y 6045 5 2 10 Solenoid valve blocking Lower not working. Check cabling between the Y6045 7.2 Lifting Low- Valve block lift
lower left (Y6045-LE), control unit and the compo- D7971/C1:36 ering 8/XX DI- cylinder, de-
open circuit. nent with diagnostic menu. AGNOSE, scription, page
lower left (Y6045-LE), control unit and the compo- D7971/C1:36 ering 8/XX DI- cylinder, de-
short circuit to ground. nent with diagnostic menu. AGNOSE, scription, page
lower right (Y6045-RI), control unit and the compo- D7971/C1:37 ering 8/XX DI- cylinder, de-
lower right (Y6045-RI), control unit and the compo- D7971/C1:37 ering 8/XX DI- cylinder, de-
Y 6046 5 7 1 Solenoid valve WTP WTP not working. Check cabling between the Y6046-1 7.9 Load Car- See separate

(Y6046-1), twistlocks control unit and the compo- A7993/C2:3 rier 128/XX DI- supplement.
out to WTP position, nent with diagnostic menu. AGNOSE,
open circuit. Check the component. page 8:94
(Y6046-1), twistlocks control unit and the compo- A7993/C2:3 rier 128/XX DI- supplement.
out to WTP position, nent with diagnostic menu. AGNOSE,
short circuit to ground. Check the component. page 8:94
(Y6046-2), twistlocks in control unit and the compo- A7993/C2:4 rier 129/XX DI- supplement.
to standard position, nent with diagnostic menu. AGNOSE,
and menu
components
(Y6046-2), twistlocks in control unit and the compo- A7993/C2:4 rier 129/XX DI- supplement.
to standard position, nent with diagnostic menu. AGNOSE,
Y 6047 5 2 Solenoid valve cab tilt Cab tilt not working. Check cabling between the Y6047 Control valve
up (Y6047), open circuit. control unit and the compo- D7971/C1:41 cab movement,
nent with diagnostic menu. description,
up (Y6047), short circuit control unit and the compo- D7971/C1:41 cab movement,
to ground. nent with diagnostic menu. description,
down (Y6048), open control unit and the compo- D7971/C1:40 cab movement,
circuit. nent with diagnostic menu. description,
down (Y6048), short cir- control unit and the compo- D7971/C1:40 cab movement,
cuit to ground. nent with diagnostic menu. description,
Y 6050 5 2 Solenoid valve blocking Boom in not Check cabling between the Y6050 7.3 Extension Valve block ex-
extension (Y6050), working. control unit and the compo- D7971/C1:35 3/XX DIAG- tension cylin-
open circuit nent with diagnostic menu. NOSE, page der, description,
Y 6050 6 2 Solenoid valve blocking Boom in not Check cabling between the Y6050 7.3 Extension Valve block ex-

extension (Y6050), working. control unit and the compo- D7971/C1:35 3/XX DIAG- tension cylin-
short circuit to ground. nent with diagnostic menu. NOSE, page der, description,
Y 6051 5 2 1 Solenoid valve regener- Regeneration, ex- Check cabling between the Y6051-1 7.3 Extension Valve block ex-
ation extension (Y6051- tension not working. control unit and the compo- D7971/C1:24 4/XX DIAG- tension cylin-
1), open circuit. nent with diagnostic menu. NOSE, page der, description,
Y 6051 6 2 1 Solenoid valve regener- Regeneration, ex- Check cabling between the Y6051-1 7.3 Extension Valve block ex-
ation extension (Y6051- tension not working. control unit and the compo- D7971/C1:24 4/XX DIAG- tension cylin-
1), short circuit to nent with diagnostic menu. NOSE, page der, description,
ground. Check the component. 8:58 page 7:39
VDRG09.01GB
D:161
and menu
components
VDRG09.01GB
Y 6051 5 2 10 Solenoid valve regener- Regeneration, lift Check cabling between the Y6051-LE 7.2 Lifting Low- Valve block lift
ation lift left (Y6051-LE), not working. control unit and the compo- D7971/C1:11 ering 9/XX DI- cylinder, de-
Y 6051 6 2 10 Solenoid valve regener- Regeneration, lift Check cabling between the Y6051-LE 7.2 Lifting Low- Valve block lift
ation lift left (Y6051-LE), not working. control unit and the compo- D7971/C1:11 ering 9/XX DI- cylinder, de-
Y 6051 5 2 20 Solenoid valve regener- Regeneration, lift Check cabling between the Y6051-RI 7.2 Lifting Low- Valve block lift
ation lift right (Y6051-RI), not working. control unit and the compo- D7971/C1:01 ering 9/XX DI- cylinder, de-
open circuit nent with diagnostic menu. AGNOSE, scription, page
Y 6051 6 2 20 Solenoid valve regener- Regeneration, lift Check cabling between the Y6051-RI 7.2 Lifting Low- Valve block lift
ation lift right (Y6051-RI), not working. control unit and the compo- D7971/C1:01 ering 9/XX DI- cylinder, de-
Y 6053 5 6 10 Solenoid valve operat- Lowering of lift legs Check cabling between the Y6053-LE 7.9 Load Car- Raising/lower-
ing position left (Y6053- not working. control unit and the compo- D7912/C1:01 rier 53/XX DI- ing rear lift legs,
LE), open circuit. nent with diagnostic menu. AGNOSE, function de-
Check the component. page 8:80 scription, page
7:148
Y 6053 6 6 10 Solenoid valve operat- Lowering of lift legs Check cabling between the Y6053-LE 7.9 Load Car- Raising/lower-
ing position left (Y6053- not working. control unit and the compo- D7912/C1:01 rier 53/XX DI- ing rear lift legs,
LE), short circuit to nent with diagnostic menu. AGNOSE, function de-
ground. Check the component. page 8:80 scription, page
7:148

Y 6053 5 6 20 Solenoid valve operat- Lowering of lift legs Check cabling between the Y6053-RI 7.9 Load Car- Raising/lower-
ing position right not working. control unit and the compo- D7912/C1:11 rier 54/XX DI- ing rear lift legs,
(Y6053-RI), open circuit. nent with diagnostic menu. AGNOSE, function de-
7:148
Y 6053 6 6 20 Solenoid valve operat- Lowering of lift legs Check cabling between the Y6053-RI 7.9 Load Car- Raising/lower-
ing position right not working. control unit and the compo- D7912/C1:11 rier 54/XX DI- ing rear lift legs,
(Y6053-RI), short circuit nent with diagnostic menu. AGNOSE, function de-
to ground. Check the component. page 8:81 scription, page
7:148
Y 6054 5 2 Solenoid valve clamp Clamp close not Check cabling between the Y6054 Raising/lower-
close (Y6054), open working. control unit and the compo- D7971/C1:36 ing rear lift legs,
circuit. nent with diagnostic menu. function de-
Check the component. scription, page
7:148
and menu
components
Y 6054 6 2 Solenoid valve clamp Clamp close not Check cabling between the Y6054 Raising/lower-
close (Y6054), short cir- working. control unit and the compo- D7971/C1:36 ing rear lift legs,
cuit to ground. nent with diagnostic menu. function de-
7:148
Y 6054 5 2 10 Solenoid valve clamp Clamp close left not Check cabling between the Y6054-LE Raising/lower-
close left (Y6054-LE), working. control unit and the compo- D7971/C1:36 ing rear lift legs,
open circuit. nent with diagnostic menu. function de-
7:148
Y 6054 6 2 10 Solenoid valve clamp Clamp close left not Check cabling between the Y6054-LE
close left (Y6054-LE), working. control unit and the compo- D7971/C1:36
Y 6054 5 2 20 Solenoid valve clamp Clamp close right Check cabling between the Y6054-RI
close right (Y6054-RI), not working. control unit and the compo- D7971/C1:38
Y 6054 5 3 10 Solenoid valve, clamp Clamp close not Check cabling between the Y6054
close (Y6054), open working. control unit and the compo- D7972/C1:29

Y 6054 6 3 10 Solenoid valve clamp Clamp close not Check cabling between the Y6054
close (Y6054), short cir- working. control unit and the compo- D7972/C1:29
VDRG09.01GB
D:163
and menu
components
VDRG09.01GB
Y 6054 6 6 Solenoid valve clamp Clamp close not Check cabling between the Y6054 7.9 Load Car- -
close (Y6054), short cir- working. control unit and the compo- D7912/C1:18 rier 71/XX DI-
cuit to ground. nent with diagnostic menu. AGNOSE,
Y 6054 5 6 10 Solenoid valve clamp Lowering of lift legs Check cabling between the Y6054-LE 7.9 Load Car- Clamping with
close left (Y6054-LE), not working. control unit and the compo- D7912/C1:21 rier 49/XX DI- lift legs, func-
open circuit. nent with diagnostic menu. AGNOSE, tion description,
close left (Y6054-LE), not working. control unit and the compo- D7912/C1:21 rier 49/XX DI- lift legs, func-
short circuit to ground. nent with diagnostic menu. AGNOSE, tion description,
Y 6054 5 6 20 Solenoid valve clamp Lowering of lift legs Check cabling between the Y6054-RI 7.9 Load Car- Clamping with
close right (Y6054-RI), not working. control unit and the compo- D7912/C1:23 rier 51/XX DI- lift legs, func-
close right (Y6054-RI), not working. control unit and the compo- D7912/C1:23 rier 51/XX DI- lift legs, func-
Y 6054 6 7 Solenoid valve clamp Lowering of lift legs Check cabling between the Y6054 7.9 Load Car- See separate
ELME (Y6054), short not working. control unit and the compo- D7911/C1:18 rier 71/XX DI- supplement.
circuit to ground. nent with diagnostic menu. AGNOSE,
Y 6055 5 2 Solenoid valve clamp Clamp open not Check cabling between the Y6055

open (Y6055), open working. control unit and the compo- D7971/C1:37
Y 6055 6 2 Solenoid valve clamp Clamp open not Check cabling between the Y6055
open (Y6055), short cir- working. control unit and the compo- D7971/C1:37
Y 6055 5 2 10 Solenoid valve clamp Clamp open left not Check cabling between the Y6055-LE
open left (Y6055-LE), working. control unit and the compo- D7971/C1:37
and menu
components
Y 6055 6 2 10 Solenoid valve clamp Clamp open left not Check cabling between the Y6055-LE
open left (Y6055-LE), working. control unit and the compo- D7971/C1:37
Y 6055 5 2 20 Solenoid valve clamp Clamp open right Check cabling between the Y6055-RI
open right (Y6055-RI), not working. control unit and the compo- D7971/C1:39
Y 6055 5 3 10 Solenoid valve clamp Clamp open not Check cabling between the Y6055
open (Y6055), open working. control unit and the compo- D7972/C1:33
Y 6055 6 3 10 Solenoid valve clamp Clamp open not Check cabling between the Y6055
open (Y6055), short cir- working. control unit and the compo- D7972/C1:33

Y 6055 6 6 Solenoid valve clamp Clamp open not Check cabling between the Y6055 7.9 Load Car- -
open (Y6054), short cir- working. control unit and the compo- D7912/C1:17 rier 72/XX DI-
cuit to ground. nent with diagnostic menu. AGNOSE,
open left (Y6055-LE), not working. control unit and the compo- D7912/C1:22 rier 50/XX DI- lift legs, func-
VDRG09.01GB
D:165
and menu
components
VDRG09.01GB
open left (Y6055-LE), not working. control unit and the compo- D7912/C1:22 rier 50/XX DI- lift legs, func-
open right (Y6055-RI), not working. control unit and the compo- D7912/C1:24 rier 52/XX DI- lift legs, func-
open right (Y6055-RI), not working. control unit and the compo- D7912/C1:24 rier 52/XX DI- lift legs, func-
Y 6055 6 7 10 Solenoid valve detach Lowering of lift legs Check cabling between the Y6055 7.9 Load Car- See separate
ELME (Y6055) not working. control unit and the compo- D7911/C1:17 rier 72/XX DI- supplement.
nent with diagnostic menu. AGNOSE,
Y 6056 5 6 110 Solenoid valve front Lowering of lift legs Check cabling between the Y6056-LF 7.9 Load Car- Raising/lower-
knee in left (Y6056-LF), not working. control unit and the compo- D7912/C1:27 rier 36/XX DI- ing front lift
open circuit. nent with diagnostic menu. AGNOSE, legs, function
Check the component. page 8:75 description,
page 7:144
Y 6056 6 6 110 Solenoid valve front Lowering of lift legs Check cabling between the Y6056-LF 7.9 Load Car- Raising/lower-
knee in left (Y6056-LF), not working. control unit and the compo- D7912/C1:27 rier 36/XX DI- ing front lift
short circuit to ground. nent with diagnostic menu. AGNOSE, legs, function

page 7:144
Y 6056 5 6 120 Solenoid valve front Lowering of lift legs Check cabling between the Y6056-RF Raising/lower-
knee in right (Y6056- not working. control unit and the compo- D7912/C1:34 ing front lift
RF), open circuit. nent with diagnostic menu. legs, function
Check the component. description,
page 7:144
Y 6056 6 6 120 Solenoid valve front Lowering of lift legs Check cabling between the Y6056-RF Raising/lower-
knee in right (Y6056- not working. control unit and the compo- D7912/C1:34 ing front lift
RF), short circuit to nent with diagnostic menu. legs, function
ground. Check the component. description,
page 7:144
and menu
components
Y 6056 5 6 210 Solenoid valve rear Lowering of lift legs Check cabling between the Y6056-LR 7.9 Load Car- Raising/lower-
knee in left (Y6056-LR), not working. control unit and the compo- D7912/C1:38 rier 44/XX DI- ing rear lift legs,
open circuit. nent with diagnostic menu. AGNOSE, function de-
7:148
knee in left (Y6056-LR), not working. control unit and the compo- D7912/C1:38 rier 44/XX DI- ing rear lift legs,
short circuit to ground. nent with diagnostic menu. AGNOSE, function de-
7:148
Y 6056 5 6 220 Solenoid valve rear Lowering of lift legs Check cabling between the Y6056-RR 7.9 Load Car- Raising/lower-
knee in right (Y6056- not working. control unit and the compo- D7912/C1:47 rier 48/XX DI- ing rear lift legs,
RR), open circuit. nent with diagnostic menu. AGNOSE, function de-
7:148
knee in right (Y6056- not working. control unit and the compo- D7912/C1:47 rier 48/XX DI- ing rear lift legs,
RR), short circuit to nent with diagnostic menu. AGNOSE, function de-
7:148
Y 6057 5 6 110 Solenoid valve front Lowering of lift legs Check cabling between the Y6057-LF Raising/lower-
knee out left (Y6057-LF), not working. control unit and the compo- D7912/C1:28 ing front lift
open circuit. nent with diagnostic menu. legs, function

page 7:144
Y 6057 6 6 110 Solenoid valve front Lowering of lift legs Check cabling between the Y6057-LF Raising/lower-

knee out left (Y6057-LF), not working. control unit and the compo- D7912/C1:28 ing front lift
short circuit to ground. nent with diagnostic menu. legs, function
page 7:144
Y 6057 5 6 120 Solenoid valve front Lowering of lift legs Check cabling between the Y6057-RF 7.9 Load Car- Raising/lower-
knee out right (Y6057- not working. control unit and the compo- D7912/C1:35 rier 37/XX DI- ing front lift
RF), open circuit. nent with diagnostic menu. AGNOSE, legs, function
page 7:144
Y 6057 6 6 120 Solenoid valve front Lowering of lift legs Check cabling between the Y6057-RF 7.9 Load Car- Raising/lower-
knee out right (Y6057- not working. control unit and the compo- D7912/C1:35 rier 37/XX DI- ing front lift
RF), short circuit to nent with diagnostic menu. AGNOSE, legs, function
ground. Check the component. page 8:75 description,
page 7:144
VDRG09.01GB
D:167
and menu
components
VDRG09.01GB
knee out left (Y6057- not working. control unit and the compo- D7912/C1:39 rier 41/XX DI- ing rear lift legs,
LR), open circuit. nent with diagnostic menu. AGNOSE, function de-
7:148
knee out left (Y6057- not working. control unit and the compo- D7912/C1:39 rier 41/XX DI- ing rear lift legs,
LR), short circuit to nent with diagnostic menu. AGNOSE, function de-
7:148
knee out right (Y6057- not working. control unit and the compo- D7912/C1:48 rier 45/XX DI- ing rear lift legs,
7:148
knee out right (Y6057- not working. control unit and the compo- D7912/C1:48 rier 45/XX DI- ing rear lift legs,
7:148
Y 6058 5 6 110 Solenoid valve front leg Lowering of lift legs Check cabling between the Y6058-LF 7.9 Load Car- Raising/lower-
up left (Y6058-LF), open not working. control unit and the compo- D7912/C1:29 rier 35/XX DI- ing front lift
circuit. nent with diagnostic menu. AGNOSE, legs, function

page 7:144

up left (Y6058-LF), short not working. control unit and the compo- D7912/C1:29 rier 35/XX DI- ing front lift
circuit to ground. nent with diagnostic menu. AGNOSE, legs, function
page 7:144
Y 6058 5 6 120 Solenoid valve front leg Lowering of lift legs Check cabling between the Y6058-RF 7.9 Load Car- Raising/lower-
up right (Y6058-RF), not working. control unit and the compo- D7912/C1:36 rier 39/XX DI- ing front lift
page 7:144
up right (Y6058-RF), not working. control unit and the compo- D7912/C1:36 rier 39/XX DI- ing front lift
page 7:144
and menu
components
Y 6058 5 6 210 Solenoid valve rear leg Lowering of lift legs Check cabling between the Y6058-LR 7.9 Load Car- Raising/lower-
up left (Y6058-LR), not working. control unit and the compo- D7912/C1:40 rier 43/XX DI- ing rear lift legs,
7:148
up left (Y6058-LR), not working. control unit and the compo- D7912/C1:40 rier 43/XX DI- ing rear lift legs,
7:148
Y 6058 6 6 100 Solenoid valve front leg Lowering of lift legs Check cabling between the Y6058-FR 7.9 Load Car- See separate
down ELME (Y6058- not working. control unit and the compo- D7912/C2:31 rier 68/XX DI- supplement.
FR). nent with diagnostic menu. AGNOSE,
Y 6058 6 6 200 Solenoid valve rear leg Lowering of lift legs Check cabling between the Y6058-RE 7.9 Load Car- See separate
up ELME (Y6058-RE). not working. control unit and the compo- D7912/C2:30 rier 70/XX DI- supplement.
Y 6058 6 7 200 Solenoid valve rear leg Lowering of lift legs Check cabling between the Y6058-RE 7.9 Load Car- See separate
up ELME (Y6058-RE). not working. control unit and the compo- D7911/C2:30 rier 70/XX DI- supplement.

Y 6058 5 7 220 Solenoid valve rear lift Lowering of lift legs Check cabling between the Y6058-RR 7.9 Load Car- Raising/lower-
leg up right (Y6058-RR), not working. control unit and the compo- D7911/C1:47 rier 47/XX DI- ing rear lift legs,
7:148
leg up right (Y6058-RR), not working. control unit and the compo- D7911/C1:47 rier 47/XX DI- ing rear lift legs,
7:148
down left (Y6059-LF), not working. control unit and the compo- D7912/C1:33 rier 34/XX DI- ing front lift
VDRG09.01GB
D:169
page 7:144
and menu
components
VDRG09.01GB
down left (Y6059-LF), not working. control unit and the compo- D7912/C1:33 rier 34/XX DI- ing front lift
page 7:144
down right (Y6059-RF), not working. control unit and the compo- D7912/C1:37 rier 38/XX DI- ing front lift
page 7:144
down right (Y6059-RF), not working. control unit and the compo- D7912/C1:37 rier 38/XX DI- ing front lift
page 7:144
down left (Y6059-LR), not working. control unit and the compo- D7912/C1:41 rier 42/XX DI- ing rear lift legs,
7:148
down left (Y6059-LR), not working. control unit and the compo- D7912/C1:41 rier 42/XX DI- ing rear lift legs,
7:148

Y 6059 6 6 200 Solenoid valve rear leg Lowering of lift legs Check cabling between the D7912/C1:11 7.9 Load Car- See separate
down ELME (Y6059- not working. control unit and the compo- rier 69/XX DI- supplement.
RE). nent with diagnostic menu. AGNOSE,
and menu
components
Y 6059 6 7 200 Solenoid valve rear leg Lowering of lift legs Check cabling between the D7911/C1:11 7.9 Load Car- See separate
down ELME (Y6059- not working. control unit and the compo- rier 69/XX DI- supplement.
RE). nent with diagnostic menu. AGNOSE,
leg down right (Y6059- not working. control unit and the compo- D7911/C1:48 rier 46/XX DI- ing rear lift legs,
7:148
leg down right (Y6059- not working. control unit and the compo- D7911/C1:48 rier 46/XX DI- ing rear lift legs,
7:148
Y 6062 5 2 Solenoid valve disen- No limitation. Check cabling between the Y6062
gage hydraulic oil pump control unit and the compo- D7971/C1:14
2 (Y6062). nent with diagnostic menu.
Y 6062 6 2 Solenoid valve disen- No limitation. Check cabling between the Y6062
gage hydraulic oil pump control unit and the compo- D7971/C1:14
2 (Y6062). nent with diagnostic menu.
Y 6063 5 3 Solenoid valve support Lowering of support Check cabling between the Y6063 7.10 Other Support jacks,
jacks up (Y6063), open jacks not working. control unit and the compo- D7972/C1:27 Functions 7/XX function de-
circuit. nent with diagnostic menu. DIAGNOSE, scription, page

jacks up (Y6063), short jacks not working. control unit and the compo- D7972/C1:27 Functions 7/XX function de-
circuit to ground. nent with diagnostic menu. DIAGNOSE, scription, page
jacks down (Y6064), jacks not working. control unit and the compo- D7972/C1:28 Functions 8/XX function de-
open circuit nent with diagnostic menu. DIAGNOSE, scription, page
jacks down (Y6064), jacks not working. control unit and the compo- D7972/C1:28 Functions 8/XX function de-
short circuit to ground. nent with diagnostic menu. DIAGNOSE, scription, page
VDRG09.01GB
D:171
and menu
components
VDRG09.01GB
Y 6065 5 7 Solenoid valve declutch Declutch of rotation Check cabling between the Y6065 7.6 Rotation 4/
rotation brake (Y6065), brake not working. control unit and the compo- D7911/C1:1 XX DIAGNOSE,
open circuit. nent with diagnostic menu. page 8:64
Y 6065 6 7 Solenoid valve declutch Declutch of rotation Check cabling between the Y6065 7.6 Rotation 4/
rotation brake (Y6065), brake not working. control unit and the compo- D7911/C1:1 XX DIAGNOSE,
short circuit to ground. nent with diagnostic menu. page 8:64
Y 6070 5 7 Solenoid valve, over- Lowering of over- Check cabling between the Y6070 7.9 Load Car- Overheight-
height-legs up (Y6070), height-legs not control unit and the compo- D7911/C1:17 rier 89/XX DI- legs, descrip-
open circuit. working. nent with diagnostic menu. AGNOSE, tion, page
Y 6070 6 7 Solenoid valve, over- Lowering of over- Check cabling between the Y6070 7.9 Load Car- Overheight-
height-legs up (Y6070), height-legs not control unit and the compo- D7911/C1:17 rier 89/XX DI- legs, descrip-
short circuit to ground. working. nent with diagnostic menu. AGNOSE, tion, page
Y 6071 5 7 20 Solenoid valve, over- Lowering of over- Check cabling between the Y6071 7.9 Load Car- Overheight-
height-legs down height-legs not control unit and the compo- D7911/C1:18 rier 88/XX DI- legs, descrip-
(Y6071), open circuit. working. nent with diagnostic menu. AGNOSE, tion, page
Y 6071 6 7 20 Solenoid valve, over- Lowering of over- Check cabling between the Y6071 7.9 Load Car- Overheight-
height-legs down height-legs not control unit and the compo- D7911/C1:18 rier 88/XX DI- legs, descrip-
(Y6071), short circuit to working. nent with diagnostic menu. AGNOSE, tion, page
ground. Check the component. page 8:89 7:130
Y 6072 5 3 1 Solenoid valve, clamp- No limitation. Check cabling between the Y6072-1 See separate

ing pressure (Y6072-1), control unit and the compo- D7972/C1:27 supplement.
and menu
components
Y 6078 5 3 1 Solenoid valve, paper No limitation. Check cabling between the Y6078-1 See separate
attachment, shutdown control unit and the compo- D7972/C1:14 supplement.
upper clamping arm nent with diagnostic menu.
(Y6078-1), open circuit. Check the component.
(Y6078-1), short circuit Check the component.
to ground.
(Y6078-2), open circuit. Check the component.
(Y6078-2), short circuit Check the component.
to ground.
Y 6080 5 Solenoid valve, cab Cab movement ac- Check cabling between the Y6080 - -
movement activation tivation not working. control unit and the compo- D7971/C2:31
(Y6080), open circuit. nent with diagnostic menu.

Y 6080 6 Solenoid valve, cab Cab movement ac- Check cabling between the Y6080 - -
movement activation tivation not working. control unit and the compo- D7971/C2:31
(Y6080), short circuit to nent with diagnostic menu.
Y 6085 5 2 Solenoid valve, split hy- Hydraulic function 1 Check cabling between the Y6085
draulic function 1 cannot be split. control unit and the compo- D7971/C1:1
VDRG09.01GB
D:173
and menu
components
VDRG09.01GB
Y 6085 5 7 Solenoid valve door Select door open- Check cabling between the Y6085 7.9 Load Car-
opener (Y6085), open ing (depending on control unit and the compo- D7911/C2:38 rier 139/XX DI-
circuit. container width) not nent with diagnostic menu. AGNOSE,
working. Check the component. page 8:97
Y 6085 6 7 Solenoid valve select Select door open- Check cabling between the Y6085 7.9 Load Car-
door opening (Y6085), ing (depending on control unit and the compo- D7911/C2:38 rier 139/XX DI-
short circuit to ground. container width) not nent with diagnostic menu. AGNOSE,
working. Check the component. page 8:97
Y 6088 5 2 Solenoid valve, shut- Deactivation of ac- Check cabling between the Y6088
down accumulator cumulator not control unit and the compo- D7971/C1:44
(Y6088), open circuit working. nent with diagnostic menu.
Y 6088 6 2 Solenoid valve, shut- Deactivation of ac- Check cabling between the Y6088
down accumulator cumulator not control unit and the compo- D7971/C1:44
Y 6089 5 2 Solenoid valve activate Quick-lift not Check cabling between the Y6089 Axial piston

extra hydraulic oil pump working. control unit and the compo- D7971/C1:1 pump with vari-
lift (Y6089), open circuit. nent with diagnostic menu. able displace-
Check the component. ment, function
description,
page 10:8
Y 6089 6 2 Solenoid valve activate Quick-lift not Check cabling between the Y6089 Axial piston
extra hydraulic oil pump working. control unit and the compo- D7971/C1:1 pump with vari-
lift (Y6089), short circuit nent with diagnostic menu. able displace-
to ground. Check the component. ment, function
description,
page 10:8
Y 6091 5 2 Solenoid valve, fan Cooling fan not Check cabling between the Y6091
speed, engine cooling working. control unit and the compo- D7971/C1:47
fan (Y6091), open nent with diagnostic menu.
circuit. Check the component.
and menu
components
Y 6091 6 2 Solenoid valve, fan Cooling fan not Check cabling between the Y6091
speed, engine cooling working. control unit and the compo- D7971/C1:47
fan (Y6091), short circuit nent with diagnostic menu.
Y 6092 5 2 Solenoid valve, fan Reversing of cool- Check cabling between the Y6092
speed direction, engine ing fan not working. control unit and the compo- D7971/C1:21
cooling fan (Y6092), nent with diagnostic menu.
open circuit. Check the component.
Y 6092 6 2 Solenoid valve, fan Reversing of cool- Check cabling between the Y6092
speed direction, engine ing fan not working. control unit and the compo- D7971/C1:21
cooling fan (Y6092), nent with diagnostic menu.
short circuit to ground. Check the component.
Y 6093 5 2 Solenoid valve pump Disengagement of Check cabling between the Y6093 7.3 Extension Solenoid valve
unloading boom in the hydraulic oil control unit and the compo- D7971/C1:14 5/XX DIAG- pump unload-
(Y6093), open circuit. pump not working. nent with diagnostic menu. NOSE, page ing, description,
10.4 Pumps 2/
XX DIAGNOSE,
page 8:134
Y 6093 6 2 Solenoid valve pump Disengagement of Check cabling between the Y6093 7.3 Extension Solenoid valve
unloading boom in the hydraulic oil control unit and the compo- D7971/C1:14 5/XX DIAG- pump unload-
(Y6093), short circuit to pump not working. nent with diagnostic menu. NOSE, page ing, description,
ground. Check the component. 8:58 page 10:25

10.4 Pumps 2/
XX DIAGNOSE,
page 8:134

Y 6094 5 2 Solenoid valve disen- Disengagement of Check cabling between the
gage hydraulic pump at- the hydraulic oil control unit and the compo-
tachment (Y6094), open pump not working. nent with diagnostic menu.
Y 6094 6 2 Solenoid valve disen- Disengagement of Check cabling between the
gage hydraulic pump at- the hydraulic oil control unit and the compo-
tachment (Y6094), short pump not working. nent with diagnostic menu.
Y 6095 5 2 Solenoid valve split - Check cabling between the Y6095 11.9 I/O D7971
function mast (Y6095), control unit and the compo- D7971/C1:40 KFU 1–75/XX
open circuit. nent with diagnostic menu. DIAGNOSE,
VDRG09.01GB
D:175
and menu
components
VDRG09.01GB
Y 6095 6 2 Solenoid valve split - Check cabling between the Y6095 11.9 I/O D7971
function mast (Y6095), control unit and the compo- D7971/C1:40 KFU 1–75/XX
short circuit to ground. nent with diagnostic menu. DIAGNOSE,
Y 6100 5 7 Solenoid valve Wide Wide body in not Check cabling between the Y6100
body in (Y6100), open working. control unit and the compo- D7911/C1:36
Y 6100 6 7 Solenoid valve Wide Wide body in not Check cabling between the Y6100
body in (Y6100), short working. control unit and the compo- D7911/C1:36
Y 6101 5 7 Solenoid valve Wide Wide body out not Check cabling between the Y6101
body out (Y6101), open working. control unit and the compo- D7911/C1:37
Y 6101 6 7 Solenoid valve Wide Wide body out not Check cabling between the Y6101
body out (Y6101), short working. control unit and the compo- D7911/C1:37
Y 6102 5 3 Solenoid valve inspec- Inspection support Check cabling between the Y6102
tion support outer posi- out not working. control unit and the compo- D7972
tion (Y6102), nent with diagnostic menu. C1:28
interruption. Check the component.

tion support outer posi- out not working. control unit and the compo- D7972
tion (Y6102), short nent with diagnostic menu. C1:28
circuit to frame. Check the component.
tion support inner posi- in not working. control unit and the compo- D7972
tion (Y6103), nent with diagnostic menu. C1:27
interruption. Check the component.
tion support inner posi- in not working. control unit and the compo- D7972
tion (Y6103), short nent with diagnostic menu. C1:27
circuit to body. Check the component.
and menu
components
Y 6104 6 7 Solenoid valve, beam Tilting of attach- Check cabling between the Y6104
lock locked (Y6104), ment more than 10° control unit and the compo- D7911/C2:31
open circuit. not working. nent with diagnostic menu.
Y 6105 6 7 Solenoid valve, beam Tilting of attach- Check cabling between the Y6105
lock unlocked (Y6105), ment more than 10° control unit and the compo- D7911/C2:30
short circuit to ground. not working. nent with diagnostic menu.
Y 6106 5 7 Solenoid valve, spread- Spreading not Check cabling between the Y6106 -
ing (Y6106), open circuit working. control unit and the compo- D7911/C1:29
Y 6106 6 7 Solenoid valve, spread- Spreading not Check cabling between the Y6106 -
ing (Y6106), short circuit working. control unit and the compo- D7911/C1:29
Y 6108 5 7 Solenoid valve, levelling Levelling not Check cabling between the Y6108 -
(Y6108), open circuit working. control unit and the compo- D7911/C1:40
Y 6108 6 7 Solenoid valve, levelling Levelling not Check cabling between the Y6108 -
(Y6108), short circuit to working. control unit and the compo- D7911/C1:40
Y 6109 5 2 Solenoid valve, genera- Generator pump Check cabling between the Y6109 -

tor pump (Y6109), open not working control unit and the compo- D7971/C1:44
Y 6109 6 2 Solenoid valve, genera- Generator pump Check cabling between the Y6109 -
tor pump (Y6109), short not working control unit and the compo- D7971/C1:44
Y 6120 5 1 1 Damper motor, recircu- Recirculation Check cabling between the Y6120 9.4 Climate Fresh air/recir-
lation air conditioning damper for ventila- control unit and the compo- D7901/C2:28 System 11/XX culation damp-
(Y6120), open circuit. tion not working. nent with diagnostic menu. DIAGNOSE, er, description,
VDRG09.01GB
D:177
and menu
components
VDRG09.01GB
Y 6120 6 1 1 Damper motor recircula- Recirculation Check cabling between the Y6120 9.4 Climate Fresh air/recir-
tion air conditioning unit damper for ventila- control unit and the compo- D7901/C2:28 System 11/XX culation damp-
(Y6120), short circuit to tion not working. nent with diagnostic menu. DIAGNOSE, er, description,
ground. Check the component. page 8:113 page 9:32
(Y6120), open circuit. tion not working. nent with diagnostic menu. DIAGNOSE, er, description,
unit (Y6120), short cir- tion not working. nent with diagnostic menu. DIAGNOSE, er, description,
cuit to ground. Check the component. page 8:113 page 9:32
Y 6150 5 2 1 Voltage feed to the elec- Joystick control or Check cabling between the Y6150/4 5.2 Power As- Control valve
tronic control module mini-wheel not control unit and the compo- D7971/C1:48 sisted 5/XX DI- steering, de-
(Y6150) for joystick con- working. nent with diagnostic menu. AGNOSE, scription, page
trol/mini-wheel, open Check the component. page 8:47 5:21
circuit.
Y 6150 6 2 1 Voltage feed to elec- Joystick control or Check cabling between the Y6150/4 5.2 Power As- Control valve
tronic steering module mini-wheel not control unit and the compo- D7971/C1:48 sisted 5/XX DI- steering, de-
trol/mini-wheel, short Check the component. page 8:47 5:21
circuit to ground.
Y 6150 5 2 2 Voltage feed to the elec- Joystick control or Check cabling between the Y6150/1 5.2 Power As- Control valve
tronic control module mini-wheel not control unit and the compo- D7971/C1:50 sisted 5/XX DI- steering, de-
trol/mini-wheel, open Check the component. page 8:47 5:21

circuit.
Y 6150 6 2 2 Voltage feed to elec- Joystick control or Check cabling between the Y6150/1 5.2 Power As- Control valve
tronic steering module mini-wheel not control unit and the compo- D7971/C1:50 sisted 5/XX DI- steering, de-
trol/mini-wheel, short Check the component. page 8:47 5:21
circuit to ground.
and menu
components
Y 6150 2 2 3 Electronic control mod- Joystick control or Check the steering valve. Y6150/2 5.2 Power As- Control valve
ule (Y6150) for joystick mini-wheel not Check control valve steering. D7971/C2:23 sisted 6/XX DI- steering, de-
control/mini-wheel, working. Check cabling between the AGNOSE, scription, page
oversteer. control unit and the compo- page 8:48 5:21
This error code may be nent with diagnostic menu.
generated if the valve
slide is pressurised in
the wrong way, for ex-
ample by turning the
steering wheel when
joystick control or mini
wheel is activated.
Y 6150 31 2 Control unit control Standard steering Check the CAN wiring be- Y6150 5.2 Power As- Control valve
valve feedback seat po- function works with tween control unit D7971 D7971 /C1:48 sisted 5/XX DI- steering, de-
sition and Control unit limited capacity and and Y6150 and power sup- AGNOSE, scription, page
mini-wheel or joystick mini-wheel or joy- ply from D7971 /C1:48. page 8:47 5:21
control (Y6150) are stick control
missing. inoperative.
Y 6301 5 3 210 Solenoid valve, drive 4 wheel drive assist Check cabling between the Y6301-LE
left-hand rear wheel for- deactivated. control unit and the compo- D7972/C1:38
wards (Y6301-LE), open nent with diagnostic menu.
left-hand rear wheel for- deactivated. control unit and the compo- D7972/C1:38
wards (Y6301-LE), short nent with diagnostic menu.

Y 6301 5 3 220 Solenoid valve, drive 4 wheel drive assist Check cabling between the Y6301-RI
right-hand rear wheel deactivated. control unit and the compo- D7972/C1:40
forwards (Y6301-RI), nent with diagnostic menu.
forwards (Y6301-RI), nent with diagnostic menu.
left-hand rear wheel deactivated. control unit and the compo- D7972/C1:39
backwards (Y6311-LE), nent with diagnostic menu.
VDRG09.01GB
D:179
and menu
components
VDRG09.01GB
left-hand rear wheel deactivated. control unit and the compo- D7972/C1:39
backwards (Y6311-LE), nent with diagnostic menu.
backwards (Y6311-RI), nent with diagnostic menu.
open circuit Check the component.
backwards (Y6311-RI), nent with diagnostic menu.
Y 6360 5 3 100 Directional control valve No limitation. Check cabling between the Y6360–FR
steering (Y6360–FR), control unit and the compo- D7972/C1:21
forward, open circuit. At nent with diagnostic menu.
revolving driver's seat. Check the component.
Y 6360 6 3 100 Directional control valve No limitation. Check cabling between the Y6360–FR
steering (Y6360–FR), control unit and the compo- D7972/C1:21
forward, short circuit to nent with diagnostic menu.
ground. At revolving Check the component.
driver's seat.
Y 6360 5 3 200 Directional control valve No limitation. Check cabling between the Y6360–RI
steering (Y6360–RI), control unit and the compo- D7972/C1:22
backward, open circuit. nent with diagnostic menu.
At revolving driver's seat. Check the component.

Y 6360 6 3 200 Directional control valve No limitation. Check cabling between the Y6360–RI
steering (Y6360–RI), control unit and the compo- D7972/C1:22
backward, short circuit nent with diagnostic menu.
to ground. At revolving Check the component.
driver's seat.
Y 6420 2 2 Solenoid valve parking Parking brake can- Check cabling between the Y6420 4.5 Park Brake Solenoid valve
brake (Y6420), incorrect not be released. control unit and the compo- D7971/C1:17 Sys 4/XX DI- parking brake,
data. nent with diagnostic menu. AGNOSE, description,
brake (Y6420), open not be released. control unit and the compo- D7971/C1:17 Sys 4/XX DI- parking brake,
circuit. nent with diagnostic menu. AGNOSE, description,
and menu
components
brake (Y6420), short cir- not be released. control unit and the compo- D7971/C1:17 Sys 4/XX DI- parking brake,
cuit to ground. nent with diagnostic menu. AGNOSE, description,
Y 6450 5 2 Magnetic clutch, cooling Air conditioning not Check cabling between the Y6450 9.4 Climate Compressor air
compressor (Y6450), working. control unit and the compo- D7971/C2:34 System 13/XX conditioning,
open circuit. nent with diagnostic menu. DIAGNOSE, description,
Y 6450 6 2 Magnetic clutch, cooling Air conditioning not Check cabling between the Y6450 9.4 Climate Compressor air
compressor (Y6450), working. control unit and the compo- D7971/C2:34 System 13/XX conditioning,
short circuit to ground. nent with diagnostic menu. DIAGNOSE, description,
K 6501 6 1 10 Windscreen wiper left, Left wiper front not Check cabling between the K6501-LE 9.5 Wiper & Wiper motor
relay (K6501-LE), short working control unit and the compo- D7901/C2:8 Washer Sys 8/ front, descrip-
circuit to ground nent with diagnostic menu. XX DIAGNOSE, tion, page 9:60
K 6501 6 1 20 Windscreen wiper right, Right wiper front Check cabling between the K6501-RI 9.5 Wiper & Wiper motor
relay (K6501-RI), short not working control unit and the compo- D7901/C2:9 Washer Sys 9/ front, descrip-
circuit to ground nent with diagnostic menu. XX DIAGNOSE, tion, page 9:60
M 6501 7 1 10 Left wiper windscreen, Left wiper front not Check cabling between the M6501-LE 9.5 Wiper & Wiper motor
position signal (M6501- working control unit and the compo- D7901/C1:10 Washer Sys 8/ front, descrip-
LE) nent with diagnostic menu. XX DIAGNOSE, tion, page 9:60
M 6501 7 1 20 Right wiper windscreen, Right wiper front Check cabling between the M6501-RI 9.5 Wiper & Wiper motor

position signal (M6501- not working control unit and the compo- D7901/C1:11 Washer Sys 9/ front, descrip-
RI) nent with diagnostic menu. XX DIAGNOSE, tion, page 9:60
M 6502 5 1 Wiper rear window Rear window wiper Check cabling between the M6502/2 9.5 Wiper & Wiper motor
(M6502), open circuit. not working. control unit and the compo- D7901/C2:17 Washer Sys 5/ rear, descrip-
nent with diagnostic menu. XX DIAGNOSE, tion, page 9:65
M 6502 6 1 Wiper rear window Rear window wiper Check cabling between the M6502/2 9.5 Wiper & Wiper motor
(M6502), short circuit to not working. control unit and the compo- D7901/C2:17 Washer Sys 5/ rear, descrip-
ground. nent with diagnostic menu. XX DIAGNOSE, tion, page 9:65
VDRG09.01GB
D:181
and menu
components
VDRG09.01GB
M 6502 7 1 Wiper rear window, po- Rear window wiper Check cabling between the M6502/3 9.5 Wiper & Wiper motor
sition signal (M6502), not working. control unit and the compo- D7901/C1:12 Washer Sys 5/ rear, descrip-
the wiper does not nent with diagnostic menu. XX DIAGNOSE, tion, page 9:65
move. Check the motor. page 8:117
M 6503 5 1 Combined wiper wind- Combined wiper Check cabling between the M6503/2 Combined Combined
screen and roof window front windscreen control unit and the compo- D7901/C2:19 wiper, wind- wiper, wind-
(M6503), open circuit. and roof window nent with diagnostic menu. screen and roof screen and
Roof window wiper not working. Check the component. window roof window
(M6503), open circuit. Wiper roof not 9.5 Wiper & Wiper motor,
working. Washer Sys 2/ front and roof,
XX DIAGNOSE, description,
Wiper roof Wiper roof
window window
9.5 Wiper & Wiper motor
Washer Sys roof, descrip-
12/XX DIAG- tion, page 9:62
NOSE, page
8:119
screen and roof window front windscreen control unit and the compo- D7901/C2:19 wiper, wind- wiper, wind-
(M6503), short circuit to and roof window nent with diagnostic menu. screen and roof screen and
ground. not working. Check the component. window roof window
Wiper roof window Wiper roof not 9.5 Wiper & Wiper motor,
(M6503), short circuit to working. Washer Sys 2/ front and roof,

ground. XX DIAGNOSE, description,

window window
NOSE, page
8:119
and menu
components
screen and roof window, front windscreen control unit and the compo- D7901/C1:13 wiper, wind- wiper, wind-
position signal (M6503). and roof window nent with diagnostic menu. screen and roof screen and
Roof window wiper, po- not working. Check the component. window roof window
sition signal (M6503). Wiper roof not 9.5 Wiper & Wiper motor,
working. Washer Sys 2/ front and roof,
window window
NOSE, page
8:119
M 6511 6 1 Relay windscreen wash- Front windscreen Check cabling between the K6511 9.5 Wiper & Washer motor
ing (K6511), short circuit washer not working. control unit and the compo- D7901/C2:10 Washer Sys and reservoir,
to ground. nent with diagnostic menu. 10/XX DIAG- description,
Check the component. NOSE, page page 9:58
8:119
M 6512 5 1 Motor, washing rear win- Rear window wash- Check cabling between the M6512 9.5 Wiper & Washer motor
dow (M6512), open er not working. control unit and the compo- D7901/C2:16 Washer Sys 6/ and reservoir,
circuit. nent with diagnostic menu. XX DIAGNOSE, description,
M 6512 6 1 Motor, washing rear win- Rear window wash- Check cabling between the M6512 9.5 Wiper & Washer motor
dow (M6512), short cir- er not working. control unit and the compo- D7901/C2:16 Washer Sys 6/ and reservoir,
cuit to ground. nent with diagnostic menu. XX DIAGNOSE, description,

VDRG09.01GB
D:183
and menu
components
VDRG09.01GB
M 6513 5 1 Motor, washer fluid, Windscreen washer, Check cabling between the M6513 Washer motor, Washer motor,
combined wiper wind- combined front control unit and the compo- D7901/C2:15 combined combined
screen and roof window windscreen and nent with diagnostic menu. wiper, wind- wiper, wind-
(M6513), open circuit. roof window not Check the component. screen and roof screen and
Motor, washer fluid, roof working. window roof window
window (M6513), open Roof window wash- 9.5 Wiper & Washer motor
circuit. er not working. Washer Sys 3/ and reservoir,
Washer motor, Washer motor,
roof window roof window
9.5 Wiper & Washer motor
Washer Sys and reservoir,
13/XX DIAG- description,
NOSE, page page 9:58
8:120
M 6513 6 1 Motor, washer fluid, Windscreen washer, Check cabling between the M6513 Washer motor, Washer motor,
combined wiper wind- combined front control unit and the compo- D7901/C2:15 combined combined
screen and roof window windscreen and nent with diagnostic menu. wiper, wind- wiper, wind-
(M6513), short circuit to roof window not Check the component. screen and roof screen and
ground. working. window roof window
Motor, washer fluid, roof Roof window wash- 9.5 Wiper & Washer motor
window (M6513), short er not working. Washer Sys 3/ and reservoir,
circuit to ground. XX DIAGNOSE, description,

Washer motor, Washer motor,
roof window roof window
9.5 Wiper & Washer motor
Washer Sys and reservoir,

13/XX DIAG- description,
NOSE, page page 9:58
8:120
M 6570 5 1 Cab fan (M6570), open Cab fan not Check cabling between the M6570 9.4 Climate Cab fan, de-
circuit. working. control unit and the compo- D7901/C2:37 System 9/XX scription, page
nent with diagnostic menu. DIAGNOSE, 9:33
M 6570 6 1 Cab fan (M6570), short Cab fan not Check cabling between the M6570 9.4 Climate Cab fan, de-
circuit to ground. working. control unit and the compo- D7901/C2:37 System 9/XX scription, page
nent with diagnostic menu. DIAGNOSE, 9:33
and menu
components
M 6570 7 1 10 Cooling fan transmis- Cooling fan trans- Check cabling between the M6570-LE
sion left (M6570-LE), no mission not working. control unit and the compo- A7991/C1:6
signal on activation. nent with diagnostic menu.
(Fan not working.) Check the component.
M 6570 7 1 20 Cooling fan transmis- Cooling fan trans- Check cabling between the M6570–RI
sion right (M6570-RI), mission not working. control unit and the compo- A7991/C1:7
no signal on activation. nent with diagnostic menu.
(Fan not working.) Check the component.
M 6580 6 2 Magnetic clutch, cooling The engine's cool- Check cabling between the M6580 1.7 Cooling
fan engine (M6580), ing fan operates at control unit and the compo- D7971/C1:47 system 4/XX
short circuit to ground. full power. nent with diagnostic menu. DIAGNOSE,
1.7 Cooling
system 5/XX
DIAGNOSE,
page 8:32
M 6580 7 2 Magnetic clutch, cooling No limitation. Possi- Check the component. M6580 1.7 Cooling
fan engine (M6580), ble subsequent Check cabling between the D7971/C2:20 system 4/XX
drive speed too low. faults with in- control unit and the compo- DIAGNOSE,
creased nent with diagnostic menu. page 8:32
temperatures. 1.7 Cooling
system 5/XX
DIAGNOSE,
page 8:32
M 6590 6 2 Cooling fan intercooler Cooling fan inter- Check cabling between the M6590 1.7 Cooling
(H6590), short circuit to cooler not working. control unit and the compo- D7971/C1:34 system 6/XX

ground. nent with diagnostic menu. DIAGNOSE,
1.7 Cooling
system 7/XX
DIAGNOSE,
page 8:33
M 6590 7 2 10 Cooling fan intercooler Cooling fan inter- Check cabling between the M6590-LE 1.7 Cooling
left (M6590-LE), no sig- cooler not working. control unit and the compo- D7971/C2:9 system 6/XX
nal on activation. (Fan nent with diagnostic menu. DIAGNOSE,
not working.) Check the component. page 8:32
1.7 Cooling
system 7/XX
DIAGNOSE,
page 8:33
VDRG09.01GB
D:185
and menu
components
VDRG09.01GB
M 6590 7 2 20 Cooling fan intercooler Cooling fan inter- Check cabling between the M6590-RI 1.7 Cooling
right (M6590-RI), no sig- cooler not working. control unit and the compo- D7971/C2:21 system 6/XX
nal on activation. (Fan nent with diagnostic menu. DIAGNOSE,
not working.) Check the component. page 8:32
1.7 Cooling
system 7/XX
DIAGNOSE,
page 8:33
M 6670 5 1 Circulation pump, pause Pause heater not Check cabling between the M6670 9.4 Climate Pause heater,
heater (M6670), open working. control unit and the compo- D7901/C2:14 System 20/XX description,
circuit. nent with diagnostic menu. DIAGNOSE, page 9:51
M 6670 6 1 Circulation pump pause Pause heater not Check cabling between the M6670 9.4 Climate Pause heater,
heater (M6670), short working. control unit and the compo- D7901/C2:14 System 20/XX description,
circuit to ground. nent with diagnostic menu. DIAGNOSE, page 9:51
M 6680 5 2 Cooling fan (M6680) Cooling of hydraulic Check cabling between the M6680 10.6 Oil Temp/ Cooling fan,
(hydraulic system), oil not working. control unit and the compo- D7971/C2:35 Clean 2/XX DI- description,
open circuit. nent with diagnostic menu. AGNOSE, page 10:37
M 6680 6 2 Cooling fan (M6680) Cooling of hydraulic Check cabling between the M6680 10.6 Oil Temp/ Cooling fan,
(hydraulic system), oil not working. control unit and the compo- D7971/C2:35 Clean 2/XX DI- description,
short circuit to ground. nent with diagnostic menu. AGNOSE, page 10:37
Y 6720 3 1 Air distribution valve Air distribution in Check cabling between the Y6720/9 9.4 Climate Air distributor,

(Y6720) position signal, cab cannot be control unit and the compo- D7901/C1:28 System 8/XX description,
high signal voltage. adjusted. nent with diagnostic menu. DIAGNOSE, page 9:48
Y 6720 4 1 Air distribution valve Air distribution in Check cabling between the Y6720/9 9.4 Climate Air distributor,
(Y6720) position signal, cab cannot be control unit and the compo- D7901/C1:28 System 8/XX description,
low signal voltage. adjusted. nent with diagnostic menu. DIAGNOSE, page 9:48
Y 6720 5 1 1 Air distribution valve Air distribution in Check cabling between the Y6720/6 9.4 Climate Air distributor,
(Y6720), open circuit. cab cannot be control unit and the compo- D7901/C2:24 System 16/XX description,
adjusted. nent with diagnostic menu. DIAGNOSE, page 9:48
(Y6720), short circuit to cab cannot be control unit and the compo- D7901/C2:24 System 16/XX description,
ground. adjusted. nent with diagnostic menu. DIAGNOSE, page 9:48
and menu
components
(Y6720), open circuit. cab cannot be control unit and the compo- D7901/C2:25 System 17/XX description,
adjusted. nent with diagnostic menu. DIAGNOSE, page 9:48
(Y6720), short circuit to cab cannot be control unit and the compo- D7901/C2:25 System 17/XX description,
ground. adjusted. nent with diagnostic menu. DIAGNOSE, page 9:48
Y 6730 3 1 Heating valve (Y6730) Cab heat cannot be Check cabling between the Y6730/9 9.4 Climate Water valve,
position signal, high sig- adjusted. control unit and the compo- D7901/C1:29 System 7/XX description,
nal voltage. nent with diagnostic menu. DIAGNOSE, page 9:38
Y 6730 4 1 Heating valve (Y6730) Cab heat cannot be Check cabling between the Y6730/9 9.4 Climate Water valve,
position signal, low sig- adjusted. control unit and the compo- D7901/C1:29 System 7/XX description,
nal voltage. nent with diagnostic menu. DIAGNOSE, page 9:38
Y 6730 5 1 1 Heating valve (Y6730), Cab heat cannot be Check cabling between the Y6730/6 9.4 Climate Water valve,
open circuit. adjusted. control unit and the compo- D7901/C2:26 System 15/XX description,
nent with diagnostic menu. DIAGNOSE, page 9:38
short circuit to ground. adjusted. control unit and the compo- D7901/C2:26 System 15/XX description,

open circuit. adjusted. control unit and the compo- D7901/C2:27 System 14/XX description,
short circuit to ground. adjusted. control unit and the compo- D7901/C2:27 System 14/XX description,
M 6740 5 2 Cooling fan (M6740) Cooling of brake Check cabling between the M6740 4.8 Oil Temp/ Cooling fan,
(brake system), open system not working. control unit and the compo- D7971/C2:37 Clean 2/XX DI- description,
circuit. If the temperature nent with diagnostic menu. AGNOSE, page 4:52
becomes too high Check the component. page 8:46
then machine
speed is limited,
and wear on the
brakes increases.
VDRG09.01GB
D:187
and menu
components
VDRG09.01GB
M 6740 6 2 Cooling fan (M6740) Cooling of brake Check cabling between the M6740 4.8 Oil Temp/ Cooling fan,
(brake system), short system not working. control unit and the compo- D7971/C2:37 Clean 2/XX DI- description,
circuit to ground. If the temperature nent with diagnostic menu. AGNOSE, page 4:52
becomes too high Check the component. page 8:46
then machine
speed is limited,
and wear on the
brakes increases.
M 6750 5 3 20 Motor seat turning Rotation of driver's Check cabling between the M6750
(M6750), turning back- seat not working. control unit and the compo- D7972/C2:35
wards, open circuit. nent with diagnostic menu.
(M6750), turning back- seat not working. control unit and the compo- D7972/C2:35
wards, short circuit to nent with diagnostic menu.
(M6750), turning for- seat not working. control unit and the compo- D7972/C2:37
wards, open circuit. nent with diagnostic menu.
(M6750), turning for- seat not working. control unit and the compo- D7972/C2:37
wards, short circuit to nent with diagnostic menu.

Y 6760 5 1 2 Solenoid valve, turnable The driver's seat Check cabling between the Y6760
driver's seat (Y6760), cannot be rotated. control unit and the compo- D7901/C2:34

Y 6760 6 1 2 Solenoid valve, turnable The driver's seat Check cabling between the Y6760
driver's seat (Y6760), cannot be rotated. control unit and the compo- D7901/C2:34
Y 6760 5 3 20 Solenoid valve, brake The operator's sta- Check cabling between the Y6760-RI
turnable driver's seat tion cannot be control unit and the compo- D7972/C1:23
(Y6760-RI), open circuit. turned. nent with diagnostic menu.
Y 6760 6 3 20 Solenoid valve, brake The operator's sta- Check cabling between the Y6760-RI
(Y6760-RI), short circuit turned. nent with diagnostic menu.
and menu
components
Y 6760 5 3 10 Solenoid valve, brake The operator's sta- Check cabling between the Y6760-LE
(Y6760-LE), open circuit. turned. nent with diagnostic menu.
Y 6760 6 3 10 Solenoid valve, brake The operator's sta- Check cabling between the Y6760-LE
(Y6760-LE), short circuit turned. nent with diagnostic menu.
Y 6820 5 2 Solenoid valve, exten- Extension out not Check cabling between the Y6820
sion out (Y6820), open working. control unit and the compo- D7971/C1:34
Y 6820 6 2 Solenoid valve exten- Extension out not Check cabling between the Y6820
sion out (Y6820), short working. control unit and the compo- D7971/C1:34
Y 6821 5 2 Solenoid valve, exten- Extension in not Check cabling between the Y6821
sion in (Y6821), open working. control unit and the compo- D7971/C1:35
Y 6821 6 2 Solenoid valve exten- Extension in not Check cabling between the Y6821
sion in (Y6821), short working. control unit and the compo- D7971/C1:35
Y 6840 5 3 Solenoid valve, torque 4 wheel drive assist Check cabling between the Y6840

control hydrostatic deactivated. control unit and the compo- D7972/C1:50
transmission (Y6840), nent with diagnostic menu.
Y 6840 6 3 Solenoid valve, torque 4 wheel drive assist Check cabling between the Y6840
control hydrostatic deactivated. control unit and the compo- D7972/C1:50
Y 6841 5 3 Solenoid valve, draining 4 wheel drive assist Check cabling between the Y6841
hydrostatic transmission deactivated. control unit and the compo- D7972/C1:1
VDRG09.01GB
D:189
and menu
components
VDRG09.01GB
Y 6841 6 3 Solenoid valve, draining 4 wheel drive assist Check cabling between the Y6841
hydrostatic transmission deactivated. control unit and the compo- D7972/C1:1
Y 6842 5 3 Solenoid valve, back 4 wheel drive assist Check cabling between the Y6842
pressure hydrostatic deactivated. control unit and the compo- D7972/C1:11
Y 6842 6 3 Solenoid valve, back 4 wheel drive assist Check cabling between the Y6842
pressure hydrostatic deactivated. control unit and the compo- D7972/C1:11
R 6900 3 11 1 Accelerator pedal Engine speed Check cabling between the R6900/5 1.1 Controls & Speed pedal,
(R6900) signal A, high limited to idle. control unit and the compo- D7902/C8:6 Instr 1/XX DI- description,
voltage signal. nent with diagnostic menu. AGNOSE, page 1:2
(R6900) signal A, high limited to idle. control unit and the compo- D7902/C8:6 Instr 1/XX DI- description,
R 6900 13 11 1 Accelerator pedal Engine speed Calibrate the accelerator R6900/5 1.1 Controls & Speed pedal,
(R6900) signal A, high limited to idle. pedal D7902/C8:6 Instr 1/XX DI- description,
voltage signal. AGNOSE, page 1:2
page 8:29

(R6900) signal B, high limited to idle. control unit and the compo- D7902/C8:5 Instr 1/XX DI- description,
(R6900) signal B, high limited to idle. control unit and the compo- D7902/C8:5 Instr 1/XX DI- description,
R 6900 13 11 2 Accelerator pedal Engine speed Calibrate the accelerator R6900/2 1.1 Controls & Speed pedal,
(R6900) signal B, high limited to idle. pedal D7902/C8:5 Instr 1/XX DI- description,
voltage signal. AGNOSE, page 1:2
page 8:29
and menu
components
R 6900 3 11 3 Accelerator pedal 2 Engine speed Check cabling between the R6900/5 Speed pedal,
(R6900) signal A, high limited to idle. control unit and the compo- D7902/C8:8 description,
voltage signal. nent with diagnostic menu. page 1:2
(R6900) signal A, low limited to idle. control unit and the compo- D7902/C8:8 description,
R 6900 13 11 3 Accelerator pedal 2 Engine speed Calibrate the accelerator R6900/5 Speed pedal,
(R6900) signal A, incor- limited to idle. pedal D7902/C8:8 description,
rectly calibrated. page 1:2
(R6900) signal B, high limited to idle. control unit and the compo- D7902/C8:7 description,
(R6900) signal B, low limited to idle. control unit and the compo- D7902/C8:7 description,
R 6900 13 11 4 Accelerator pedal 2 Engine speed Calibrate the accelerator R6900/2 Speed pedal,
(R6900) signal B, incor- limited to idle. pedal D7902/C8:7 description,
rectly calibrated. page 1:2

R 6900 2 11 40 Travel direction selector Neutral position. Check cabling between the R6900 2.1 Controls & Speed pedal,
in accelerator pedal for- control unit and the compo- Instr 4/XX DI- description,
ward/reverse (R6900), nent with diagnostic menu. AGNOSE, page 1:2

logic error. Check the component. page 8:40
M 6930 5 2 1 Pump central lubrication, Central lubrication Check cabling between the M6930 9.14 Central Central lubrica-
frame (M6930), open not working. control unit and the compo- D7971/C1:46 Lubr 1/XX DI- tion, descrip-
circuit. nent with diagnostic menu. AGNOSE, tion, page
M 6930 6 2 1 Pump central lubrication, Central lubrication Check cabling between the M6930 9.14 Central Central lubrica-
frame (M6930), short not working. control unit and the compo- D7971/C1:46 Lubr 1/XX DI- tion, descrip-
circuit to ground. nent with diagnostic menu. AGNOSE, tion, page
M 6930 5 7 2 Pump central lubrication Central lubrication Check cabling between the M6930 9.14 Central Central lubrica-
attachment (M6930), not working. control unit and the compo- D7911/C1:22 Lubr 3/XX DI- tion, descrip-
open circuit. nent with diagnostic menu. AGNOSE, tion, page
VDRG09.01GB
D:191
and menu
components
VDRG09.01GB
M 6930 6 7 2 Pump central lubrication Central lubrication Check cabling between the M6930 9.14 Central Central lubrica-
attachment (M6930), not working. control unit and the compo- D7911/C1:22 Lubr 3/XX DI- tion, descrip-
short circuit to ground. nent with diagnostic menu. AGNOSE, tion, page
B 6941 3 11 Motor, right-hand dash- Movement of dash- Check cabling between the B6941/9 9.1 Controls & Instrument and
board panel forward/ board panel not control unit and the compo- D7902/C2:3 Instr 5/XX DI- control panels,
backward position sig- working. nent with diagnostic menu. AGNOSE, function de-
nal, high signal voltage. Check the component. page 8:108 scription, page
9:131
backward position sig- working. nent with diagnostic menu. AGNOSE, function de-
nal, low signal voltage. Check the component. page 8:108 scription, page
9:131
B 6941 7 11 Motor, right-hand dash- Movement of dash- Check that nothing is block- B6941/9 9.1 Controls & Instrument and
board panel forward/ board panel not ing the movement of the D7902/C2:3 Instr 5/XX DI- control panels,
backward position sig- working. dashboard panel. AGNOSE, function de-
nal, mechanical fault. Check the motor. page 8:108 scription, page
9:131
M 6941 5 11 1 Motor right dashboard Movement of dash- Check cabling between the M6941/5 9.1 Controls & Instrument and
panel forwards/back- board panel not control unit and the compo- D7902/C2:7 Instr 5/XX DI- control panels,
wards (M6941), open working. nent with diagnostic menu. AGNOSE, function de-
circuit Check the component. page 8:108 scription, page

9:131
M 6941 6 11 1 Motor, right-hand dash- Movement of dash- Check cabling between the M6941/5 9.1 Controls & Instrument and

backward (M6941), working. nent with diagnostic menu. AGNOSE, function de-
short circuit to ground. Check the component. page 8:108 scription, page
9:131
panel forwards/back- board panel not control unit and the compo- D7902/C2:8 Instr 5/XX DI- control panels,
wards (M6941), open working. nent with diagnostic menu. AGNOSE, function de-
circuit Check the component. page 8:108 scription, page
9:131
backward (M6941), working. nent with diagnostic menu. AGNOSE, function de-
short circuit to ground. Check the component. page 8:108 scription, page
9:131
and menu
components
board panel up/down board panel not control unit and the compo- D7902/C2:4 Instr 7/XX DI- control panels,
position signal, high sig- working. nent with diagnostic menu. AGNOSE, function de-
nal voltage. Check the component. page 8:109 scription, page
9:131
position signal, low sig- working. nent with diagnostic menu. AGNOSE, function de-
nal voltage. Check the component. page 8:109 scription, page
9:131
B 6942 7 11 Motor, right-hand dash- Movement of dash- Check that nothing is block- B6942/9 9.1 Controls & Instrument and
board panel up/down board panel not ing the movement of the D7902/C2:4 Instr 7/XX DI- control panels,
position signal, mechan- working. dashboard panel. AGNOSE, function de-
ical fault. Check the motor. page 8:109 scription, page
9:131
panel up/down (M6942), board panel not control unit and the compo- D7902/C2:9 Instr 7/XX DI- control panels,
open circuit. working. nent with diagnostic menu. AGNOSE, function de-
9:131
(M6942), short circuit to working. nent with diagnostic menu. AGNOSE, function de-

9:131

panel up/down (M6942), board panel not control unit and the compo- D7902/C2:10 Instr 7/XX DI- control panels,
open circuit. working. nent with diagnostic menu. AGNOSE, function de-
9:131
(M6942), short circuit to working. nent with diagnostic menu. AGNOSE, function de-
9:131
B 6943 3 11 Motor, steering panel Movement of steer- Check cabling between the B6943/9 9.1 Controls & Instrument and
up/down position signal, ing panel not control unit and the compo- D7902/C1:9 Instr 3/XX DI- control panels,
high signal voltage. working. nent with diagnostic menu. AGNOSE, function de-
9:131
VDRG09.01GB
D:193
and menu
components
VDRG09.01GB
B 6943 4 11 Motor, steering panel Movement of steer- Check cabling between the B6943/9 9.1 Controls & Instrument and
up/down position signal, ing panel not control unit and the compo- D7902/C1:9 Instr 3/XX DI- control panels,
low signal voltage. working. nent with diagnostic menu. AGNOSE, function de-
9:131
B 6943 7 11 Motor, steering panel Movement of steer- Check that nothing is block- B6943/9 9.1 Controls & Instrument and
up/down position signal, ing panel not ing the movement of the D7902/C1:9 Instr 3/XX DI- control panels,
mechanical problem. working. dashboard panel. AGNOSE, function de-
Check the motor. page 8:108 scription, page
9:131
M 6943 5 11 1 Motor steering panel up/ Movement of steer- Check cabling between the M6943/5 9.1 Controls & Instrument and
down (M6943), open ing panel not control unit and the compo- D7902/C2:5 Instr 3/XX DI- control panels,
circuit. working. nent with diagnostic menu. AGNOSE, function de-
9:131
M 6943 6 11 1 Motor, steering panel Movement of steer- Check cabling between the M6943/5 9.1 Controls & Instrument and
up/down (M6943), short ing panel not control unit and the compo- D7902/C2:5 Instr 3/XX DI- control panels,
circuit to ground. working. nent with diagnostic menu. AGNOSE, function de-
9:131
M 6943 5 11 2 Motor steering panel up/ Movement of steer- Check cabling between the M6943/6 9.1 Controls & Instrument and
down (M6943), open ing panel not control unit and the compo- D7902/C2:6 Instr 3/XX DI- control panels,
circuit. working. nent with diagnostic menu. AGNOSE, function de-

9:131
M 6943 6 11 2 Motor, steering panel Movement of steer- Check cabling between the M6943/6 9.1 Controls & Instrument and

up/down (M6943), short ing panel not control unit and the compo- D7902/C2:6 Instr 3/XX DI- control panels,
circuit to ground. working. nent with diagnostic menu. AGNOSE, function de-
9:131
P 7080 14 1 Operating times do not No limitation Connect the Kalmar Service D7901
correspond to reference tool and Repair or contact
Control unit KFU Cargotec support.
(D7971).
(D7971).
and menu
components
(D7971).
(D7971).
(D7971).
(D7971).
D 7090 0 1 Temperature of the cir- Battery contactor Allow the battery to cool
cuit board that controls open. No power. down.
the battery is above the
configured shut-off level
within the interval 85 to
90 °C. (90 °C is the
standard threshold
value).
D 7090 15 1 Temperature of the cir- Speed limitation. Allow the battery to cool

cuit board that controls down.
configured warning level
that is within the interval
75 to 85 °C. (80 °C is
the standard threshold
value).
D 7090 16 1 Temperature of the cir- Battery contactor Allow the battery to cool
cuit board that controls open. No power. down.
85 °C (standard thresh-
old value 85 °C).
D 7090 31 1 No communication with Speed limitation. Check CAN bus between
Control unit BMS. KCU and battery control unit.
VDRG09.01GB
D:195
and menu
components
VDRG09.01GB
B 7202 2 3 Logic error sensor con- No load handling Check the sensors, see B7202-FL 7.9 Load Car- Sensor, con-
tact B7202-XX, a sensor functions are Sensor, contact, checking, D7911/C2:17 rier 4/XX DIAG- tact, descrip-
has been active for lon- working. page 7:140 B7202-FR NOSE, page tion, page
ger than 120 seconds. Check cabling between the D7911/C2:16 8:68 7:139
control unit and the compo- B7202-RL
nent with diagnostic menu. D7911/C2:14
B7202-RR
D7911/C2:13
B 7202 2 7 Logic error sensor con- No load handling Check the sensors, see B7202-FL 7.9 Load Car- Sensor, con-
tact B7202-XX, a sensor functions are Sensor, contact, checking, D7911/C2:17 rier 4/XX DIAG- tact, descrip-
has been active for lon- working. page 7:140 B7202-FR NOSE, page tion, page
ger than 120 seconds. Check cabling between the D7911/C2:16 8:68 7:139
control unit and the compo- B7202-RL
nent with diagnostic menu. D7911/C2:14
B7202-RR
D7911/C2:13
B 7205 2 3 Sensor, twistlocks No load handling Check cabling between the - - -
(B7205) jammed, active functions are control unit and the compo-
>120s. working. nent with diagnostic menu.
Check the component
B 7205 3 7 10 Sensor twistlocks left No load handling Check cabling between the B7204-LE Sensor, con-
(B7205-LE), signal volt- functions are control unit and the compo- D7911/C2:23 tact, descrip-
age too high. working. nent with diagnostic menu. tion, page
Check the component 7:139

(B7205-LE), signal volt- functions are control unit and the compo- D7911/C2:23 tact, descrip-
age too low. working. nent with diagnostic menu. tion, page

(B7205-LE), calibration functions are control unit and the compo- D7911/C2:23 tact, descrip-
error. working. nent with diagnostic menu. tion, page
B 7205 3 7 20 Sensor, twistlocks right No load handling Check cabling between the B7204-RI Sensor, con-
(B7205-RI), signal volt- functions are control unit and the compo- D7911/C2:21 tact, descrip-
(B7205-RI), signal volt- functions are control unit and the compo- D7911/C2:21 tact, descrip-
and menu
components
(B7205-RI), calibration functions are control unit and the compo- D7911/C2:21 tact, descrip-
B 7205 3 7 110 Sensor twistlocks left No load handling Check cabling between the B7204–LF Sensor, con-
(B7205-LF), signal volt- functions are control unit and the compo- D7911/C2:19 tact, descrip-
(B7205-LF), signal volt- functions are control unit and the compo- D7911/C2:19 tact, descrip-
(B7205-LF), calibration functions are control unit and the compo- D7911/C2:19 tact, descrip-
B 7205 3 7 120 Sensor twistlocks right No load handling Check cabling between the B7204–RF Sensor, con-
(B7205-RF), signal volt- functions are control unit and the compo- D7911/C2:18 tact, descrip-
(B7205-RF), signal volt- functions are control unit and the compo- D7911/C2:18 tact, descrip-

(B7205-RF), calibration functions are control unit and the compo- D7911/C2:18 tact, descrip-
B 7205 3 7 210 Sensor twistlocks left No load handling Check cabling between the B7204–LR Sensor, con-
(B7205-LR), signal volt- functions are control unit and the compo- D7911/C2:23 tact, descrip-
(B7205-LR), signal volt- functions are control unit and the compo- D7911/C2:23 tact, descrip-
VDRG09.01GB
D:197
and menu
components
VDRG09.01GB
(B7205-LR), calibration functions are control unit and the compo- D7911/C2:23 tact, descrip-
B 7205 3 7 220 Sensor twistlocks right No load handling Check cabling between the B7204-RR Sensor, con-
(B7205-RR), signal volt- functions are control unit and the compo- D7911/C2:21 tact, descrip-
(B7205-RR), signal volt- functions are control unit and the compo- D7911/C2:21 tact, descrip-
(B7205-RR), calibration functions are control unit and the compo- D7911/C2:21 tact, descrip-
B 7205 7 7 10 Logic error Sensor twist- No load handling Check that the sensors are B7204-LE 7.9 Load Car- Sensor, con-
locks left (B7204-LE functions are free of dirt. D7911/C2:19 rier 5/XX DIAG- tact, descrip-
and (B7205-LE), both working. Check sensor positions, see B7205-LE NOSE, page tion, page
sensors active Position sensor, checking D7911/C2:23 8:68 7:139
simultaneously. and adjustment, page 7:5
Check indicator plates and
twistlocks mechanism.

B 7205 7 7 20 Logic error Sensor twist- No load handling Check that the sensors are B7204-RI 7.9 Load Car- Sensor, con-
locks right (B7204-RI functions are free of dirt. D7911/C2:18 rier 5/XX DIAG- tact, descrip-
and B7205-RI), both working. Check sensor positions, see B7205-RI NOSE, page tion, page
sensors active Position sensor, checking D7911/C2:21 8:68 7:139
simultaneously. and adjustment, page 7:5
Check indicator plates and
twistlocks mechanism.
and menu
components
G 7214 1 1 The State of Charge Charge the battery and allow
(SoC) that is reported by it to equalise.
each battery module de-
viates from one to an-
other by more than the
programmable threshold
value. The program-
mable threshold value is
35% (standard thresh-
old value is 30%).
B 7216 2 7 Sensor fan position lift- No limitation. Check that the sensor's indi- B7216-LE
ing head (B7216-LE, Machine can start cator pin has not become D7911/C1:49
B7216-RI). to damp the speed stuck. B7216-RI
on lowering. Check the cable harness be- D7911/C1:46
tween the control unit and
the sensor using the diag-
nostic menu.
Check the sensor.
B 7219 7 6 Combi-attachment se- Stops lifting func- Check cabling between the B7219–LR 7.9 Load Car- Lift legs, gener-
quence error. tion and sets speed control unit and the compo- D7912/2:18 rier 27/XX DI- al, page 7:143
For leg lowering, se- limitation to max. 5 nent with diagnostic menu. B7219–LF AGNOSE,
quences 1-5 are km/h Check the component. D7912/2:10 page 8:72
counted for each leg B7219–RR
where sequence 5 is D7912/2:23

reached when the leg is B7219–RF
in the bottom position D7912/2:14
where the container is

coupled.
The error code appears
if the sum of the se-
quence is <20 (5 x 4
legs) at the same time
as two or more sensors
are high for each side
right/left (seated and
clamp)
VDRG09.01GB
D:199
and menu
components
VDRG09.01GB
B 7226 3 2 1 Sensor, hydraulic pres- Load sensor and Check the cable harness be- B7226-1 8.2 Monitoring Sensor hy-
sure lift cylinder, piston overload system tween the control unit and D7971/C2:10 17/XX DIAG- draulic pres-
side, left (B7226-1), high not working. Lift the sensor using the diag- NOSE, page sure lift
signal voltage. and extension nostic menu. 8:104 cylinder, de-
blocked. Check the sensor. 8.2 Monitoring scription, page
18/XX DIAG- 8:15
NOSE, page
8:104
side, left (B7226-1), low not working. Lift the sensor using the diag- NOSE, page sure lift
18/XX DIAG- 8:15
NOSE, page
8:104
side, left (B7226-1), cali- not working. Lift the sensor using the diag- NOSE, page sure lift
bration error. and extension nostic menu. 8:104 cylinder, de-
18/XX DIAG- 8:15
NOSE, page
8:104
side, right (B7226-2), not working. Lift the sensor using the diag- NOSE, page sure lift

high signal voltage. and extension nostic menu. 8:104 cylinder, de-
18/XX DIAG- 8:15
NOSE, page
8:104
low signal voltage. and extension nostic menu. 8:104 cylinder, de-
18/XX DIAG- 8:15
NOSE, page
8:104
and menu
components
sure lift cylinder, rod overload system tween the control unit and D7971/C2:11 17/XX DIAG- draulic pres-
side, left (B7226-3), high not working. Lift the sensor using the diag- NOSE, page sure lift
18/XX DIAG- 8:15
NOSE, page
8:104
side, left (B7226-3), low not working. Lift the sensor using the diag- NOSE, page sure lift
18/XX DIAG- 8:15
NOSE, page
8:104
high signal voltage. and extension nostic menu. 8:104 cylinder, de-
18/XX DIAG- 8:15
NOSE, page
8:104

low signal voltage. and extension nostic menu. 8:104 cylinder, de-
18/XX DIAG- 8:15
NOSE, page
8:104
B 7228 3 2 Height sensor, lift Can give speed lim- Check the cable harness be- B7228
(B7228), high voltage. itations depending tween the control unit and D7971/C2:18
on the configuration. the sensor using the diag-
nostic menu.
Check the sensor.
(B7228), low voltage. itations depending tween the control unit and D7971/C2:18
nostic menu.
Check the sensor.
VDRG09.01GB
D:201
and menu
components
VDRG09.01GB
(B7228), high voltage. itations depending tween the control unit and D7911/C2:24
nostic menu.
Check the sensor.
(B7228), low voltage. itations depending tween the control unit and D7911/C2:24
nostic menu.
Check the sensor.
B 7229 3 2 Sensor tilt angle Can give speed lim- Check the cable harness be- B7229
(B7229), high signal itations depending tween the control unit and D7971/C2:15
voltage. on the configuration. the sensor using the diag-
nostic menu.
Check the sensor.
(B7229), low signal itations depending tween the control unit and D7971/C2:15
voltage. on the configuration. the sensor using the diag-
nostic menu.
Check the sensor.
(B7229), calibration itations depending tween the control unit and D7971/C2:15
error. on the configuration. the sensor using the diag-
nostic menu.
Check the sensor.
B 7230 3 7 Sensor damping attach- Damping in vicinity Check the cable harness be- B7230 7.9 Load Car- Sensor damp-

ment (B7230), high sig- of the container not tween the control unit and D7911/C2:12 rier 78/XX DI- ing attachment,
nal voltage. working the sensor using the diag- AGNOSE, description,
nostic menu. page 8:88 page 7:31
Check the sensor.
B 7230 4 7 Sensor damping attach- Damping in vicinity Check the cable harness be- B7230 7.9 Load Car- Sensor damp-
ment (B7230), low sig- of the container not tween the control unit and D7911/C2:12 rier 78/XX DI- ing attachment,
nal voltage. working the sensor using the diag- AGNOSE, description,
Check the sensor.
B 7235 3 2 10 Sensor power cell left When connected to Check the cable harness be- B7235-LE 8.2.11 Load
(B7235-LE), high signal OLS with control, tween the control unit and D7971/C2:10 sensors, page
voltage. error codes give the sensor using the diag- 8:10
speed limitations nostic menu.
and lift and tilt in Check the sensor.
are stopped.
and menu
components
(B7235-LE), low signal OLS with control, tween the control unit and D7971/C2:10 sensors, page
are stopped.
(B7235-LE), calibration OLS with control, tween the control unit and D7971/C2:10 sensors, page
error. error codes give the sensor using the diag- 8:10
are stopped.
B 7235 3 2 20 Sensor power cell right When connected to Check the cable harness be- B7235-RI 8.2.11 Load
(B7235-RI), high signal OLS with control, tween the control unit and D7971/C2:13 sensors, page
are stopped.
(B7235-RI), low signal OLS with control, tween the control unit and D7971/C2:13 sensors, page
are stopped.
(B7235-RI), calibration OLS with control, tween the control unit and D7971/C2:13 sensors, page

error. error codes give the sensor using the diag- 8:10
are stopped.
B 7235 3 7 110 Sensor attachment load, TDB Check the cable harness be- B7235–LF 7.9 Load Car-
left front (B7235-LF), tween the control unit and A7992/C1:10 rier 108/XX DI-
high signal voltage. the sensor using the diag- AGNOSE,
nostic menu. page 8:90
Check the sensor.
B 7235 4 7 110 Sensor attachment load, TDB Check the cable harness be- B7235–LF 7.9 Load Car-
left front (B7235-LF), tween the control unit and A7992/C1:10 rier 108/XX DI-
low signal voltage. the sensor using the diag- AGNOSE,
Check the sensor.
VDRG09.01GB
D:203
and menu
components
VDRG09.01GB
B 7235 3 7 120 Sensor attachment load, TDB Check the cable harness be- B7235–RF 7.9 Load Car-
right front (B7235-RF), tween the control unit and A7992/C1:11 rier 108/XX DI-
Check the sensor.
B 7235 4 7 120 Sensor attachment load, TDB Check the cable harness be- B7235–RF 7.9 Load Car-
right front (B7235-RF), tween the control unit and A7992/C1:11 rier 108/XX DI-
Check the sensor.
B 7235 3 7 210 Sensor attachment load, TDB Check the cable harness be- B7235–LR 7.9 Load Car-
left rear (B7235-LR), tween the control unit and A7992/C1:12 rier 108/XX DI-
Check the sensor.
B 7235 4 7 210 Sensor attachment load, TDB Check the cable harness be- B7235–LR 7.9 Load Car-
left rear (B7235-LR), tween the control unit and A7992/C1:12 rier 108/XX DI-
Check the sensor.
B 7235 3 7 220 Sensor attachment load, TDB Check the cable harness be- B7235-RR 7.9 Load Car-
right rear (B7235-RR), tween the control unit and A7992/C2:1 rier 108/XX DI-

Check the sensor.
B 7235 4 7 220 Sensor attachment load, TDB Check the cable harness be- B7235-RR 7.9 Load Car-

right rear (B7235-RR), tween the control unit and A7992/C2:1 rier 108/XX DI-
Check the sensor.
B 7236 3 2 Sensor power cell tilt When connected to Check the cable harness be- B7236 8.2.11 Load
(B7236), high signal OLS with control, tween the control unit and D7971/C2:11 sensors, page
voltage error codes give the sensor using the diag- 8:10
are stopped.
B 7236 4 2 Sensor power cell tilt When connected to Check the cable harness be- B7236 8.2.11 Load
(B7236), low signal OLS with control, tween the control unit and D7971/C2:11 sensors, page
voltage error codes give the sensor using the diag- 8:10
are stopped.
and menu
components
B 7236 13 2 Tilt power cell sensor When connected to Check the cable harness be- B7236 8.2.11 Load
(B7236). OLS with control, tween the control unit and D7971/C2:11 sensors, page
error codes give the sensor using the diag- 8:10
are stopped.
B 7237 2 7 Logic error Sensor No load handling Check that the sensor's indi- B7237-LE 8.2.11 Load
upper container (B7237- functions are cator pin has not become D7971/C2:7 sensors, page
LE / B7237-RI), a sen- working. stuck. B7237-RI 8:10
sor has been active for Check the cable harness be- D7971/C2:15
longer than 120 tween the control unit and
seconds. the sensor using the diag-
nostic menu.
Check the sensor.
B 7238 3 2 Tilt cylinder pressure When connected to Check the cable harness be- B7238 8.2.11 Load
sensor (B7238) OLS with control, tween the control unit and D7971/C2:11 sensors, page
are stopped.

are stopped.

are stopped.
B 7241 3 2 Sensor boom angle Load sensor and Check the cable harness be- B7241 8.2 Monitoring Sensor boom
(B7241), high signal overload system tween the control unit and D7971/C2:15 16/XX DIAG- angle, descrip-
voltage. not working. Lift the sensor using the diag- NOSE, page tion, page 8:17
and extension nostic menu. 8:103
blocked. Check the sensor.
Regeneration lift
and end position
damping not
working.
VDRG09.01GB
D:205
and menu
components
VDRG09.01GB
B 7241 4 2 Sensor boom angle Load sensor and Check the cable harness be- B7241 8.2 Monitoring Sensor boom
(B7241), low signal overload system tween the control unit and D7971/C2:15 16/XX DIAG- angle, descrip-
Regeneration lift
and end position
damping not
working.
B 7241 7 2 Check the cable harness be- B7241 8.2 Monitoring Sensor boom
tween the control unit and D7971/C2:15 16/XX DIAG- angle, descrip-
the sensor using the diag- NOSE, page tion, page 8:17
nostic menu. 8:103
Check the sensor.
B 7242 7 2 Sensor central lubrica- Central lubrication Check the cable harness be- B7242 9.14 Central Sensor, central
tion frame (B7242), time pump running with tween the control unit and D7971/C1:12 Lubr 1/XX DI- lubrication, de-
error. fixed lubrication the sensor using the diag- AGNOSE, scription, page
cycle time. nostic menu. page 8:132 9:147
Check the sensor.
B 7242 7 7 Sensor central lubrica- Central lubrication Check the cable harness be- B7242 9.14 Central Sensor, central
tion attachment (B7242), pump running with tween the control unit and D7911/C2:20 Lubr 3/XX DI- lubrication, de-
time error. fixed lubrication the sensor using the diag- AGNOSE, scription, page
cycle time. nostic menu. page 8:133 9:147
Check the sensor.

B 7243 3 2 Sensor electronic dip- Oil level indicator Check the cable harness be- B7243
LPS stick engine oil (B7243) not working. tween the control unit and D7971/C2:9

nostic menu.
Check the sensor.
B 7243 4 2 Sensor electronic dip- Oil level indicator Check the cable harness be- B7243
stick engine oil (B7243) not working. tween the control unit and D7971/C2:9
nostic menu.
Check the sensor.
B 7244 3 2 Electric transmission Limits transmission Check the cable harness be- B7244 11.9 I/O D7971
dipstick sensor (B7244) performance tween the control unit and D7971/C2:17 KFU 1–75/XX
the sensor using the diag- DIAGNOSE,
Check the sensor.
and menu
components
B 7244 4 2 Electric transmission Limits transmission Check the cable harness be- B7244 11.9 I/O D7971
dipstick sensor (B7244) performance tween the control unit and D7971/C2:17 KFU 1–75/XX
the sensor using the diag- DIAGNOSE,
Check the sensor.
B 7245 3 2 10 Sensor, wheel angle. No limitation but the Check the cable harness be- B7245-LE 5.2 Power As-
performance of the tween the control unit and D7971/C2:12 sisted 9/XX DI-
transmission is the sensor using the diag- AGNOSE,
impaired. nostic menu. page 8:48
Check the sensor. 5.2 Power As-
sisted 10/XX
DIAGNOSE,
page 8:48
B 7245 4 2 10 Sensor, wheel angle. No limitation but the Check the cable harness be- B7245-LE 5.2 Power As-
performance of the tween the control unit and D7971/C2:12 sisted 9/XX DI-
transmission is the sensor using the diag- AGNOSE,
impaired. nostic menu. page 8:48
Check the sensor. 5.2 Power As-
sisted 10/XX
DIAGNOSE,
page 8:48
B 7245 3 2 20 Sensor, feedback steer- Steering turns off Check the cable harness be- B7245-RI 5.2 Power As-
ing, channel 2. automatically. tween the control unit and D7971/C2:28 sisted 9/XX DI-
the sensor using the diag- AGNOSE,

Check the sensor.
B 7245 4 2 20 Sensor, feedback steer- Steering turns off Check the cable harness be- B7245-RI 5.2 Power As-

ing, channel 2. automatically. tween the control unit and D7971/C2:28 sisted 9/XX DI-
the sensor using the diag- AGNOSE,
Check the sensor.
B 7252 3 11 Sensor, ambient bright- Searchlight and Make sure there are no ob- B7252 8.1 Controls & Cab overview,
ness (B7252), high sig- function light in sili- jects or dirt in front of the D7902/C6:20 Instr 1/XX DI- page 9:5
nal voltage. cone panels can sensor in the driveline panel. AGNOSE,
give incorrect page 8:101
brightness.
B 7252 4 11 Sensor, ambient bright- Searchlight and Make sure there are no ob- B7252 8.1 Controls & Cab overview,
ness (B7252), low signal function light in sili- jects or dirt in front of the D7902/C6:20 Instr 1/XX DI- page 9:5
voltage. cone panels can sensor in the driveline panel. AGNOSE,
give incorrect page 8:101
brightness.
VDRG09.01GB
D:207
and menu
components
VDRG09.01GB
B 7253 3 7 Sensor tilt or levelling Sensor tilt or level- Check the cable harness be- B7253 7.7 Tilt 9/XX
angle attachment ling angle attach- tween the control unit and D7911/C2:15 DIAGNOSE,
(B7253), high signal ment not working. the sensor using the diag- page 8:65
voltage. nostic menu.
Check the sensor.
B 7253 4 7 Sensor tilt or levelling Sensor tilt or level- Check the cable harness be- B7253 7.7 Tilt 9/XX
angle attachment ling angle attach- tween the control unit and D7911/C2:15 DIAGNOSE,
(B7253), low signal ment not working. the sensor using the diag- page 8:65
Check the sensor.
B 7254 3 1 Sensor cab position Overload system Check the cable harness be- B7254 9.10 Cab sus- Sensor cab po-
(B7254), high signal and load centre lim- tween the control unit and D7901/C1:32 pension 1/XX sition, descrip-
voltage. itation assume the the sensor using the diag- DIAGNOSE, tion, page
cab is in fully slid- nostic menu. page 8:130 9:117
forward/raised posi- Check the sensor. 9.10 Cab sus- Sensor cab po-
tion and limit the pension 4/XX sition, descrip-
functions DIAGNOSE, tion, page
accordingly. page 8:131 9:130
B 7254 4 1 Sensor cab position Overload system Check the cable harness be- B7254 9.10 Cab sus- Sensor cab po-
(B7254), low signal and load centre lim- tween the control unit and D7901/C1:32 pension 1/XX sition, descrip-
voltage. itation assume the the sensor using the diag- DIAGNOSE, tion, page
cab is in fully slid- nostic menu. page 8:130 9:117
forward/raised posi- Check the sensor. 9.10 Cab sus- Sensor cab po-
tion and limit the pension 4/XX sition, descrip-

functions DIAGNOSE, tion, page
accordingly. page 8:131 9:130
B 7255 3 1 Sensor cab tilt position No limitation. Check the cable harness be- B7255

(B7255), high signal tween the control unit and D7901/C1:31
voltage. the sensor using the diag-
nostic menu.
Check the sensor.
B 7255 4 1 Sensor cab tilt position No limitation. Check the cable harness be- B7255
(B7255), low signal tween the control unit and D7901/C1:31
voltage. the sensor using the diag-
nostic menu.
Check the sensor.
and menu
components
B 7258 2 7 Logic error Sensor lock- No load handling Check that the sensor's indi- B7258-LE
ing wedge position functions are cator pin has not become D7911/C2:29 /
locked (B7258-LE / working. stuck. 1:42
B7258-RI), a sensor has Check the cable harness be- B7258-RI
been active for longer tween the control unit and D7971/C2:28 /
than 120 seconds. the sensor using the diag- 2:45
nostic menu.
Check the sensor.
B 7259 7 3 Position inspection sup- Stops lift/lower and Check the cable harness be- B7259 -
port left. tilt, and gives speed tween the control unit and D7972
limitation max. 10 the sensor using the diag- C2:14 / C2:23
km/h. nostic menu.
Check the sensor.
B 7260 7 3 Position inspection sup- Stops lift/lower and Check the cable harness be- B7260–RI -
port right. tilt, and gives speed tween the control unit and D7972
limitation max. 10 the sensor using the diag- C2:15 / C2:16
km/h. nostic menu.
Check the sensor.
B 7570 3 2 Sensor fuel level Incorrect display of Check the cable harness be- B7570 1.2 Fuel Sys- Sensor, fuel
(B7570), high signal fuel volume (empty tween the control unit and D7971/C2:24 tem 1/XX DI- level, descrip-
voltage. or full). the sensor using the diag- AGNOSE, tion, page 1:6
Check the sensor.
B 7570 4 2 Sensor fuel level Incorrect display of Check the cable harness be- B7570 1.2 Fuel Sys- Sensor, fuel
(B7570), low signal fuel volume (empty tween the control unit and D7971/C2:24 tem 1/XX DI- level, descrip-
voltage. or full). the sensor using the diag- AGNOSE, tion, page 1:6

Check the sensor.
B 7572 1 2 Exhaust back pressure Incorrect display of Check the cable harness be- B7572 1.3 Aux Ex-
sensor (B7572), data exhaust back tween the control unit and D7971/C2:9 haust Clean 1/
valid but below normal pressure. the sensor using the diag- XX Diagnose,
operating range. nostic menu. page 8:30
Check the sensor.
B 7572 3 2 Sensor exhaust back Incorrect display of Check the cable harness be- B7572 1.3 Aux Ex-
pressure (B7572), high exhaust back tween the control unit and D7971/C2:9 haust Clean 1/
signal voltage. pressure. the sensor using the diag- XX Diagnose,
Check the sensor.
VDRG09.01GB
D:209
and menu
components
VDRG09.01GB
B 7572 4 2 Sensor exhaust back Incorrect display of Check the cable harness be- B7572 1.3 Aux Ex-
pressure (B7572), low exhaust back tween the control unit and D7971/C2:9 haust Clean 1/
signal voltage. pressure. the sensor using the diag- XX Diagnose,
Check the sensor.
B 7572 15 2 Sensor exhaust back Value too high, ex- Clean the filter. B7572 1.3 Aux Ex-
pressure (B7572), high haust back pres- D7971/C2:9 haust Clean 1/
value, still approved. sure. Least severe XX Diagnose,
level. page 8:30
B 7572 16 2 Sensor exhaust back Value too high, ex- Clean the filter. B7572 1.3 Aux Ex-
pressure (B7572), high haust back pres- D7971/C2:9 haust Clean 1/
value, still approved. sure. Moderately XX Diagnose,
severe level. page 8:30
B 7600 0 2 0 Speed sensor (B7600). Reduction of en- Check the wiring between B7600
gine speed. control unit and sensor. D7971/C2:21
Check the sensor.
B 7600 8 2 0 Speed sensor (B7600). Reduction of en- Check the wiring between B7600
gine speed. control unit and sensor. D7971/C2:21
Check the sensor.
B 7601 0 3 210 Sensor, speed left-hand - Check cabling between the B7601-LE
rear wheel (B7601-LE), control unit and the compo- D7972/C2:12
data valid but outside nent with diagnostic menu.
usage range. Check the component.

B 7601 4 3 210 Sensor, speed left-hand - Check cabling between the B7601-LE
rear wheel (B7601-LE), control unit and the compo- D7972/C2:12

voltage below normal nent with diagnostic menu.
value or short circuit to Check the component.
ground.
B 7601 0 3 220 Sensor, speed right- - Check cabling between the B7601-RI
hand rear wheel control unit and the compo- D7972/C2:28
(B7601-RI), data valid nent with diagnostic menu.
but outside usage range. Check the component.
B 7601 4 3 220 Sensor, speed right- - Check cabling between the B7601-RI
hand rear wheel control unit and the compo- D7972/C2:28
(B7601-RI), voltage be- nent with diagnostic menu.
low normal value or Check the component.
short circuit to ground.
and menu
components
B 7680 3 3 1 Sensor, clamping pres- No clamping pres- Check the cable harness be- B7680-1 See separate
sure single/left clamp sure control for sin- tween the control unit and D7972/C2:15 supplement.
(B7680-1), high signal gle/left clamp. the sensor using the diag-
Check the sensor.
(B7680-1), low signal gle/left clamp. the sensor using the diag-
Check the sensor.
(B7680-2), high signal gle/left clamp. the sensor using the diag-
Check the sensor.
(B7680-2), low signal gle/left clamp. the sensor using the diag-
Check the sensor.
sure right clamp sure control for tween the control unit and D7972/C2:16 supplement.
(B7680-3), high signal right clamp. the sensor using the diag-

Check the sensor.

(B7680-3), low signal right clamp. the sensor using the diag-
Check the sensor.
(B7680-4), high signal right clamp. the sensor using the diag-
Check the sensor.
(B7680-4), low signal right clamp. the sensor using the diag-
Check the sensor.
VDRG09.01GB
D:211
and menu
components
VDRG09.01GB
B 7680 3 7 10 Sensor function lifting Lift with lifting tool Check the cable harness be- B7680-LE 7.9 Load Car- See separate
tool tool changer left not working. tween the control unit and D7911/C2:24 rier 74/XX DI- supplement.
(B7680-LE), high signal the sensor using the diag- AGNOSE,
voltage. nostic menu. page 8:87
Check the sensor.
B 7680 4 7 10 Sensor function lifting Lift with lifting tool Check the cable harness be- B7680-LE 7.9 Load Car- See separate
tool tool changer left not working. tween the control unit and D7911/C2:24 rier 74/XX DI- supplement.
(B7680-LE), low signal the sensor using the diag- AGNOSE,
Check the sensor.
B 7680 3 7 20 Sensor function lift tool, Lift with lifting tool Check the cable harness be- B7680-RI 7.9 Load Car- See separate
tool changer right not working. tween the control unit and D7911/C2:25 rier 74/XX DI- supplement.
(B7680-RI), high signal the sensor using the diag- AGNOSE,
Check the sensor.
B 7680 4 7 20 Sensor function lift tool, Lift with lifting tool Check the cable harness be- B7680-RI 7.9 Load Car- See separate
tool changer right not working. tween the control unit and D7911/C2:25 rier 74/XX DI- supplement.
(B7680-RI), low signal the sensor using the diag- AGNOSE,
Check the sensor.
B 7681 3 2 Sensor brake pressure Brake lights and Check the cable harness be- B7681 4.3 Power As- Brake pressure
(B7681), high signal declutch not tween the control unit and D7971/C2:7 sisted 3/XX DI- sensor, de-
voltage. working. the sensor using the diag- AGNOSE, scription, page
nostic menu. page 8:44 4:35

Check the sensor.
B 7681 4 2 Sensor brake pressure Brake lights and Check the cable harness be- B7681 4.3 Power As- Brake pressure

(B7681), low signal declutch not tween the control unit and D7971/C2:7 sisted 3/XX DI- sensor, de-
voltage. working. the sensor using the diag- AGNOSE, scription, page
nostic menu. page 8:44 4:35
Check the sensor.
B 7682 3 2 Sensor parking brake Indicator light park- Check the cable harness be- B7682 4.5 Park Brake
(B7682), high signal ing brake and warn- tween the control unit and D7971/C2:17 Sys 3/XX DI-
voltage. ing for low brake the sensor using the diag- AGNOSE,
pressure not nostic menu. page 8:45
switching off. Gear Check the sensor.
cannot be engaged
because the signal
for released parking
brake is not
working.
and menu
components
(B7682), low signal ing brake and warn- tween the control unit and D7971/C2:17 Sys 3/XX DI-
voltage. ing for low brake the sensor using the diag- AGNOSE,
cannot be engaged
because the signal
brake is not
working.
(B7682), value too high. ing brake and warn- tween the control unit and D7971/C2:17 Sys 3/XX DI-
ing for low brake the sensor using the diag- AGNOSE,
cannot be engaged
because the signal
brake is not
working.
B 7683 3 2 Sensor accumulator Indicator light park- Check the cable harness be- B7683 4.3 Power As- Accumulator
pressure (B7683), high ing brake and warn- tween the control unit and D7971/C2:8 sisted 4/XX DI- pressure sen-
signal voltage. ing for low brake the sensor using the diag- AGNOSE, sor, description,
pressure not nostic menu. page 8:44 page 4:32

cannot be engaged
because the signal

brake is not
working.
B 7683 4 2 Sensor accumulator Indicator light park- Check the cable harness be- B7683 4.3 Power As- Accumulator
pressure (B7683), low ing brake and warn- tween the control unit and D7971/C2:8 sisted 4/XX DI- pressure sen-
signal voltage. ing for low brake the sensor using the diag- AGNOSE, sor, description,
pressure not nostic menu. page 8:44 page 4:32
cannot be engaged
because the signal
brake is not
working.
VDRG09.01GB
D:213
and menu
components
VDRG09.01GB
B 7686 3 2 Sensor boom length Load sensor and Check the cable harness be- B7686 8.2 Monitoring Sensor, boom
(B7686), high signal overload system tween the control unit and D7971/C2:16 16/XX DIAG- length, descrip-
Regeneration ex-
tension and end po-
sition damping not
working.
B 7686 4 2 Sensor boom length Load sensor and Check the cable harness be- B7686 8.2 Monitoring Sensor, boom
(B7686), low signal overload system tween the control unit and D7971/C2:16 16/XX DIAG- length, descrip-
Regeneration ex-
tension and end po-
sition damping not
working.
B 7686 7 2 Sensor, boom length Load sensor and Check the cable harness be- B7686 8.2 Monitoring Sensor, boom
(B7686), mechanical overload system tween the control unit and D7971/C2:16 16/XX DIAG- length, descrip-
problem. not working. Lift the sensor using the diag- NOSE, page tion, page 8:18
Regeneration ex-
tension and end po-
sition damping not
working.

B 7688 3 7 Sensor LS-pressure at- Attachment func- Check the cable harness be- B7688 10.4 Pumps 6/
tachment (B7688), high tions work but at full tween the control unit and D7911/C1:5 XX DIAGNOSE,
signal voltage. pressure. the sensor using the diag- page 8:134
nostic menu. 10.4 Pumps 7/
Check the sensor. XX DIAGNOSE,
page 8:134
B 7688 4 7 Sensor LS-pressure at- Attachment func- Check the cable harness be- B7688 10.4 Pumps 6/
tachment (B7688), low tions work but at full tween the control unit and D7911/C1:5 XX DIAGNOSE,
signal voltage. pressure. the sensor using the diag- page 8:134
nostic menu. 10.4 Pumps 7/
Check the sensor. XX DIAGNOSE,
page 8:134
and menu
components
B 7690 2 7 10 Sensor, left-hand end Check the cable harness be- B7690 7.5 Spreading
position 20'-40' (B7690) tween the control unit and D7911/C2:08 8/XX DIAG-
activation damping. the sensor using the diag- NOSE, page
nostic menu. 8:60
Check the sensor. 7.5 Spreading
9/XX DIAG-
NOSE, page
8:60
B 7690 2 7 20 Sensor, right-hand end Check the cable harness be- B7690 7.5 Spreading
position 20'-40' (B7690) tween the control unit and D7911/C2:09 8/XX DIAG-
activation damping. the sensor using the diag- NOSE, page
nostic menu. 8:60
9/XX DIAG-
NOSE, page
8:60
B 7701 2 3 Revolving driver's seat, Drive in neutral. Check the cable harness be- B7701
incorrect or no feedback. tween the control unit and D7972/C1:12
the sensor using the diag- D7972/C1:13
nostic menu.
Check the sensor.
B 7720 0 2 High temperature oil, Machine speed is Check the function of the B7720 4.8 Oil Temp/ Sensor, oil
brake system. limited. cooling fan. D7971/C2:29 Clean 1/XX DI- temperature
Check that the radiator is AGNOSE, brake system,

not clogged. page 8:46 description,
Check the oil level in the page 4:54
brake system's tank.

B 7720 32 2 Sensor temperature oil Display of brake oil Check the cable harness be- B7720 4.8 Oil Temp/ Sensor, oil
brake system (B7720), temperature not tween the control unit and D7971/C2:29 Clean 1/XX DI- temperature
high resistance or open working, warning the sensor using the diag- AGNOSE, brake system,
circuit. for high brake oil nostic menu. page 8:46 description,
temperature not Check the sensor. page 4:54
working. Machine
speed is limited.
B 7720 33 2 Sensor temperature oil Display of brake oil Check the cable harness be- B7720 4.8 Oil Temp/ Sensor, oil
brake system (B7720), temperature not tween the control unit and D7971/C2:29 Clean 1/XX DI- temperature
low resistance or short working, warning the sensor using the diag- AGNOSE, brake system,
circuit. for high brake oil nostic menu. page 8:46 description,
temperature not Check the sensor. page 4:54
working. Machine
speed is limited.
VDRG09.01GB
D:215
and menu
components
VDRG09.01GB
B 7740 32 1 Sensor ambient temper- Air conditioning not Check the cable harness be- B7740 9.4 Climate Ambient tem-
ature (B7740), high reworking. tween the control unit and D7901/C1:36 System 4/XX perature sen-
sistance or open circuit. the sensor using the diag- DIAGNOSE, sor, description,
Check the sensor. 9.4 Climate
System 5/XX
DIAGNOSE,
page 8:111
B 7740 33 1 Sensor ambient temper- Air conditioning not Check the cable harness be- B7740 9.4 Climate Ambient tem-
ature (B7740), low reworking. tween the control unit and D7901/C1:36 System 4/XX perature sen-
sistance or short circuit. the sensor using the diag- DIAGNOSE, sor, description,
System 5/XX
DIAGNOSE,
page 8:111
B 7751 32 1 Sensor inside tempera- Air conditioning not Check the cable harness be- B7751 9.4 Climate Interior temper-
ture (B7751), high reworking. tween the control unit and D7901/C1:33 System 4/XX ature sensor,
sistance or open circuit. the sensor using the diag- DIAGNOSE, description,
System 5/XX
DIAGNOSE,
page 8:111
B 7751 33 1 Sensor inside tempera- Air conditioning not Check the cable harness be- B7751 9.4 Climate Interior temper-
ture (B7751), low resist- working. tween the control unit and D7901/C1:33 System 4/XX ature sensor,
ance or short circuit. the sensor using the diag- DIAGNOSE, description,

System 5/XX
DIAGNOSE,
page 8:111
B 7752 32 1 Sensor fan temperature Air conditioning not Check cabling between the B7752 9.4 Climate Fan tempera-
(B7752), high resistance working. control unit and the compo- D7901/C1:34 System 4/XX ture sensor,
or open circuit. nent with diagnostic menu. DIAGNOSE, description,
Check the sensor. page 8:111 page 9:50
9.4 Climate
System 5/XX
DIAGNOSE,
page 8:111
and menu
components
B 7752 33 1 Sensor fan temperature Air conditioning not Check the cable harness be- B7752 9.4 Climate Fan tempera-
(B7752), low resistance working. tween the control unit and D7901/C1:34 System 4/XX ture sensor,
or short circuit. the sensor using the diag- DIAGNOSE, description,
System 5/XX
DIAGNOSE,
page 8:111
B 7753 32 1 Sensor temperature dis- Air conditioning not Check the cable harness be- B7753 9.4 Climate Temperature
play (B7753), high reworking. tween the control unit and D7901/C1:35 System 4/XX deicing sensor,
sistance or open circuit. the sensor using the diag- DIAGNOSE, description,
System 5/XX
DIAGNOSE,
page 8:111
B 7753 33 1 Sensor temperature dis- Air conditioning not Check the cable harness be- B7753 9.4 Climate Temperature
play (B7753), low resist- working. tween the control unit and D7901/C1:35 System 4/XX deicing sensor,
ance or short circuit. the sensor using the diag- DIAGNOSE, description,
System 5/XX
DIAGNOSE,
page 8:111
B 7755 1 2 Sensor ECC water level Heater in cab not Fill with glycol-mixed water. B7755 See Mainte-
(B7755) in water heater working. D7971/C2:20 nance manual
air conditioning, water

level low.
B 7760 32 2 Sensor temperature hy- Check the cable harness be- B7760 10.6 Oil Temp/
draulic oil (B7760), high tween the control unit and D7971/C2:25 Clean 1/XX DI-
resistance or open the sensor using the diag- AGNOSE,
circuit. nostic menu. page 8:135
Check the sensor.
B 7760 33 2 Sensor temperature hy- Check the cable harness be- B7760 10.6 Oil Temp/
draulic oil (B7760), low tween the control unit and D7971/C2:25 Clean 1/XX DI-
resistance or short the sensor using the diag- AGNOSE,
circuit. nostic menu. page 8:135
Check the sensor.
VDRG09.01GB
D:217
and menu
components
VDRG09.01GB
B 7770 2 3 Potentiometer, turnable Drive in neutral. Check the cable harness be- B7770
operator's station tween the control unit and D7972/C2:07
(B7770), no change of the sensor using the diag-
angle when turning nostic menu.
requested. Check the sensor.
B 7770 3 3 Potentiometer turnable Drive in neutral. Check the cable harness be- B7770
(B7770), high signal the sensor using the diag-
Check the sensor.
B 7770 4 3 Potentiometer turnable Drive in neutral. Check the cable harness be- B7770
(B7770), low signal the sensor using the diag-
Check the sensor.
B 7770 2 3 Potentiometer, turnable Drive in neutral. Check the cable harness be- B7770
(B7770). the sensor using the diag-
nostic menu.
Check the sensor.
B 7770 2 7 10 Sensor, left-hand 30- Spreading deacti- Check the cable harness be- B7770 7.5 Spreading
foot stop (B7770). vated in inner and tween the control unit and D7911/C2:10 8/XX DIAG-
outer position. the sensor using the diag- NOSE, page

nostic menu. 8:60
9/XX DIAG-
NOSE, page

8:60
B 7770 2 7 20 Sensor, right-hand 30- Spreading deacti- Check the cable harness be- B7770 7.5 Spreading
foot stop (B7770). vated in inner and tween the control unit and D7911/C2:11 8/XX DIAG-
outer position. the sensor using the diag- NOSE, page
nostic menu. 8:60
9/XX DIAG-
NOSE, page
8:60
B 7770 3 7 Position sensor side No limitation but Check the cable harness be- B7770 7.9 Load Car-
shift (B7770), high sig- skewed load sys- tween the control unit and D7911/C2:02 rier 111/XX DI-
nal voltage. tem can interrupt the sensor using the diag- AGNOSE,
lifting. nostic menu. page 8:91
Check the sensor.
and menu
components
B 7770 4 7 Position sensor side No limitation but Check the cable harness be- B7770 7.9 Load Car-
shift (B7770), low signal skewed load sys- tween the control unit and D7911/C2:02 rier 111/XX DI-
voltage. tem can interrupt the sensor using the diag- AGNOSE,
lifting. nostic menu. page 8:91
Check the sensor.
D 7801 31 2 20 Control unit, engine con- Propulsion of truck Check the CAN wiring be- D7801
trol, propulsion right not working. tween control unit D7971 D7901/C1:31,
(D7801) missing. and D7901. C1:32
D 7802 31 2 10 Control unit, engine con- Propulsion of truck Check the CAN wiring be- D7802
trol, propulsion left not working. tween control unit D7971 D7902/C1:31,
(D7802) missing. and D7902. C1:32
D 7811 31 2 Control unit, engine con- Hydraulics not Check the CAN wiring be- D7811
trol, pump hydraulics working. tween control unit D7971 D7911/C1:31,
(D7811) missing. and D7911. C1:32
D 7811 31 2 Control unit, engine con- Hydraulics not Check the CAN wiring be- D7811
trol, pump hydraulics working. tween control unit D7971 D7911–2/
(D7811-2) missing. and D7911-2. C1:31, C1:32
D 7812 31 2 Control unit, engine con- Brake and AC not Check the CAN wiring be- D7812
trol, pump brakes and working tween control unit D7971 D7912/C1:31,
cooling compressor and D7912. C1:32
(D7812) missing.
A 7870 2 2 Sensor fault, overload Load handling func- Check and rectify error co- -
system. One of the sen- tions are blocked. des for position sensor and
sors connected to the pressure sensor.
overload system has ac-

tive error codes
VDRG09.01GB
D:219
and menu
components
VDRG09.01GB
D 7901 31 11 Control unit cab KCU Functions in cab Check the cable harness to D7901/C1:3 11.6 Communi- 11.6.2 Redun-
(D7901) missing. not working. the control unit. D7901/C1:4 cation 1/XX DI- dant CAN bus,
Troubleshoot the CAN bus D7901/C1:6 AGNOSE, page 11:50
with the diagnostic menu. D7901/C1:7 page 8:160
11.6 Communi-
cation 2/XX DI-
AGNOSE,
page 8:160
11.6 Communi-
cation 3/XX DI-
AGNOSE,
page 8:160
11.6 Communi-
cation 4/XX DI-
AGNOSE,
page 8:161
11.6 Communi-
cation 5/XX DI-
AGNOSE,
page 8:161
D 7902 31 11 KPU control unit Controls in the right Check the cable harness to D7902/C1:3 11.6 Communi- 11.6.2 Redun-
(D7902) missing. dashboard panel or the control unit. D7902/C1:4 cation 1/XX DI- dant CAN bus,
steering panel not Troubleshoot the CAN bus D7902/C1:5 AGNOSE, page 11:50
working. with the diagnostic menu. D7902/C1:6 page 8:160
11.6 Communi-
cation 2/XX DI-
AGNOSE,
page 8:160

11.6 Communi-
cation 3/XX DI-
AGNOSE,
page 8:160
11.6 Communi-
cation 4/XX DI-
AGNOSE,
page 8:161
11.6 Communi-
cation 5/XX DI-
AGNOSE,
page 8:161
and menu
components
D 7911 31 11 Control unit KAU Functions, attach- Check the cable harness to D7911/C1:3 11.6 Communi- 11.6.2 Redun-
(D7911) missing ment not working. the control unit. D7911/C1:4 cation 1/XX DI- dant CAN bus,
Troubleshoot the CAN bus D7911/C1:6 AGNOSE, page 11:50
with the diagnostic menu. D7911/C1:7 page 8:160
11.6 Communi-
cation 2/XX DI-
AGNOSE,
page 8:160
11.6 Communi-
cation 3/XX DI-
AGNOSE,
page 8:160
11.6 Communi-
cation 4/XX DI-
AGNOSE,
page 8:161
11.6 Communi-
cation 5/XX DI-
AGNOSE,
page 8:161
D 7912 31 11 Control unit KAU-2 Functions con- Check the cable harness to D7912/C1:3 11.6 Communi- 11.6.2 Redun-
(D7912) missing nected to Control the control unit. D7912/C1:4 cation 1/XX DI- dant CAN bus,
unit KAU-2 (D7912) Troubleshoot the CAN bus D7912/C1:6 AGNOSE, page 11:50
not working, e.g. with the diagnostic menu. D7912/C1:7 page 8:160
combi attachment, 11.6 Communi-

etc. cation 2/XX DI-
AGNOSE,
page 8:160

11.6 Communi-
cation 3/XX DI-
AGNOSE,
page 8:160
11.6 Communi-
cation 4/XX DI-
AGNOSE,
page 8:161
11.6 Communi-
cation 5/XX DI-
AGNOSE,
page 8:161
D 7930 31 2 1 Transmission control Gear selection not Check the cable harness to D7971/C1:31 11.6.2 Redun-
unit (D7930) missing. working. the control unit. D7971/C1:32 dant CAN bus,
page 11:50
VDRG09.01GB
D:221
and menu
components
VDRG09.01GB
D 7940 31 2 1 Engine control unit Engine does not re- Check the cable harness to D7971/C1:31 11.6.2 Redun-
(D7940) missing spond to com- the control unit. D7971/C1:32 dant CAN bus,
mands from the cab. page 11:50
D 7940 31 2 2 Control unit, engine Engine does not re- Check the cable harness to D7971/C1:31 11.6.2 Redun-
ACM (D7940) missing spond to com- the control unit. D7971/C1:32 dant CAN bus,
mands from the cab. page 11:50
D 7950 31 11 KID control unit (D7950) Display not working. Check the cable harness to D7950/C1:3 Troubleshoot- 11.6.2 Redun-
missing the control unit. D7950/C1:4 ing with menu dant CAN bus,
Troubleshoot the CAN bus D7950/C1:6 not possible. page 11:50
with the diagnostic menu. D7950/C1:7
D 7950 31 12 KID control unit (D7950) Display not working. Check the cable harness to D7950/C1:3 Troubleshoot- 11.6.2 Redun-
missing the control unit. D7950/C1:4 ing with menu dant CAN bus,
Troubleshoot the CAN bus D7950/C1:6 not possible. page 11:50
with the diagnostic menu. D7950/C1:7
D 7971 31 11 Control unit KFU Numerous func- Check the cable harness to D7971/C1:3 11.6 Communi- 11.6.2 Redun-
(D7971) missing tions not working, the control unit. D7971/C1:4 cation 1/XX DI- dant CAN bus,
engine, transmis- Troubleshoot the CAN bus D7971/C1:6 AGNOSE, page 11:50
sion, load handling, with the diagnostic menu. D7971/C1:7 page 8:160
etc. 11.6 Communi-
cation 2/XX DI-
AGNOSE,
page 8:160
11.6 Communi-
cation 3/XX DI-
AGNOSE,
page 8:160

11.6 Communi-
cation 4/XX DI-
AGNOSE,
page 8:161
11.6 Communi-
cation 5/XX DI-
AGNOSE,
page 8:161
and menu
components
D 7972 31 11 Control unit KFU-2 Functions con- Check the cable harness to D7972/C1:3 11.6 Communi- 11.6.2 Redun-
(D7972) missing nected to Control the control unit. D7972/C1:4 cation 1/XX DI- dant CAN bus,
unit KFU-2 (D7972) Troubleshoot the CAN bus D7972/C1:6 AGNOSE, page 11:50
not working, e.g. with the diagnostic menu. D7972/C1:7 page 8:160
turnable driver’s 11.6 Communi-
seat, etc. cation 2/XX DI-
AGNOSE,
page 8:160
11.6 Communi-
cation 3/XX DI-
AGNOSE,
page 8:160
11.6 Communi-
cation 4/XX DI-
AGNOSE,
page 8:161
11.6 Communi-
cation 5/XX DI-
AGNOSE,
page 8:161
A 7991 31 1 Control unit KEM Engine does not re- Check cabling between the D7991/C1:3 11.5 Distr of
(D7991) missing spond to com- control unit and the compo- D7991/C1:4 Electr 47/XX
mands from the cab. nent with diagnostic menu. DIAGNOSE,
A 7992 31 7 Control unit KEM-2 Levelling of load Check cabling between the A7992/C1:3 11.6 Communi-
(A7992) missing not working control unit and the compo- A7992/C1:4 cation 17/XX
nent with diagnostic menu. DIAGNOSE,

D 7992 31 1 Control unit BMS Speed limitation Check CAN bus between D7992 - -
missing. KCU and battery control unit
BMS.
A 7993 31 7 Control unit KEM-3 WTP (Wide Twist- Check cabling between the D7993/C1:3 11.6 Communi-
(D7993) missing lock Position) not control unit and the compo- D7993/C1:4 cation 18/XX
working. nent with diagnostic menu. DIAGNOSE,
E 8020 5 2 Electrically heated rear Electrically heated Check cabling between the E8020 9.9 Glass Wind Rear view mir-
view mirror (E8020), rear view mirror not control unit and the compo- D7971/C2:22 Mirr 1/XX DI- ror, description,
open circuit. working. nent with diagnostic menu. AGNOSE, page 9:98
VDRG09.01GB
D:223
and menu
components
VDRG09.01GB
E 8020 6 2 Electrically heated rear Electrically heated Check cabling between the E8020-LE 9.9 Glass Wind Rear view mir-
view mirror (E8020-LE) rear view mirror not control unit and the compo- E8020-RI Mirr 1/XX DI- ror, description,
and (R8020-RI), short working. nent with diagnostic menu. D7971/C2:22 AGNOSE, page 9:98
circuit to ground. Check the component. page 8:129
E 8050 11 2 Water heater air condi- Heater unit not pro- Check cabling between the E8050
tioning (E8050) viding any heat in control unit and the compo- D7971/C2:30
inoperative. the cab. nent with diagnostic menu.
R 8070 3 11 1 Control lever lifting/low- Lift and lower not Check cabling between the S8150/4 7.1 Controls Control lever
ering (S8150-R8070-1), working. control unit and the compo- D7902/C3:3 and Instr 5/XX (Ego), descrip-
high signal voltage. nent with diagnostic menu. DIAGNOSE, tion, page 7:6
Check the lever. page 8:53
R 8070 4 11 1 Control lever lifting/low- Lift and lower not Check cabling between the S8150/4 7.1 Controls Control lever
ering (S8150-R8070-1), working. control unit and the compo- D7902/C3:3 and Instr 5/XX (Ego), descrip-
low signal voltage. nent with diagnostic menu. DIAGNOSE, tion, page 7:6
R 8070 3 11 2 Control lever boom out/ Boom in and out as Check cabling between the S8150/3 7.1 Controls Control lever
in (S8150-R8070-2), well as levelling not control unit and the compo- D7902/C3:4 and Instr 5/XX (Ego), descrip-
high signal voltage. working. nent with diagnostic menu. DIAGNOSE, tion, page 7:6
R 8070 4 11 2 Control lever boom out/ Boom in and out as Check cabling between the S8150/3 7.1 Controls Control lever
in (S8150-R8070-2), low well as levelling not control unit and the compo- D7902/C3:4 and Instr 5/XX (Ego), descrip-
signal voltage. working. nent with diagnostic menu. DIAGNOSE, tion, page 7:6
R 8070 3 11 3 Control lever side shift Side shift and Check cabling between the S8150/3 7.1 Controls Control lever

and spreading (S8150- spreading not control unit and the compo- D7902/C3:5 and Instr 6/XX (Ego), descrip-
R8070-3), high signal working. nent with diagnostic menu. DIAGNOSE, tion, page 7:6
voltage. Check the lever. page 8:53
R 8070 4 11 3 Control lever side shift Side shift and Check cabling between the S8150/3 7.1 Controls Control lever
and spreading (S8150- spreading not control unit and the compo- D7902/C3:5 and Instr 6/XX (Ego), descrip-
R8070-3), low signal working. nent with diagnostic menu. DIAGNOSE, tion, page 7:6
voltage. Check the lever. page 8:53
R 8070 3 11 4 Control lever rotation Rotation and tilt not Check cabling between the S8150/6 7.1 Controls Control lever
and tilt (S8150-R8070- working. control unit and the compo- D7902/C3:6 and Instr 6/XX (Ego), descrip-
4), high signal voltage. nent with diagnostic menu. DIAGNOSE, tion, page 7:6
and menu
components
R 8070 4 11 4 Control lever rotation Rotation and tilt not Check cabling between the S8150/6 7.1 Controls Control lever
and tilt (S8150-R8070- working. control unit and the compo- D7902/C3:6 and Instr 6/XX (Ego), descrip-
4), low signal voltage. nent with diagnostic menu. DIAGNOSE, tion, page 7:6
R 8070 3 11 5 Control lever 5th func- 5th function not Check cabling between the R8070-5
tion (R8070-5), high sig- working. control unit and the compo- D7902/C3:7
nal voltage. nent with diagnostic menu.
Check the lever.
tion (R8070-5), low sig- working. control unit and the compo- D7902/C3:7
Check the lever.
tion (R8070-6), high sig- working. control unit and the compo- D7902/C3:8
Check the lever.
tion (R8070-6), low sig- working. control unit and the compo- D7902/C3:8
Check the lever.
R 8092 3 11 1 Brake position A. Engine speed Check cabling between the R8092 4.1 Controls & -
limited to idle. control unit and the compo- D7902/C8:8 Instr 1/XX DI-

R 8092 4 11 1 Brake position A. Engine speed Check cabling between the R8092 4.1 Controls & -

R 8092 13 11 1 Brake position A, cali- Engine speed Check cabling between the R8092 4.1 Controls & -
bration error. limited to idle. control unit and the compo- D7902/C8:8 Instr 1/XX DI-
R 8092 14 11 1 Brake position A, cali- Engine speed Check cabling between the R8092 4.1 Controls & -
R 8092 3 11 2 Brake position B. Engine speed Check cabling between the R8092 4.1 Controls & -
VDRG09.01GB
D:225
and menu
components
VDRG09.01GB
R 8092 4 11 2 Brake position B. Engine speed Check cabling between the R8092 4.1 Controls & -
R 8092 13 11 2 Brake position B, cali- Engine speed Check cabling between the R8092 4.1 Controls & -
R 8092 14 11 2 Brake position B, cali- Engine speed Check cabling between the R8092 4.1 Controls & -
M 8100 5 1 Condenser roof Climate system not Check cabling between the M8100 Condenser unit,
(M8100) working. control unit and the compo- D7901/C2:36 description,
M 8100 6 1 Condenser roof Climate system not Check cabling between the M8100 Condenser unit,
(M8100) working. control unit and the compo- D7901/C2:36 description,
R 8250 3 1 1 Control lever/mini-wheel Joystick control or Check cabling between the R8250-1 5.2 Power As- Joystick
channel 1 (R8250-1), mini-wheel not control unit and the compo- D7901/C1:37 sisted 3/XX DI- control:
high signal voltage. working. nent with diagnostic menu. AGNOSE, Joystick, de-
Check the potentiometer. page 8:47 scription, page
5:6

Mini-wheel:
Mini-wheel, de-
scription, page
5:5
R 8250 4 1 1 Control lever/mini-wheel Joystick control or Check cabling between the R8250-1 5.2 Power As- Joystick
channel 1 (R8250-1), mini-wheel not control unit and the compo- D7901/C1:37 sisted 3/XX DI- control:
low signal voltage. working. nent with diagnostic menu. AGNOSE, Joystick, de-
Check the potentiometer. page 8:47 scription, page
5:6
Mini-wheel:
Mini-wheel, de-
scription, page
5:5
and menu
components
R 8250 3 1 2 Mini-wheel channel 2 Mini-wheel not Check cabling between the R8250-2 5.2 Power As- Mini-wheel, de-
(R8250-2), high signal working. control unit and the compo- D7901/C1:38 sisted 3/XX DI- scription, page
voltage. nent with diagnostic menu. AGNOSE, 5:5
Check the potentiometer. page 8:47
R 8250 4 1 2 Mini-wheel channel 2 Mini-wheel not Check cabling between the R8250-2 5.2 Power As- Mini-wheel, de-
(R8250-2), low signal working. control unit and the compo- D7901/C1:38 sisted 3/XX DI- scription, page
voltage. nent with diagnostic menu. AGNOSE, 5:5
Check the potentiometer. page 8:47
H 8500 6 1 Horn (H8500), short cir- Horn not working. Check cabling between the H8500-1 9.7 Signalling Horn, descrip-
cuit to ground. control unit and the compo- D7901/C2:12 Sys 1/XX DI- tion, page 9:81
K 8881 6 1 Relay heater rear win- Rear window heat- Check cabling between the K8881 9.9 Glass Wind Rear window,
dow (K8881), short cir- er not working. control unit and the compo- D7901/C2:6 Mirr 2/XX DI- description,
cuit to ground. nent with diagnostic menu. AGNOSE, page 9:98
D 9001 31 1 VDI, communication VDI not working. Check cabling between the D9001 11.6 Communi- Communica-
error. control unit and the compo- cation 12/XX tion with the
nent with diagnostic menu. DIAGNOSE, machine, de-
11:54
H 9003 5 7 Buzzer, automatic Buzzer for auto- Check cabling between the H9003 7.5 Spreading Buzzer auto-
spreading 20'-40', open matic spreading not control unit and the compo- D7911/C1:43 16/XX DIAG- matic spread-
circuit working. nent with diagnostic menu. NOSE, page ing 20'-40',
Check the component. 8:63 description,
page 7:84

H 9003 6 7 Buzzer automatic Buzzer for auto- Check cabling between the H9003 7.5 Spreading Buzzer auto-
spreading 20'-40', short matic spreading not control unit and the compo- D7911/C1:43 16/XX DIAG- matic spread-
circuit to ground. working. nent with diagnostic menu. NOSE, page ing 20'-40',
8:63 description,
page 7:84
G 9023 0 1 BMS switches off the Battery contactor Allow the battery to cool
system without permis- open. No power. down.
sion from VMU. Battery
temperature is above
the configured shut-off
level within the interval
60 to 70 °C. (standard
threshold value 65 °C).
VDRG09.01GB
D:227
and menu
components
VDRG09.01GB
G 9023 1 1 Battery temperature is Battery contactor Warm up the battery.
below the configured open. No power.
shut-off level. State of
Charge (SoC) is within
the interval -6 to -3 °C
(standard threshold val-
ue -5 °C). Operating po-
sition is within the
interval -16 to -10 °C
ue -15 °C).
G 9023 2 1 The temperature sensor Contact Cargotec support.
in the battery module
registers temperatures
above 250 °C or lower
than -100 °C.
G 9023 15 1 Battery temperature is Speed limitation. Allow the battery to cool
above the configured down.
warning level that is
60 °C (standard thresh-
old value 55 °C).
G 9023 16 1 Battery temperature is Battery contactor Allow the battery to cool
above the configured open. No power. down.

alarm level within the in-
terval 60 to 65 °C.

ue 65 °C).
G 9023 17 1 Battery temperature is Speed limitation. Warm up the battery.
below configured warn-
ing level. State of
the interval 1 to 9 °C
ue 2 °C). Operating po-
interval -6 to 1 °C
ue -5 °C).
and menu
components
G 9023 18 1 Battery temperature is Battery contactor Warm up the battery.
below the configured open. No power.
shut-off level. State of
the interval -2 to 2 °C
ue 0 °C). Operating po-
interval -12 to -5 °C
ue -11 °C).
D 9130 13 2 Sensor tyre pressure Tyre pressure mon- Repeat the calibration of the D9130 6.3 Tyres and Tyre pressure
monitoring system, cali- itoring not working. sensors, see Maintenance Rims 6/XX Di- monitoring, de-
bration error. manual agnose, page scription, page
8:51 6:25
D 9130 14 2 1 Sensor tyre pressure left Tyre pressure mon- Check the component. D9130-1 6.3 Tyres and Tyre pressure
front outer (D9130-1), itoring for the wheel Repeat the calibration of the Rims 1/XX Di- monitoring, de-
no contact with the not working. sensors, see Maintenance agnose, page scription, page
sensor manual 8:49 6:25
front inner (D9130-1), itoring for the wheel Repeat the calibration of the Rims 2/XX Di- monitoring, de-
no contact with the not working. sensors, see Maintenance agnose, page scription, page
D 9130 14 2 3 Sensor tyre pressure Tyre pressure mon- Check the component. D9130-3 6.3 Tyres and Tyre pressure
right front inner (D9130- itoring for the wheel Repeat the calibration of the Rims 3/XX Di- monitoring, de-
1), no contact with the not working. sensors, see Maintenance agnose, page scription, page

right front outer (D9130- itoring for the wheel Repeat the calibration of the Rims 4/XX Di- monitoring, de-
1), no contact with the not working. sensors, see Maintenance agnose, page scription, page
right rear (D9130-1), no itoring for the wheel Repeat the calibration of the Rims 5/XX Di- monitoring, de-
contact with the sensor not working. sensors, see Maintenance agnose, page scription, page
manual 8:51 6:25
rear (D9130-1), no con- itoring for the wheel Repeat the calibration of the Rims 6/XX Di- monitoring, de-
tact with the sensor not working. sensors, see Maintenance agnose, page scription, page
manual 8:51 6:25
VDRG09.01GB
D:229
and menu
components
VDRG09.01GB
D 9130 31 2 Sensor tyre pressure Tyre pressure mon- Check the component. D9130 6.3 Tyres and Tyre pressure
monitoring system com- itoring not working. Repeat the calibration of the D7971/C1:31 Rims 6/XX Di- monitoring, de-
munication error. sensors, see Maintenance D7971/C1:32 agnose, page scription, page
manual 8:51 6:25
A 9150 31 1 Kalmar MTU (Machine Does not affect the Check cabling between the D9150 11.6 Communi- Communica-
Telematic Unit), commu- machine's function- control unit and the compo- cation 11/XX tion with the
nication error. ality but no ma- nent with diagnostic menu. DIAGNOSE, machine, de-
chine data is sent Check the component. page 8:163 scription, page
to Insight. 11.6 Communi- 11:54
MTU is also re- cation 12/XX
quired for VGM DIAGNOSE,
(Verified Gross page 8:163
Mass) when you 11.6 Communi-
want to use key- cation 13/XX
board and printer. DIAGNOSE,
page 8:163
11.6 Communi-
cation 14/XX
DIAGNOSE,
page 8:163
A 9170 11 1 External scales, internal External scales not Check cabling between the A9170 11.6 Communi- See separate
error. working. control unit and the compo- cation 20/XX supplement.
A 9170 31 1 External scales, com- External scales not Check cabling between the A9170 11.6 Communi- See separate
munication error. working. control unit and the compo- cation 19/XX supplement.

A 9170 2 1 100 External scales, weigh- External scales not Check cabling between the A9170 11.6 Communi- See separate
ing unit attachment, working. control unit and the compo- cation 21/XX supplement.
communication error. nent with diagnostic menu. DIAGNOSE,
11.6 Communi-
cation 22/XX
DIAGNOSE,
page 8:165
11.6 Communi-
cation 23/XX
DIAGNOSE,
page 8:165
and menu
components
A 9170 2 1 110 External scales, weigh- Scales not working. Check cabling between the A9170 11.6 Communi- See separate
ing unit attachment pin control unit and the compo- cation 21/XX supplement.
0, communication error. nent with diagnostic menu. DIAGNOSE,
11.6 Communi-
cation 22/XX
DIAGNOSE,
page 8:165
11.6 Communi-
cation 23/XX
DIAGNOSE,
page 8:165
A 9170 2 1 120 External scales, weigh- Scales not working. Check cabling between the A9170 11.6 Communi- See separate
ing unit attachment pin control unit and the compo- cation 21/XX supplement.
1, communication error. nent with diagnostic menu. DIAGNOSE,
11.6 Communi-
cation 22/XX
DIAGNOSE,
page 8:165
11.6 Communi-
cation 23/XX
DIAGNOSE,
page 8:165
G 9205 0 1 The current is above Battery contactor Search for short circuit or
configured alarm level open. No power. abnormal current

G 9205 2 1 Max. current or min. cur- Contact Cargotec support.
rent reported by the bat-
tery module deviates
more than 10 A from the
average value.
G 9205 15 1 Current is above config- Speed limitation. Search for short circuit or
ured warning level for a abnormal current
configured time. consumers.
G 9205 16 1 The current is above Battery contactor Search for short circuit or
configured alarm level open. No power. abnormal current
VDRG09.01GB
D:231
and menu
components
VDRG09.01GB
A 9630 5 2 Control unit fire extin- Fire extinguishing Check cabling between the A9630 See separate
guishing system system not working. control unit and the compo- D7971/C2:26 supplement.
(A9630), open circuit. nent with diagnostic menu.
A 9630 6 2 Control unit fire extin- Fire extinguishing Check cabling between the A9630 See separate
guishing system system not working. control unit and the compo- D7971/C2:26 supplement.
(A9630), short circuit to nent with diagnostic menu.
H 9650 6 2 1 Reverse alarm (H9650) Reverse alarm not Check cabling between the H9650 9.7 Signalling Reverse alarm,
working. control unit and the compo- D7971/C1:18 Sys 5/XX DI- description,
nent with diagnostic menu. AGNOSE, page 9:82
H 9650 6 3 2 Reverse alarm (H9650– Reverse alarm front Check cabling between the H9650–2 Reverse alarm,
2) front. not working. control unit and the compo- D7972/C1:18 description,
At turnable operator's nent with diagnostic menu. page 9:82
station. Check the component.
G 9850 0 1 Cell voltage is above the Battery contactor BMS service tool is needed
configured alarm level open. No power. to find defective cell or mod-
within the interval 3.8 to ule that must be replaced.
4.0 V (standard thresh- Contact Cargotec support.
old value 4.0 V).
G 9850 1 1 Cell voltage is below the Battery contactor Charge the battery.
configured shut-off level open. No power.
within the interval 3.8 to
4.0 V (standard thresh-

old value 4.0 V).
G 9850 2 1 Voltage sensor for bat- Contact Cargotec support.
tery modules registers
error in voltage due to
poor connection of the
sensor cables.
G 9850 15 1 Cell voltage is below the Speed limitation. BMS service tool is needed
configured warning level to find defective cell or mod-
old value 3.9 V).
and menu
components
G 9850 16 1 Cell voltage is above the Battery contactor BMS service tool is needed
configured shut-off level open. No power. to find defective cell or mod-
old value 4.2 V).
G 9850 17 1 Cell voltage is below the Speed limitation. Charge the battery.
old value 2.8 V).
G 9850 18 1 Cell voltage is below the Battery contactor Charge the battery.
configured alarm level open. No power.
old value 2.3 V).
10001 54 1 Buffer overflow in error - Connect the Kalmar Service -
code issue VDI. System tool and Repair or contact
error. Cargotec support.
10001 55 1 No response to SPN re- - Connect the Kalmar Service -
quest. System error. tool and Repair or contact
Cargotec support.
10001 56 1 Execution time for node - Connect the Kalmar Service -

exceeds max. permitted tool and Repair or contact
time. Error code issue to Cargotec support.
VDI probably incorrect.

System error.
10002 14 1 Control unit KCU Speed limitation. Contact Cargotec support. D7901 11.5.3.1 KCU
(D7901), configuration control unit
numbers do not match. (D7901), page
11:27
10002 14 2 Control unit KFU Speed limitation. Contact Cargotec support. D7971 11.5.3.4 Con-
(D7971), wrong configu- trol unit KFU
ration number. (D7971), page
11:34
10002 14 3 Control unit KFU-2 Speed limitation. Contact Cargotec support. D7972 11.5.3.5 Con-
(D7972), wrong configu- trol unit KFU-2
11:36
VDRG09.01GB
D:233
and menu
components
VDRG09.01GB
10002 14 6 Control unit KAU-2 Speed limitation. Contact Cargotec support. D7912 11.5.3.9 Con-
(D7912), wrong configu- trol unit KAU-2
11:42
10002 14 7 Control unit KAU Speed limitation. Contact Cargotec support. D7911 11.5.3.8 Con-
(D7911), wrong configu- trol unit KAU
11:40
10002 14 11 Control unit KPU Speed limitation. Contact Cargotec support. D7902 11.5.3.2 KPU
(D7902), wrong configu- control unit
11:30
10002 14 12 Control unit KID Speed limitation. Contact Cargotec support. D7950 11.5.3.3 Con-
(D7950), wrong configu- trol unit, KID
11:32
10003 14 1 Control unit KCU Speed limitation. Contact Cargotec support. D7901 11.5.3.1 KCU
(D7901), wrong soft- control unit
ware version. (D7901), page
11:27
10003 14 3 Control unit KFU-2 Speed limitation. Contact Cargotec support. D7972 11.5.3.5 Con-
(D7972), wrong soft- trol unit KFU-2

11:36
10003 14 6 Control unit KAU-2 Speed limitation. Contact Cargotec support. D7912 11.5.3.9 Con-
(D7912), wrong soft- trol unit KAU-2

11:42
10003 14 7 Control unit KAU Speed limitation. Contact Cargotec support. D7911 11.5.3.8 Con-
(D7911), wrong soft- trol unit KAU
11:40
10003 14 12 Control unit KID Speed limitation. Contact Cargotec support. D7950 11.5.3.3 Con-
(D7950), wrong soft- trol unit, KID
11:32
10004 14 1 Control unit KCU Functions con- Contact Cargotec support. D7901 11.5.3.1 KCU
(D7901), set-up file nected to the KCU control unit
missing. control unit (D7901) (D7901), page
not working. 11:27
and menu
components
10004 14 2 Control unit KFU Functions con- Contact Cargotec support. D7971 11.5.3.4 Con-
(D7971), set-up file nected to the KFU trol unit KFU
not working. 11:34
10004 14 3 Control unit KFU-2 Functions con- Contact Cargotec support. D7972 11.5.3.5 Con-
(D7972), set-up file nected to Control trol unit KFU-2
missing. unit KFU-2 (D7972) (D7972), page
not working. 11:36
10004 14 6 Control unit KAU-2 Functions con- Contact Cargotec support. D7912 11.5.3.9 Con-
(D7912), set-up file nected to Control trol unit KAU-2
missing. unit KAU-2 (D7912) (D7912), page
not working. 11:42
10004 14 7 Control unit KAU Functions con- Contact Cargotec support. D7911 11.5.3.8 Con-
(D7911), set-up file nected to Control trol unit KAU
missing. unit KAU (D7911) (D7911), page
not working. 11:40
10004 14 11 Control unit KPU Functions con- Contact Cargotec support. D7902 11.5.3.2 KPU
(D7902), set-up file nected to the KPU control unit
not working. 11:30
10004 14 12 Control unit KID Display not working. Contact Cargotec support. D7950 11.5.3.3 Con-
(D7950), set-up file trol unit, KID

missing. (D7950), page
11:32
10005 14 1 1 Control unit KCU System error, ma- Contact Cargotec support. D7901 11.5.3.1 KCU

(D7901), parameter file chine not drivable. control unit
drive-train missing. (D7901), page
11:27
10005 14 2 1 Control unit KFU System error, ma- Contact Cargotec support. D7971 11.5.3.4 Con-
(D7971), parameter file chine not drivable. trol unit KFU
11:34
10005 14 2 2 Control unit KFU Scales, OLS not Contact Cargotec support. D7971 11.5.3.4 Con-
(D7971), parameter file working. trol unit KFU
load sensor missing. (D7971), page
11:34
10005 14 2 3 Control unit KFU Fuel gauge may Contact Cargotec support. D7971 11.5.3.4 Con-
(D7971), parameter file display an incorrect trol unit KFU
fuel tank missing. value. (D7971), page
11:34
VDRG09.01GB
D:235
and menu
components
VDRG09.01GB
10005 14 2 4 Control unit KFU Central lubrication Contact Cargotec support. D7971 11.5.3.4 Con-
(D7971), parameter file frame not working. trol unit KFU
central lubrication frame (D7971), page
missing. 11:34
10005 14 2 5 Control unit KFU Speedometer may Contact Cargotec support. D7971 11.5.3.4 Con-
(D7971), parameter file display an incorrect trol unit KFU
tyres front missing. value. (D7971), page
11:34
10005 14 2 6 Control unit KFU Overload system Contact Cargotec support. D7971 11.5.3.4 Con-
(D7971), parameter file not working, lifting/ trol unit KFU
overload system lowering blocked. (D7971), page
missing. 11:34
10005 14 2 7 Control unit KFU Eco Drive Mode not Contact Cargotec support. D7971 11.5.3.4 Con-
(D7971), parameter file working. trol unit KFU
Eco Drive Mode missing. (D7971), page
11:34
10005 14 3 1 Control unit KFU System error, ma- Contact Cargotec support. D7971 11.5.3.5 Con-
(D7971), parameter file chine not drivable. trol unit KFU-2
11:36
10005 14 7 4 Control unit KFU Central lubrication Contact Cargotec support. D7971 11.5.3.4 Con-
(D7971), parameter file not working. trol unit KFU
central lubrication (D7971), page

missing. 11:34
10005 14 11 1 Control unit KPU Machine not Contact Cargotec support. D7902 11.5.3.2 KPU

(D7902), parameter file drivable. control unit
11:30
10005 14 11 7 Control unit KPU Control lever not Contact Cargotec support. D7902 11.5.3.2 KPU
(D7902), parameter file working. control unit
control lever missing. (D7902), page
11:30
10005 14 12 1 Control unit KID Machine not Contact Cargotec support. D7950 11.5.3.3 Con-
(D7950), parameter file drivable. trol unit, KID
11:32
and menu
components
10101 3 1 Control unit KCU Functionality of Check fuse FA9968-RD:2. FA9968-RD:2 11.5 Distr of Ignition voltage
(D7901), high battery controls in the cab Check batteries and D7901/C2:38 Electr 1/XX DI- (15), function
voltage. may be affected. alternator. AGNOSE, description,
Check the cable harness be- page 8:137 page 11:18
tween battery and control
unit.
10101 4 1 Control unit KCU Functionality of Check fuse FA9968-RD:2. FA9968-RD:2 11.5 Distr of Ignition voltage
(D7901), low battery controls in the cab Check the cable harness be- D7901/C2:38 Electr 1/XX DI- (15), function
voltage. may be affected. tween battery and control AGNOSE, description,
unit. page 8:137 page 11:18
Check the control unit.
10102 3 1 Control unit KCU KCU control unit Check batteries and F9954:2 11.5 Distr of Ignition voltage
(D7901), high ignition (D7901) not alternator. D7901/C3:1 Electr 1/XX DI- (15), function
voltage. working. Check the cable harness be- AGNOSE, description,
tween electronic box frame page 8:137 page 11:18
and control unit.
10102 4 1 Control unit KCU KCU control unit Check fuse FA9954 2. F9954:2 11.5 Distr of Ignition voltage
(D7901), low ignition (D7901) not Check the cable harness be- D7901/C3:1 Electr 1/XX DI- (15), function
voltage. working. tween electronic box frame AGNOSE, description,
and control unit. page 8:137 page 11:18
10102 4 1 1 Control unit KEM Control unit KEM Check fuse F9958-BK:5. F9958-BK:5 11.5 Distr of Ignition voltage
(A7991), low ignition (A7991) not Check the cable harness be- A7991/C1:2 Electr 47/XX (15), function
voltage. working. tween electronic box frame DIAGNOSE, description,

and control unit. page 8:148 page 11:18
10102 3 2 Control unit KFU Control unit KFU Check batteries and F9954-1:3 11.5 Distr of Ignition voltage

and control unit.
10102 4 2 Control unit KFU Control unit KFU Check the cable harness be- F9954-1:3 11.5 Distr of Ignition voltage
(D7971), low ignition (D7971) not tween electronic box frame D7971/C3:1 Electr 4/XX DI- (15), function
voltage. working. and control unit. AGNOSE, description,
page 8:137 page 11:18
10102 5 2 2 Control unit KFU Engine cannot be Check cable harness be- D7940 11.9 I/O D7971 Ignition voltage
(D7971), ignition voltage started. tween control unit and D7971/C1:49 KFU 1–75/XX (15), function
to Control unit engine, engine. DIAGNOSE, description,
short circuit to ground. Check the control unit. page 8:167 page 11:18
10102 6 2 2 Control unit KFU Engine cannot be Check cable harness be- D7940 11.9 I/O D7971 Ignition voltage
(D7971), ignition voltage started. tween control unit and D7971/C1:49 KFU 1–75/XX (15), function
to Control unit engine, engine. DIAGNOSE, description,
VDRG09.01GB
D:237
short circuit to ground. Check the control unit. page 8:167 page 11:18
and menu
components
VDRG09.01GB
10102 3 3 Control unit KFU-2 Control unit KFU-2 Check batteries and F9954-1:3 11.5 Distr of Ignition voltage
and control unit.
10102 4 3 Control unit KFU-2 Control unit KFU-2 Check the cable harness be- F9954-1:3 11.5 Distr of Ignition voltage
(D7972), low ignition (D7972) not tween electronic box frame D7972/C3:1 Electr 7/XX DI- (15), function
voltage. working. and control unit. AGNOSE, description,
page 8:138 page 11:18
10102 3 6 Control unit KAU-2 Control unit KAU-2 Check batteries and F9954-1:3 11.5 Distr of Ignition voltage
(D7912), high ignition (D7912) not alternator. D7912/C3:1 Electr 10/XX (15), function
voltage. working. Check the cable harness be- DIAGNOSE, description,
and control unit.
10102 4 6 Control unit KAU-2 Control unit KAU-2 Check the cable harness be- F9954-1:3 11.5 Distr of Ignition voltage
(D7912), low ignition (D7912) not tween electronic box frame D7912/C3:1 Electr 10/XX (15), function
voltage. working. and control unit. DIAGNOSE, description,
page 8:139 page 11:18
10102 3 7 Control unit KAU Control unit KAU Check batteries and F9954-1:3 11.5 Distr of Ignition voltage
and control unit.

10102 4 7 Control unit KAU Control unit KAU Check the cable harness be- F9954-1:3 11.5 Distr of Ignition voltage

page 8:140 page 11:18
10102 4 7 1 Control unit KEM-2 Control unit KEM-2 Check the cable harness be- F9954-1:3 11.5 Distr of Ignition voltage
(A7992), low ignition (A7992), not tween electronic box frame D7911/C1:2 Electr 48/XX (15), function
page 8:148 page 11:18
10102 4 7 2 Control unit KEM-3 Control unit KEM-3 Check the cable harness be- F9954-1:3 11.5 Distr of Ignition voltage
(A7993), low ignition (A7993), not tween electronic box frame D7911/C1:2 Electr 49/XX (15), function
page 8:149 page 11:18
10102 3 11 Control unit KPU KPU control unit Check batteries and F9968-BK:1 11.5 Distr of Ignition voltage
and control unit.
and menu
components
10102 4 11 Control unit KPU KPU control unit Check the cable harness be- F9968-BK:1 11.5 Distr of Ignition voltage
page 8:140 page 11:18
10102 3 12 Control unit KID KID control unit Check batteries and F9968-BK:1 11.5 Distr of Ignition voltage
and control unit.
10102 4 12 Control unit KID KID control unit Check the cable harness be- F9968-BK:1 11.5 Distr of Ignition voltage
page 8:142 page 11:18
10103 6 1 Control unit KCU No control units Check the cable harness be- D7901/C2:35 11.5 Distr of Redundant
(D7901), redundant volt- working. tween Control unit KCU Electr 2/XX DI- voltage feed of
age feed from control (D7901) and other units. AGNOSE, control units,
units, short circuit to page 8:137 function de-
ground. scription, page
11:16
10103 3 2 Control unit KFU Control unit KFU Check batteries and D7901/C2:35 11.5 Distr of Redundant
(D7971), high voltage (D7971) not alternator. D7971/C1:2 Electr 4/XX DI- voltage feed of
redundant voltage feed. working. Check the cable harness be- AGNOSE, control units,
tween Control unit KFU page 8:137 function de-

(D7971) and Control unit scription, page
KCU (D7901). 11:16
10103 4 2 Control unit KFU Control unit KFU Check the cable harness be- D7901/C2:35 11.5 Distr of Redundant

(D7971), low voltage re- (D7971) not tween Control unit KFU D7971/C1:2 Electr 4/XX DI- voltage feed of
dundant voltage feed. working. (D7971) and Control unit AGNOSE, control units,
KCU (D7901). page 8:137 function de-
scription, page
11:16
10103 3 3 Control unit KFU-2 Control unit KFU-2 Check batteries and D7901/C2:35 11.5 Distr of Redundant
(D7972), high voltage (D7972) not alternator. D7912/C1:2 Electr 7/XX DI- voltage feed of
redundant voltage feed. working. Check the cable harness be- AGNOSE, control units,
tween Control unit KFU page 8:138 function de-
KCU (D7901). 11:16
VDRG09.01GB
D:239
and menu
components
VDRG09.01GB
10103 4 3 Control unit KFU-2 Control unit KFU-2 Check the cable harness be- D7901/C2:35 11.5 Distr of Redundant
(D7972), low voltage re- (D7972) not tween Control unit KFU D7912/C1:2 Electr 7/XX DI- voltage feed of
dundant voltage feed. working. (D7972) and Control unit AGNOSE, control units,
scription, page
11:16
10103 3 6 Control unit KAU-2 Control unit KAU-2 Check batteries and D7901/C2:35 11.5 Distr of Redundant
(D7912), high voltage (D7912) not alternator. D7912/C1:2 Electr 10/XX voltage feed of
redundant voltage feed. working. Check the cable harness be- DIAGNOSE, control units,
tween Control unit KAU page 8:139 function de-
KCU (D7901). 11:16
10103 4 6 Control unit KAU-2 Control unit KAU-2 Check the cable harness be- D7901/C2:35 11.5 Distr of Redundant
(D7912), low voltage re- (D7912) not tween Control unit KAU D7912/C1:2 Electr 10/XX voltage feed of
dundant voltage feed. working. (D7912) and Control unit DIAGNOSE, control units,
scription, page
11:16
10103 3 7 Control unit KAU Control unit KAU Check batteries and D7901/C2:35 11.5 Distr of Redundant
tween Control unit KAU page 8:140 function de-
KCU (D7901). 11:16

10103 4 7 Control unit KAU Control unit KAU Check the cable harness be- D7901/C2:35 11.5 Distr of Redundant
(D7911), low voltage re- (D7911) not tween Control unit KAU D7911/C1:2 Electr 13/XX voltage feed of

scription, page
11:16
10103 4 11 Control unit KPU KPU control unit Check the cable harness be- D7901/C2:35 11.5 Distr of Redundant
(D7902), low voltage re- (D7902) not tween KPU control unit and D7902/C1:7 Electr 16/XX voltage feed of
dundant voltage feed. working. KCU control unit. DIAGNOSE, control units,
page 8:140 function de-
scription, page
11:16
10103 3 12 Control unit KID KID control unit Check batteries and D7901/C2:35 11.5 Distr of Redundant
tween Control unit KID page 8:142 function de-
KCU (D7901). 11:16
and menu
components
10103 4 12 Control unit KID KID control unit Check the cable harness be- D7901/C2:35 11.5 Distr of Redundant
(D7950), low voltage re- (D7950) not tween Control unit KID D7950/C1:9 Electr 23/XX voltage feed of
scription, page
11:16
10104 0 1 5 V Reference voltage Analogue controls Check cabling between the D7901/C1:8 11.5 Distr of 11.5.3.1 KCU
Control unit KCU in cab not working control unit and the compo- A3720-1:4, Electr 1/XX DI- control unit
(D7901), above 5.1 V. (mini-wheel/steer- nent with diagnostic menu. R8250-1/RD, AGNOSE, (D7901), page
ing lever and con- Check the component. Y6720/10, page 8:137 11:27
trols for air Y6730/10
conditioning).
(D7901), below 4.9 V. (mini-wheel/steer- nent with diagnostic menu. R8250-1/RD, AGNOSE, (D7901), page
conditioning).
(D7901), above 4.5 V. (mini-wheel/steer- nent with diagnostic menu. R8250-1/RD, AGNOSE, (D7901), page
conditioning).

(D7901), below 4.5 V. (mini-wheel/steer- nent with diagnostic menu. R8250-1/RD, AGNOSE, (D7901), page
conditioning).
10104 3 1 1 5 V Reference voltage Transmission fan Check cabling between the A7991/C1:8
Control unit KEM not working. control unit and the compo-
(A7991), above 5.1 V. nent with diagnostic menu.
10104 4 1 1 5 V Reference voltage Transmission fan Check cabling between the A7991/C1:8
Control unit KEM not working. control unit and the compo-
(A7991), below 4.9 V. nent with diagnostic menu.
VDRG09.01GB
D:241
and menu
components
VDRG09.01GB
10104 0 2 5 V Reference voltage Sensor for pressure Check cabling between the D7971/C1:8 11.5 Distr of 11.5.3.4 Con-
Control unit KFU lift cylinder, boom control unit and the compo- B2020/1, Electr 4/XX DI- trol unit KFU
(D7971), above 5.1 V. angle, boom length, nent with diagnostic menu. B7228/1 AGNOSE, (D7971), page
fuel level, brake Check component. B7235-LE/1, page 8:137 11:34
pressure, accumu- B7235-RI/1,
lator pressure and B7226-1/2,
parking brake not B7226-2/2,
working. B7226-3/2,
B7238/2,
B7245-LE/1,
B7245-RI/1.
B7570, B7681/
2, B7683/2,
(D7971), below 4.9 V. angle, boom length, nent with diagnostic menu. B7228/1 AGNOSE, (D7971), page
working. B7226-3/2,
B7238/2,
B7245-LE/1,
B7245-RI/1.
B7570, B7681/
2, B7683/2,

(D7971), above 4.5 V. angle, boom length, nent with diagnostic menu. B7228/1 AGNOSE, (D7971), page
working. B7226-3/2,
B7238/2,
B7245-LE/1,
B7245-RI/1.
B7570, B7681/
2, B7683/2,
and menu
components
(D7971), below 4.5 V. angle, boom length, nent with diagnostic menu. B7228/1 AGNOSE, (D7971), page
working. B7226-3/2,
B7238/2,
B7245-LE/1,
B7245-RI/1.
B7570, B7681/
2, B7683/2,
(D7971), redundant angle, boom length, nent with diagnostic menu. B7228/1 AGNOSE, (D7971), page
unsynchronised. fuel level, brake Check component. B7235-LE/1, page 8:137 11:34
working. B7226-3/2,
B7238/2,
B7245-LE/1,
B7245-RI/1.
B7570, B7681/
2, B7683/2,
10104 3 3 5 V Reference voltage Sensors connected Check the cable harness at D7972/C1:8 11.5 Distr of 11.5.3.5 Con-
Control unit KFU-2 to the control unit the control unit. Electr 7/XX DI- trol unit KFU-2

(D7972), above 5.1 V. provide incorrect AGNOSE, (D7972), page
signal page 8:138 11:36
Control unit KFU-2 to the control unit the control unit. Electr 7/XX DI- trol unit KFU-2
(D7972), below 4.9 V. provide incorrect AGNOSE, (D7972), page
Control unit KAU-2 to the control unit the control unit. Electr 10/XX trol unit KAU-2
(D7912), above 5.1 V. provide incorrect DIAGNOSE, (D7912), page
Control unit KAU-2 to the control unit the control unit. Electr 10/XX trol unit KAU-2
(D7912), below 4.9 V. provide incorrect DIAGNOSE, (D7912), page
VDRG09.01GB
D:243
and menu
components
VDRG09.01GB
Control unit KAU to the control unit the control unit. Electr 13/XX trol unit KAU
(D7911), above 5.1 V. provide incorrect DIAGNOSE, (D7911), page
10104 3 7 1 5 V Reference voltage Sensors connected Check the cable harness at D7911/C1:8 11.5 Distr of
Control unit KEM-2 to the control unit the control unit. Electr 48/XX
(A7992), above 5.1 V. provide incorrect DIAGNOSE,
signal page 8:148
(A7993), above 5.1 V. provide incorrect DIAGNOSE,
signal page 8:149
Control unit KAU to the control unit the control unit. Electr 13/XX trol unit KAU
(D7911), below 4.9 V. provide incorrect DIAGNOSE, (D7911), page
(A7992), below 4.9 V. provide incorrect DIAGNOSE,
signal page 8:148
(A7993), below 4.9 V. provide incorrect DIAGNOSE,
signal page 8:159
10104 1 11 5 V Reference voltage Steering panel up/ Check cabling between the D7902/C2:1 11.5 Distr of 11.5.3.2 KPU

Control unit KPU down, right instru- control unit and the compo- M6941/10, Electr 17/XX control unit
(D7902), above 5.1 V. ment up/down and nent with diagnostic menu. M6942/10, DIAGNOSE, (D7902), page
forward/back do not Check component. M6943/10 page 8:141 11:30
work.
(D7902), below 4.9 V. ment up/down and nent with diagnostic menu. M6942/10, DIAGNOSE, (D7902), page
work.
(D7902), above 4.5 V. ment up/down and nent with diagnostic menu. M6942/10, DIAGNOSE, (D7902), page
work.
and menu
components
(D7902), below 4.5 V. ment up/down and nent with diagnostic menu. M6942/10, DIAGNOSE, (D7902), page
work.
10104 3 11 1 5 V Reference voltage Switches and con- Check cabling between the D7902/C6:1 11.5 Distr of Cab overview,
from Control unit KPU trols on the steering control unit and the compo- A3700/1 Electr 18/XX page 9:5
(D7902) to steering panel do not work. nent with diagnostic menu. DIAGNOSE,
wheel panel (panel for Check component. page 8:141
wipers and drive-train),
above 5.1 V.
10104 4 11 1 5 V Reference voltage Switches and con- Check cabling between the D7902/C6:1, 11.5 Distr of Cab overview,
from Control unit KPU trols on the steering control unit and the compo- D7902/C7:01, Electr 18/XX page 9:5
(D7902) to steering panel do not work. nent with diagnostic menu. D7902/C9:01 DIAGNOSE,
wheel panel (panel for Check component. A3700/1 page 8:141
wipers and drive-train),
below 4.9 V.
10104 6 11 2 Background lighting The lighting in the Check cabling between the D7902/C6:18, Cab overview,
steering wheel panel steering panel does control unit and the compo- D7902/C7:20, page 9:5
(panel for wipers and not illuminate. nent with diagnostic menu. D7902/C7:22
drive-train), short circuit Check component. A3700/1
to ground.
10104 6 11 3 Function lighting steer- The function light- Check cabling between the D7902/C6:19, Cab overview,
ing wheel panel (panel ing in the steering control unit and the compo- D7902/C7:21, page 9:5
for wipers and drive- panel does not nent with diagnostic menu. D7902/C7:23
train), short circuit to illuminate. Check component. A3700/1
ground.

10104 3 12 5 V Reference voltage Control wheel panel Check cabling between the D7950/C1:8 11.5 Distr of 11.5.3.3 Con-
Control unit KID does not work. control unit and the compo- S1017/2 Electr 23/XX trol unit, KID
(D7950), below 4.9 V. nent with diagnostic menu. DIAGNOSE, (D7950), page
Check component. page 8:142 11:32
10104 4 12 5 V Reference voltage Control wheel panel Check cabling between the D7950/C1:8 11.5 Distr of 11.5.3.3 Con-
from Control unit KID does not work. control unit and the compo- S1017/2 Electr 23/XX trol unit, KID
(D7950), above 5.1 V. nent with diagnostic menu. DIAGNOSE, (D7950), page
VDRG09.01GB
D:245
and menu
components
VDRG09.01GB
10105 2 2 1 Control unit KFU Lift, lower, boom in Check cabling between the D7971/C1:10 11.5 Distr of 11.5.3.4 Con-
(D7971) reference and boom out not control unit and the compo- Y6004/2, Electr 28/XX trol unit KFU
ground 1, loose working. nent with diagnostic menu. Y6005/2, DIAGNOSE, (D7971), page
connection. Check component. Y6006/2, page 8:143 11:34
Y6007/2,
Y6045-LE,
Y6045-RI
ground 1, open circuit. working. nent with diagnostic menu. Y6005/2, DIAGNOSE, (D7971), page
Check component. Y6006/2, page 8:143 11:34
Y6007/2,
Y6045-LE,
Y6045-RI
ground 1, high current. working. nent with diagnostic menu. Y6005/2, DIAGNOSE, (D7971), page
Check component. Y6006/2, page 8:143 11:34
Y6007/2,
Y6045-LE,
Y6045-RI
10105 2 2 2 Control unit KFU Boom in, regenera- Check cabling between the D7971/C1:30 11.5 Distr of 11.5.3.4 Con-
(D7971) reference tion boom out and control unit and the compo- Y6051-1/2, Electr 29/XX trol unit KFU
ground 2, loose cab movement not nent with diagnostic menu. Y6050/2, DIAGNOSE, (D7971), page
connection. working. Check component. Y6016/2, page 8:144 11:34
Y6017/2

ground 2, open circuit. cab movement not nent with diagnostic menu. Y6050/2, DIAGNOSE, (D7971), page
working. Check component. Y6016/2, page 8:144 11:34
Y6017/2
ground 2, high current. cab movement not nent with diagnostic menu. Y6050/2, DIAGNOSE, (D7971), page
working. Check component. Y6016/2, page 8:144 11:34
Y6017/2
10105 2 3 1 Control unit KFU-2 Support jacks do Check cabling between the D7972/C1:10 11.5 Distr of 11.5.3.5 Con-
(D7972) reference not work. control unit and the compo- Y6063/2, Electr 33/XX trol unit KFU-2
ground 1, loose nent with diagnostic menu. Y6064/2 DIAGNOSE, (D7972), page
connection. Check component. page 8:145 11:36
and menu
components
ground 1, open circuit. nent with diagnostic menu. Y6064/2 DIAGNOSE, (D7972), page
ground 1, high current. nent with diagnostic menu. Y6064/2 DIAGNOSE, (D7972), page
10105 2 3 2 Control unit KFU-2 No limitation. Check cabling between the D79712C1:30 11.5 Distr of 11.5.3.5 Con-
(D7972) reference control unit and the compo- Electr 34/XX trol unit KFU-2
ground 2, loose nent with diagnostic menu. DIAGNOSE, (D7972), page
connection. Check component. page 8:145 11:36
10105 5 3 2 Control unit KFU-2 No limitation. Check cabling between the D7972/C1:30 11.5 Distr of 11.5.3.5 Con-
ground 2, open circuit. nent with diagnostic menu. DIAGNOSE, (D7972), page
10105 6 3 2 Control unit KFU-2 No limitation. Check cabling between the D7972/C1:30 11.5 Distr of 11.5.3.5 Con-
ground 2, high current. nent with diagnostic menu. DIAGNOSE, (D7972), page
10105 2 6 Control unit KAU-2 No limitation. Check cabling between the D7912/C2:35 11.12 I/O 11.5.3.9 Con-
(D7912) reference control unit and the compo- D7912 KAU2 trol unit KAU-2
ground indicator lights, nent with diagnostic menu. 1–75/XX DIAG- (D7912), page
loose contact. Check component. NOSE, page 11:42
8:167

10105 6 6 Control unit KAU-2 No limitation. Check cabling between the D7912/C2:35 11.12 I/O 11.5.3.9 Con-
(D7912) reference control unit and the compo- D7912 KAU2 trol unit KAU-2
ground indicator lights, nent with diagnostic menu. 1–75/XX DIAG- (D7912), page
high current. Check component. NOSE, page 11:42
8:167
10105 2 6 1 Control unit KAU-2 Lift legs left side not Check cabling between the D7912/C1:10 11.5 Distr of 11.5.3.9 Con-
(D7912) reference working. control unit and the compo- Y6056-LF/2, Electr 38/XX trol unit KAU-2
ground 1, loose nent with diagnostic menu. Y6056-LR/2, DIAGNOSE, (D7912), page
connection. Check component. Y6057-LR/2, page 8:146 11:42
Y6057-LF/2,
Y6058-LF/2,
Y6058-LR/2,
Y6059-LF/2,
Y6059-LR/2
VDRG09.01GB
D:247
and menu
components
VDRG09.01GB
ground 1, open circuit. nent with diagnostic menu. Y6056-LR/2, DIAGNOSE, (D7912), page
Check component. Y6057-LR/2, page 8:146 11:42
Y6057-LF/2,
Y6058-LF/2,
Y6058-LR/2,
Y6059-LF/2,
Y6059-LR/2
ground 1, high current. nent with diagnostic menu. Y6056-LR/2, DIAGNOSE, (D7912), page
Check component. Y6057-LR/2, page 8:146 11:42
Y6057-LF/2,
Y6058-LF/2,
Y6058-LR/2,
Y6059-LF/2,
Y6059-LR/2
10105 2 6 2 Control unit KAU-2 Lift legs right side Check cabling between the D7912/C1:30 11.5 Distr of 11.5.3.9 Con-
(D7912) reference not working. control unit and the compo- Y6056-RF/2, Electr 39/XX trol unit KAU-2
ground 2, loose nent with diagnostic menu. Y6056-RR/2, DIAGNOSE, (D7912), page
connection. Check component. Y6057-RF/2, page 8:146 11:42
Y6057-RR/2,
Y6058-RF/2,
Y6059-RF/2

ground 2, open circuit. nent with diagnostic menu. Y6056-RR/2, DIAGNOSE, (D7912), page
Check component. Y6057-RF/2, page 8:146 11:42
Y6057-RR/2,
Y6058-RF/2,
Y6059-RF/2
ground 2, high current. nent with diagnostic menu. Y6056-RR/2, DIAGNOSE, (D7912), page
Check component. Y6057-RF/2, page 8:146 11:42
Y6057-RR/2,
Y6058-RF/2,
Y6059-RF/2
and menu
components
10105 2 6 3 Control unit KAU-2 Clamping function Check cabling between the D7912/C2:37 11.5.3.9 Con-
(D7912) reference lift legs side not control unit and the compo- Y6053-LE/2, trol unit KAU-2
ground 3, loose working. nent with diagnostic menu. Y6053-RI/2, (D7912), page
connection. Check component. Y6054-LE/2, 11:42
Y6054-RI/2,
Y6055-LE/2,
Y6055-RI/2
10105 6 6 3 Control unit KAU-2 Clamping function Check cabling between the D7912/C2:37 11.5.3.9 Con-
(D7912) reference lift legs side not control unit and the compo- Y6053-LE/2, trol unit KAU-2
ground 3, high current. working. nent with diagnostic menu. Y6053-RI/2, (D7912), page
Check component. Y6054-LE/2, 11:42
Y6054-RI/2,
Y6055-LE/2,
Y6055-RI/2
10105 2 7 1 Control unit KAU Side shift, spread- Check cabling between the D7971/C1:10 11.5 Distr of 11.5.3.8 Con-
(D7911) reference ing, rotation, con- control unit and the compo- Y6020/2, Electr 43/XX trol unit KAU
ground 1, loose trollable tilt, nent with diagnostic menu. Y6012/2, DIAGNOSE, (D7911), page
connection. hydraulic levelling, Check component. Y6018/2, page 8:147 11:40
twistlock not Y6019/2,
working. Y6008/2,
Y6009/2,
Y6010/2,
Y6011/2,
Y6035/2,
Y6036/2,
Y6039/2,
Y6040/2,

ground 1, open circuit. trollable tilt, nent with diagnostic menu. Y6012/2, DIAGNOSE, (D7911), page
hydraulic levelling, Check component. Y6018/2, page 8:147 11:40
working. Y6008/2,
Y6009/2,
Y6010/2,
Y6011/2,
Y6035/2,
Y6036/2,
Y6039/2,
Y6040/2,
VDRG09.01GB
D:249
and menu
components
VDRG09.01GB
ground 1, high current. trollable tilt, nent with diagnostic menu. Y6012/2, DIAGNOSE, (D7911), page
hydraulic levelling, Check component. Y6018/2, page 8:147 11:40
working. Y6008/2,
Y6009/2,
Y6010/2,
Y6011/2,
Y6035/2,
Y6036/2,
Y6039/2,
Y6040/2,
10105 2 7 2 Control unit KAU Lift legs right side, Check cabling between the D7971/C1:30 11.5 Distr of 11.5.3.8 Con-
(D7911) reference not working. control unit and the compo- H5780-LE/2, Electr 44/XX trol unit KAU
ground 2, loose nent with diagnostic menu. H578-RI/2, DIAGNOSE, (D7911), page
connection. Check component. H5760/2, page 8:147 11:40
Y6061-RR/2,
Y6013-RR/2,
Y6065/2,
Y6058-RR/2,
Y6059-RR/2
ground 2, open circuit. nent with diagnostic menu. H578-RI/2, DIAGNOSE, (D7911), page
Check component. H5760/2, page 8:147 11:40
Y6061-RR/2,
Y6013-RR/2,

Y6065/2,
Y6058-RR/2,
Y6059-RR/2
ground 2, high current. nent with diagnostic menu. H578-RI/2, DIAGNOSE, (D7911), page
Check component. H5760/2, page 8:147 11:40
Y6061-RR/2,
Y6013-RR/2,
Y6065/2,
Y6058-RR/2,
Y6059-RR/2
and menu
components
10105 2 7 3 Control unit KAU The indicator lights Check cabling between the D7971/C2:35 11.5.3.8 Con-
(D7911) reference on the boom are control unit and the compo- H5620-1/2, trol unit KAU
ground 3, loose not working. nent with diagnostic menu. H5630-1/2, (D7911), page
connection. Check component. H5640-1/2, 11:40
H5001-1/2
10105 6 7 3 Control unit KAU The indicator lights Check cabling between the D7971/C2:35 11.5.3.8 Con-
(D7911) reference on the boom are control unit and the compo- H5620-1/2, trol unit KAU
ground 3, high current. not working. nent with diagnostic menu. H5630-1/2, (D7911), page
Check component. H5640-1/2, 11:40
H5001-1/2
10105 5 7 2 Control unit KEM-3 WTP not working. Check cabling between the A7993/C2:9 7.9 Load Car-
(A7993) reference control unit and the compo- Y6046-1 rier 130/XX DI-
ground, open circuit. nent with diagnostic menu. Y6046-2 AGNOSE,
Check component. page 8:95
10105 6 7 2 Control unit KEM-3 WTP not working. Check cabling between the A7993/C2:9 7.9 Load Car-
(A7993) reference control unit and the compo- Y6046-1 rier 130/XX DI-
ground, high current. nent with diagnostic menu. Y6046-2 AGNOSE,
10106 6 1 24 V voltage feed mini- Mini-wheel/joystick Check cabling between the D7901/C2:5 11.5 Distr of Mini-wheel, de-
wheel/joystick control, control do not work. control unit and the compo- S1130/1, Electr 3/XX DI- scription, page
short circuit to ground. nent with diagnostic menu. S1310-3/+, AGNOSE, 5:5
Check component. S1992/1, page 8:137 Joystick, de-
S1470/2. scription, page

B7250/1, 5:6
M6501-LE/53a,
M6501-RI/53a,
M6502/53a,

M6503/53a,
B2190/1,
B2460/1
10106 5 2 1 24 V voltage feed sen- Central lubrication Check cabling between the D7971/C2/32 11.5 Distr of
sor frame, short circuit frame and start in- control unit and the compo- B7242/BN Electr 5/XX DI-
to ground. terlock for engine nent with diagnostic menu. AGNOSE,
heater not working. Check component. page 8:138
10106 6 2 1 24 V voltage feed sen- Central lubrication Check cabling between the D7971/C2/32 11.5 Distr of
sor frame, short circuit frame and start in- control unit and the compo- B7242/BN Electr 5/XX DI-
to ground. terlock for engine nent with diagnostic menu. AGNOSE,
heater not working. Check component. page 8:138
VDRG09.01GB
D:251
and menu
components
VDRG09.01GB
10106 5 2 2 24 V voltage feed sen- - Check cabling between the D7971/C2:33 11.5 Distr of
sor frame, short circuit control unit and the compo- - Electr 6/XX DI-
10106 6 2 2 24 V voltage feed sen- - Check cabling between the D7971/C2:33 11.5 Distr of
sor frame, short circuit control unit and the compo- - Electr 6/XX DI-
10106 6 3 1 24 V voltage feed sen- Turnable operator's Check cabling between the D7972/C2:32 11.5 Distr of -
sor turnable operator's station not working. control unit and the compo- Electr 8/XX DI-
station, short circuit to nent with diagnostic menu. AGNOSE,
ground. Check component. page 8:138
10106 6 3 2 24 V voltage feed sen- Turnable operator's Check cabling between the D7972/C2:33 11.5 Distr of -
sor turnable operator's station not working. control unit and the compo- Electr 9/XX DI-
station, short circuit to nent with diagnostic menu. AGNOSE,
10106 6 6 1 24 V voltage feed sen- Lift legs not working. Check cabling between the D7912/2:34 11.5 Distr of -
sor attachment ELME control unit and the compo- Electr 50/XX
952/953, short circuit to nent with diagnostic menu. DIAGNOSE,
10106 6 6 110 24 V voltage feed sen- Lift leg left front not Check cabling between the D7912/2:32 11.5 Distr of
sor attachment left-hand working. control unit and the compo- B7212-LE/A, Electr 11/XX
side, short circuit to nent with diagnostic menu. B7213-LF/A, DIAGNOSE,
ground. Check component. B7215-LF/A, page 8:139
B7217-LF/A,

B7219-LF/A
10106 6 6 120 24 V voltage feed sen- Lift leg right front Check cabling between the D7912/2:33 11.5 Distr of
sor attachment right- not working. control unit and the compo- B7213-RF/A, Electr 12/XX
hand side, short circuit nent with diagnostic menu. B7215-RF/A, DIAGNOSE,
to ground. Check component. B7217-RF/A, page 8:139
B7219-RF/A
10106 6 6 210 24 V voltage feed sen- Lift leg left rear not Check cabling between the D7912/2:26
sor attachment left-hand working. control unit and the compo- B7213-LR/A,
side, short circuit to nent with diagnostic menu. B7215-LR/A,
ground. Check component. B7217-LR/A,
B7219-LR/A
and menu
components
10106 6 6 220 24 V voltage feed sen- Lift leg right rear Check cabling between the D7912/2:27
sor attachment right- not working. control unit and the compo- B7212-RI/A,
hand side, short circuit nent with diagnostic menu. B7213-RF/A,
to ground. Check component. B7215-RF/A,
B7217-RF/A,
B7219-RF/A
10106 6 7 2 24 V voltage feed WTP WTP not working. Check cabling between the A7993/C2:10 7.9 Load Car-
sensor, short circuit to control unit and the compo- B7693–LF rier 133/XX DI-
ground. nent with diagnostic menu. B7693–LR AGNOSE,
Check component. B7693–RF page 8:95
B7693–RR
B7694–LF
B7694–LR
B7694–RF
B7694–RR
10106 6 7 10 24 V voltage feed sen- Twistlocks, spread- Check cabling between the D7911/2:32 11.5 Distr of
sor attachment left-hand ing stop and damp- control unit and the compo- B7202-FL/BN, Electr 14/XX
side, short circuit to ing as well as nent with diagnostic menu. B7202-RL/BN, DIAGNOSE,
ground. rotation stop not Check component. B7204-LE/BN, page 8:140
working. B7205-LE/BN,
B7225/BN,
B7690/BN,
B7770/BN
10106 6 7 20 24 V voltage feed sen- Twistlocks, spread- Check cabling between the D7911/2:33 11.5 Distr of
sor attachment right- ing stop and damp- control unit and the compo- B7202-RR, Electr 15/XX
hand side, short circuit ing as well as nent with diagnostic menu. B7202-FR/BN, DIAGNOSE,
to ground. central lubrication Check component. B7204-RI/BN, page 8:140

attachment not B7205-RI/BN,
working. B7242/BN
10106 6 7 1 24 V voltage feed sen- Attachment func- Check cabling between the D7911/2:34
sor attachment ELME, tions not working. control unit and the compo-
Check component.
10106 6 7 1 24 V voltage feed sen- Attachment func- Check cabling between the D7911/2:37
sor attachment external, tions not working. control unit and the compo-
Check component.
VDRG09.01GB
D:253
and menu
components
VDRG09.01GB
10106 6 11 1 24 V voltage feed to Switches and con- Check cabling between the D7902/C3:9 11.5 Distr of
switches and controls in trols in the cab not control unit and the compo- S1004/3, Electr 19/XX
the cab, short circuit to working. nent with diagnostic menu. S1006FR/1, DIAGNOSE,
ground. Check component. S1006R/3, page 8:141
S1006-FR/3,
S1008/3,
S1008-2/3,
S1010/3,
S1010-2/3,
S1012-2/3,
S1013/3,
S1015/3,
S1014/3,
S1023-1/3,
S1024/1,
S1031/2,
S1046/3,
S1028/3,
S1029/3,
S1037/3,
S1049/3,
S1310-2/6,
S1490/1,
S1690/3,
S1750/3,
S1751/3,
S1752/3,
S1990-1/3,
S1990-2/3,

S1990-3/3,
S1990-4/3,
S1990-5/3,
S1990-6/3,
S1990-7/3,
S2992/3,
S8150/7,
S8070-1/1,
S8070-2/1,
S8070-3/1,
S8070-4/1,
S8070-5/1,
10106 6 11 2 24V voltage feed to Bypass safety sys- Check cabling between the D7902/C4:1 11.5 Distr of
switches in the cab, tem, lock twistlocks, control unit and the compo- S1003/3, Electr 84/XX
short circuit to ground. switch off sounds in nent with diagnostic menu. S1005/3, DIAGNOSE,
cab do not work. Check component. S1047/3 page 8:157
and menu
components
10106 6 11 3 24V voltage feed to Mini-wheel/joystick Check cabling between the D7902/C5:1 11.5 Distr of
switches and controls in control, travel direc- control unit and the compo- B7700-1/BN, Electr 85/XX
the cab, short circuit to tion selector, direc- nent with diagnostic menu. B7700-2/BN, DIAGNOSE,
ground. tion indicators do Check component. S1310/1, page 8:158
not work. S1600/31,
S1600/49a
10106 6 11 4 24V voltage feed to Control breaker Check cabling between the D7902/C8:1 11.5 Distr of Control breaker
switch, control breaker cannot be control unit and the compo- S2500/1 Electr 22/XX voltage, func-
(S2500), short circuit to disengaged. nent with diagnostic menu. DIAGNOSE, tion description,
ground. Check component. page 8:142 page 11:20
10107 6 11 1 Lighting switch, short Lighting switch is Check cabling between the D7902/C3:10 8.1 Controls & Cab overview,
circuit to ground. not working. control unit and the compo- S1006R/6, Instr 3/XX DI- page 9:5
nent with diagnostic menu. S1006FR/6, AGNOSE,
Check component. S1008/6, page 8:102
S1008-2/6,
S1010/6,
S1012/6,
S1013/6,
S1028/6,
S1029/6,
S1031/6,
S1690/6,
S1750/6,
S1751/6,
S1752/6,
S1990-2/6,
S1990-5/6,
S1990-6/6,

S1990-7/6,
S2992/6
10201 35 11 RedCAN, CAN error. Speed limitation. Use diagnostic menu to find - 11.6 Communi- 11.6.2 Redun-
incorrect segment. cation 1/XX DI- dant CAN bus,
AGNOSE, page 11:50
page 8:160
11.6 Communi-
cation 6/XX DI-
AGNOSE,
page 8:161
VDRG09.01GB
D:255
and menu
components
VDRG09.01GB
10201 35 12 RedCAN, CAN error. Speed limitation. Use diagnostic menu to find - 11.6 Communi- 11.6.2 Redun-
incorrect segment. cation 1/XX DI- dant CAN bus,
AGNOSE, page 11:50
page 8:160
11.6 Communi-
cation 6/XX DI-
AGNOSE,
page 8:161
10201 40 12 Control unit KID Display not working. Troubleshooting with menu - 11.6 Communi- 11.6.2 Redun-
(D7950), has lost con- not possible. cation 8/XX DI- dant CAN bus,
tact with the CAN bus AGNOSE, page 11:50
after start-up. page 8:162
10201 41 11 RedCAN, node not Display not working. Troubleshooting with menu - 11.6 Communi- 11.6.2 Redun-
found on start. not possible. cation 8/XX DI- dant CAN bus,
AGNOSE, page 11:50
page 8:162
10201 42 12 Control unit KID No limitation. Use diagnostic menu to find - 11.6 Communi- 11.6.2 Redun-
(D7950), segment error incorrect segment. cation 6/XX DI- dant CAN bus,
redundant CAN bus nor- AGNOSE, page 11:50
mal side. page 8:161
10201 43 12 Control unit KID No limitation. Use diagnostic menu to find - 11.6 Communi- 11.6.2 Redun-
(D7950), segment error incorrect segment. cation 6/XX DI- dant CAN bus,
redundant CAN bus re- AGNOSE, page 11:50

dundant side. page 8:161
10201 44 12 Control unit KID Display not working. Use diagnostic menu to find - 11.6 Communi- 11.6.2 Redun-

(D7950), control unit in- incorrect segment. cation 2/XX DI- dant CAN bus,
correctly located on the AGNOSE, page 11:50
CAN bus. page 8:160
11.6 Communi-
cation 4/XX DI-
AGNOSE,
page 8:161
10202 35 2 CAN bus drive-train Gear selection not Check the cable harness D7971/C1:31, 11.6.3 CAN
open circuit working. and termination resistance. D7971/C1:32 bus drive-train,
Engine does not re- If the error persists, contact D7940, D7930 page 11:54
spond to com- Cargotec.
mands from the cab.
10301 2 1 Control unit KCU Memory errors can Connect the Kalmar Service D7901 11.5.3.1 KCU
(D7901) memory error disrupt machine Tool and Repair. If the error control unit
non-volatile memory. operations. persists, replace the control (D7901), page
unit. 11:27
and menu
components
10301 2 2 Control unit KFU Memory errors can Connect the Kalmar Service D7971 11.5.3.4 Con-
(D7971) memory error disrupt machine Tool and Repair. If the error trol unit KFU
unit. 11:34
10301 2 3 Control unit KFU-2 Memory errors can Connect the Kalmar Service D7972 11.5.3.5 Con-
(D7972) memory error disrupt machine Tool and Repair. If the error trol unit KFU-2
unit. 11:36
10301 2 6 Control unit KAU-2 Memory errors can Connect the Kalmar Service D7912 11.5.3.9 Con-
(D7912) memory error disrupt machine Tool and Repair. If the error trol unit KAU-2
unit. 11:42
10301 2 7 Control unit KAU Memory errors can Connect the Kalmar Service D7911 11.5.3.8 Con-
(D7911) memory error disrupt machine Tool and Repair. If the error trol unit KAU
unit. 11:40
10301 2 11 Control unit KPU Memory errors can Connect the Kalmar Service D7902 11.5.3.2 KPU
(D7902) memory error disrupt machine Tool and Repair. If the error control unit
unit. 11:30
10301 2 12 Control unit KID Memory errors can Connect the Kalmar Service D7950 11.5.3.3 Con-
(D7950) memory error disrupt machine Tool and Repair. If the error trol unit, KID

unit. 11:32
10302 2 2 Control unit KFU Memory errors can Connect the Kalmar Service D7971 11.5.3.4 Con-
(D7971), application log. disrupt machine Tool and Repair. If the error trol unit KFU

operations. persists, replace the control (D7971), page
unit. 11:34
10302 2 3 Control unit KFU-2 Memory errors can Connect the Kalmar Service D7972 11.5.3.5 Con-
(D7972), application log. disrupt machine Tool and Repair. If the error trol unit KFU-2
unit. 11:36
10302 2 6 Control unit KAU-2 Memory errors can Connect the Kalmar Service D7912 11.5.3.9 Con-
(D7912), application log. disrupt machine Tool and Repair. If the error trol unit KAU-2
unit. 11:42
10302 2 7 Control unit KAU Memory errors can Connect the Kalmar Service D7911 11.5.3.8 Con-
(D7911), application log. disrupt machine Tool and Repair. If the error trol unit KAU
unit. 11:40
VDRG09.01GB
D:257
and menu
components
VDRG09.01GB
10302 2 11 Control unit KPU Memory errors can Connect the Kalmar Service D7902 11.5.3.2 KPU
(D7902), application log. disrupt machine Tool and Repair. If the error control unit
unit. 11:30
10302 2 12 Control unit, KID Memory errors can Connect the Kalmar Service D7950 11.5.3.3 Con-
(D7950), application log. disrupt machine Tool and Repair. If the error trol unit, KID
unit. 11:32
10303 0 2 Control unit KFU None when the er- Clean dirt and dust from the D7971 11.5.3.4 Con-
(D7971), high tempera- ror becomes active, control unit and its immedi- trol unit KFU
ture circuit board. but may affect the ate surroundings. (D7971), page
lifespan of the con- 11:34
trol unit.
10303 0 3 Control unit KFU-2 None when the er- Clean dirt and dust from the D7972 11.5.3.5 Con-
(D7972), high tempera- ror becomes active, control unit and its immedi- trol unit KFU-2
trol unit.
10303 0 6 Control unit KAU-2 None when the er- Clean dirt and dust from the D7912 11.5.3.9 Con-
(D7912), high tempera- ror becomes active, control unit and its immedi- trol unit KAU-2
trol unit.
10303 0 7 Control unit KAU None when the er- Clean dirt and dust from the D7911 11.5.3.8 Con-
(D7911), high tempera- ror becomes active, control unit and its immedi- trol unit KAU

trol unit.
10303 0 11 Control unit KPU None when the er- Clean dirt and dust from the D7902 11.5.3.2 KPU
(D7902), high tempera- ror becomes active, control unit and its immedi- control unit
trol unit.
10303 0 12 Control unit KID None when the er- Clean dirt and dust from the D7950 11.5.3.3 Con-
(D7950), high tempera- ror becomes active, control unit and its immedi- trol unit, KID
trol unit.
and menu
components
10304 2 1 Control unit KCU Slow response on Fully de-energise the ma- D7901 11.5.3.1 KCU
(D7901), long process- machine functions. chine by switching off the control unit
ing time for programs. ignition and switching off the (D7901), page
main switch. Restart the ma- 11:27
chine. If the error persists,
contact Cargotec support.
10304 2 3 Control unit KFU Slow response on Fully de-energise the ma- D7972 11.5.3.5 Con-
(D7972), long process- machine functions. chine by switching off the trol unit KFU-2
10304 2 11 Control unit KPU Slow response on Fully de-energise the ma- D7902 11.5.3.2 KPU
(D7902), long process- machine functions. chine by switching off the control unit
10304 2 12 Control unit KID Slow response on Fully de-energise the ma- D7950 11.5.3.3 Con-
(D7950), long process- machine functions. chine by switching off the trol unit, KID

10305 6 1 Control unit KCU Fuses can blow If there are other error codes, D7901 11.5.3.1 KCU
(D7901), high power and functionality check these first. control unit

consumption. can be lost. Check the wiring. (D7901), page
11:27
10305 6 2 Control unit KFU Fuses can blow If there are other error codes, D7971 11.5.3.4 Con-
(D7971), high power and functionality check these first. trol unit KFU
11:34
10305 6 3 Control unit KFU-2 Fuses can blow If there are other error codes, D7972 11.5.3.5 Con-
(D7972), high power and functionality check these first. trol unit KFU-2
11:36
10305 6 6 Control unit KAU-2 Fuses can blow If there are other error codes, D7912 11.5.3.9 Con-
(D7912), high power and functionality check these first. trol unit KAU-2
11:42
VDRG09.01GB
D:259
and menu
components
VDRG09.01GB
10305 6 7 Control unit KAU Fuses can blow If there are other error codes, D7912 11.5.3.8 Con-
(D7911), high power and functionality check these first. trol unit KAU
11:40
10305 6 11 Control unit KPU Fuses can blow If there are other error codes, D7902 11.5.3.2 KPU
(D7902), high power and functionality check these first. control unit
11:30
10305 6 12 Control unit KID Fuses can blow If there are other error codes, D7950 11.5.3.3 Con-
(D7950), high power and functionality check these first. trol unit, KID
11:32
10306 3 2 1 Control unit KFU Lift, lower extension Check the supply voltage to D7971/C1:27, 11.5 Distr of 11.5.3.4 Con-
(D7971), control breaker and cab movement the control unit, connection C1:28, C1:29, Electr 7/XX DI- trol unit KFU
voltage group 1.1 high not working. C3:1. C1:33, AGNOSE, (D7971), page
voltage. Check the wiring. page 8:138 11:34
voltage group 1.1 low not working. C3:1. C1:33, AGNOSE, (D7971), page

10306 3 2 4 Control unit KFU Mini-wheel/joystick Check the supply voltage to D7971/C1:47, 11.5 Distr of 11.5.3.4 Con-
(D7971), control breaker control do not work. the control unit, connection C1:48, C1:50 Electr 10/XX trol unit KFU
voltage group 1.4 high C3:1. DIAGNOSE, (D7971), page
and menu
components
10306 4 2 4 Control unit KFU Mini-wheel/joystick Check the supply voltage to D7971/C1:47, 11.5 Distr of 11.5.3.4 Con-
voltage group 1.4 low C3:1. DIAGNOSE, (D7971), page
10306 3 2 5 Control unit KFU Hydraulic oil cooler Check the supply voltage to D7971/C2:35, 11.5 Distr of 11.5.3.4 Con-
(D7971), control breaker fan and brake sys- the control unit, connection C2:37 Electr 11/XX trol unit KFU
voltage group 1.5 high tem oil cooler may C3:1. DIAGNOSE, (D7971), page
voltage. stop working. Check the wiring. page 8:139 11:34
10306 4 2 5 Control unit KFU Hydraulic oil cooler Check the supply voltage to D7971/C2:35, 11.5 Distr of 11.5.3.4 Con-
voltage group 1.5 low tem oil cooler may C3:1. DIAGNOSE, (D7971), page
10306 3 2 2 Control unit KFU No limitation, but Check the supply voltage to D7971/C1:47, 11.5 Distr of 11.5.3.4 Con-
(D7971), control breaker may affect the con- the control unit, connection C1:48, C1:50 Electr 26/XX trol unit KFU
voltage group 2 short trol unit's function in C3:1. DIAGNOSE, (D7971), page
circuit to voltage. the long term. Check the wiring. page 8:143 11:34
10306 3 3 1 Control unit KFU-2 All electric servo Check the supply voltage to D7972/C1:27, 11.5 Distr of 11.5.3.5 Con-
(D7972), control breaker functions may stop the control unit, connection C1:28, C1:29, Electr 26/XX trol unit KFU-2
voltage group 1.1 high working. C3:1. C1:33 DIAGNOSE, (D7972), page
(D7972), control breaker functions may stop the control unit, connection C1:29, C1:33 Electr 26/XX trol unit KFU-2
voltage group 1.1 low working. C3:1. DIAGNOSE, (D7972), page

voltage group 1.2 high working. C3:1. C1:36, C1:37 DIAGNOSE, (D7972), page
voltage group 1.2 low working. C3:1. C1:36, C1:37 DIAGNOSE, (D7972), page
VDRG09.01GB
D:261
and menu
components
VDRG09.01GB
voltage group 1.3 low working. C3:1. C1:41 DIAGNOSE, (D7972), page
10306 3 3 4 Control unit KFU-2 Mini-wheel/joystick Check the supply voltage to D7971/C1:47, 11.5 Distr of 11.5.3.4 Con-
10306 4 3 4 Control unit KFU-2 Mini-wheel/joystick Check the supply voltage to D7971/C1:47, 11.5 Distr of 11.5.3.4 Con-
10306 3 3 5 Control unit KFU-2 Hydraulic oil cooler Check the supply voltage to D7971/C2:35, 11.5 Distr of 11.5.3.4 Con-
10306 4 3 5 Control unit KFU-2 Hydraulic oil cooler Check the supply voltage to D7971/C2:35, 11.5 Distr of 11.5.3.4 Con-
10306 3 6 1 Control unit KAU-2 All electric servo Check the supply voltage to D7912/C1:27, 11.5 Distr of 11.5.3.9 Con-
(D7912), control breaker functions may stop the control unit, connection C1:29, C1:33 Electr 45/XX trol unit KAU-2
voltage group 1.1 high working. C3:1. DIAGNOSE, (D7912), page

(D7912), control breaker functions may stop the control unit, connection C1:29, C1:33 Electr 45/XX trol unit KAU-2
(D7912), control breaker functions may stop the control unit, connection C1:35, C1:36, Electr 46/XX trol unit KAU-2
and menu
components
(D7912), control breaker functions may stop the control unit, connection C1:48, C1:50 Electr 48/XX trol unit KFU
(D7912), control breaker functions may stop the control unit, connection C2:37 Electr 49/XX trol unit KFU
(D7912), control breaker functions may stop the control unit, connection C2:37 Electr 49/XX trol unit KFU
10306 3 7 1 Control unit KAU All electric servo Check the supply voltage to D7971/C1:27, 11.5 Distr of 11.5.3.4 Con-

(D7911), control breaker functions may stop the control unit, connection C1:35, C1:36, Electr 66/XX trol unit KFU
VDRG09.01GB
D:263
and menu
components
VDRG09.01GB
10306 3 7 4 Control unit KAU Mini-wheel/joystick Check the supply voltage to D7971/C1:47, 11.5 Distr of 11.5.3.4 Con-
10306 4 7 4 Control unit KAU Mini-wheel/joystick Check the supply voltage to D7971/C1:47, 11.5 Distr of 11.5.3.4 Con-
10306 3 7 5 Control unit KAU Hydraulic oil cooler Check the supply voltage to D7971/C2:35, 11.5 Distr of 11.5.3.4 Con-
10306 4 7 5 Control unit KAU Hydraulic oil cooler Check the supply voltage to D7971/C2:35, 11.5 Distr of 11.5.3.4 Con-

10307 2 1 Control unit KCU No limitation. Fully de-energise the ma- D7901 11.5.3.1 KCU
(D7901), memory error, chine by switching off the control unit
flash memory. ignition and switching off the (D7901), page
10307 2 2 Control unit KFU No limitation. Fully de-energise the ma- D7971 11.5.3.4 Con-
(D7971), memory error, chine by switching off the trol unit KFU
and menu
components
10307 2 3 Control unit KFU-2 No limitation. Fully de-energise the ma- D7972 11.5.3.5 Con-
(D7972), memory error, chine by switching off the trol unit KFU-2
10307 2 6 Control unit KAU-2 No limitation. Fully de-energise the ma- D7912 11.5.3.9 Con-
(D7912), memory error, chine by switching off the trol unit KAU-2
10307 2 7 Control unit KAU No limitation. Fully de-energise the ma- D7911 11.5.3.8 Con-
(D7911), memory error, chine by switching off the trol unit KAU
10307 2 11 Control unit KPU No limitation. Fully de-energise the ma- D7902 11.5.3.2 KPU

10307 2 12 Control unit KID No limitation. Fully de-energise the ma- D7950 11.5.3.3 Con-
(D7950), memory error, chine by switching off the trol unit, KID

RAM memory. ignition and switching off the (D7901), page
VDRG09.01GB
D:265
and menu
components
VDRG09.01GB


and menu
components
Bootloader memory. ignition and switching off the (D7901), page


VDRG09.01GB
D:267
and menu
components
VDRG09.01GB
10310 12 1 Internal error on PCB, Internal error on Fully de-energise the ma- - - -
D7902. PCB can disrupt chine by switching off the
machine operations. ignition and switching off the
main switch. Restart the ma-
replace the control unit.


and menu
components
10311 4 2 1 Control breaker voltage Breaks output Check the supply voltage to D7971/ C2:30, 11.5 Distr of 11.5.3.4 Con-
group 2.1 Control unit C2:30–31. the control unit, connection C2:31 Electr 12/XX trol unit KFU
KFU (D7971). C3:1. DIAGNOSE, (D7971), page
Check the wiring. page 8:139 11:34
10311 4 2 2 Control breaker voltage Breaks output Check the supply voltage to D7971/C1:01, 11.5 Distr of 11.5.3.4 Con-
group 2.2 Control unit C1:01, C1:43 and the control unit, connection C1:43, C2:01, Electr 13/XX trol unit KFU
KFU (D7971). C2:01-02. C3:1. C2:02 DIAGNOSE, (D7971), page
group 2.3 Control unit C1:11, C1:44 and the control unit, connection C1:44, C2:03, Electr 14/XX trol unit KFU
KFU (D7971). C2:03–04. C3:1. C2:04 DIAGNOSE, (D7971), page
group 2.4 Control unit C1:12, C1:45, the control unit, connection C1:45, C1:49, Electr 15/XX trol unit KFU
KFU (D7971). C1:49 and C2:05. C3:1. C2:05 DIAGNOSE, (D7971), page
KFU (D7971). C1:15, C1:21, C3:1. C1:21, C1:22, DIAGNOSE, (D7971), page

C1:22, C2:06 and Check the wiring. C2:06, C2:27 page 8:140 11:34
C2:27.
VDRG09.01GB
D:269
and menu
components
VDRG09.01GB
KFU (D7971). C1:20, C1:26, C3:1. C1:26, C1: 42, DIAGNOSE, (D7971), page
C1:42, C1:46, Check the wiring. C1:46, C2:26, page 8:141 11:34
C2:26, C2:32 and C2:32, C2:33
C2:33.
group 2.1 Control unit C2:30 and C2:31. the control unit, connection C2:31 Electr 31/XX trol unit KFU
KFU-2 (D7972). C3:1. DIAGNOSE, (D7971), page
KFU-2 (D7972). C2:02 and C2:03. C3:1. C2:02 DIAGNOSE, (D7971), page
KFU-2 (D7972). C1:15, C1:21, C3:1. C1:21, C1:22, DIAGNOSE, (D7971), page

C2:27.
and menu
components
KFU-2 (D7972). C1:20, C1:26, C3:1. C1:26, C1:42, DIAGNOSE, (D7971), page
C2:26, C2:32 and C2:32, C2:33
C2:33.
KAU-2 (D7912). C3:1. DIAGNOSE, (D7971), page
KAU-2 (D7912). C2:01 and C2:02. C3:1. C2:02 DIAGNOSE, (D7971), page
KAU-2 (D7912). C1:15, C1:21, C3:1. C1:21, C1:22, DIAGNOSE, (D7971), page

C2:27.
VDRG09.01GB
D:271
and menu
components
VDRG09.01GB
KAU-2 (D7912). C1:20, C1:26, C3:1. C1:26, C1:42, DIAGNOSE, (D7971), page
C2:26, C2:32 and C2:32, C2:33
C2:33.
KAU (D7911). C3:1. DIAGNOSE, (D7971), page
KAU (D7911). C2:01 and C2:02. C3:1. C2:02 DIAGNOSE, (D7971), page
KAU (D7911). C1:15, C1:21, C3:1. C1:21, C1:22, DIAGNOSE, (D7971), page

C2:27.
and menu
components
KAU (D7911). C1:20, C1:26, C3:1. C1:26, C1:42, DIAGNOSE, (D7971), page
C2:26, C2:32 and C2:32, C2:33
C2:33.

VDRG09.01GB
D:273
D:274

E:1
E Schematics
Contents E Schematics
Schematics...........................................................................................................E:3
Common hydraulics .......................................................................................... E:3
Hydraulic diagrams, compilation .................................................................. E:3
Hydraulic diagram brake system.................................................................. E:4
Hydraulic diagram, basic machine ............................................................... E:6
Hydraulic diagram top lift.............................................................................. E:8
Hydraulic diagram top lift, hydraulic levelling ............................................. E:10
Hydraulic diagram top lift, overheight-legs................................................. E:12
Hydraulic diagram combi attachment......................................................... E:14
Hydraulic diagram, spreading hydraulic cylinder ....................................... E:20
Hydraulic diagram cab movement and support jacks ................................ E:22
Common electrics ........................................................................................... E:24
Circuit diagrams, subdivision ..................................................................... E:24
Circuit diagram, description ....................................................................... E:24
Component designations ........................................................................... E:25
Circuit diagrams, compilation ..................................................................... E:26

E:2

E Schematics – Schematics E:3
E Schematics
Common hydraulics
Hydraulic diagrams, compilation
Designation Drawing number
Hydraulic diagram brake system, page E:4 A40740.1700 page 02
Hydraulic diagram, basic machine, page E:6 A40740.1700 page 01
Hydraulic diagram top lift, page E:8 A60787.0200
Hydraulic diagram top lift, hydraulic levelling, page E:10 A60787.0100
Hydraulic diagram top lift, overheight-legs, page E:12 A60787.0300
Hydraulic diagram combi attachment, page E:14 A60787.0400
Hydraulic diagram, spreading hydraulic cylinder, page E:20 A60787.0900
Hydraulic diagram cab movement and support jacks, page E:22 A60532.0400

E:4 E Schematics – Common hydraulics
Hydraulic diagram brake system
17
5
5
16
15
4
4
14
3
8
9
2
2
2
2
10
12
13
022776 (A40740.1700/02 ver 01)

1
11

E Schematics – Common hydraulics E:5
1. Brake valve
2. Accumulator brake pressure
3. Parking brake caliper
4. Brake cylinder
5. Wheel brakes
6. Drive axle block
7. Brake pressure sensor (B7681)
8. Sensor declutch
9. Sensor parking brake pressure (B7682)
10. Accumulator charging valve
11. Accumulator pressure sensor (B7683)
13. Oil filter brake system
14. Thermal bypass valve
15. Cooler brake system
16. Oil tank brake system

Hydraulic diagram, basic machine
16
15
14
10
19
17
20 18
20
11
13
21
12
16
9
23
22
24
g
11
8
10
d
5
26
25
b
4
c
a
7
6
3
27
28
2
022775 (A40740.1700 ver. 02)

29
1

1. Electric steering module

3. Control valve steering
4. Steering valve
5. Connection to attachment
6. Relief valve, attachment
7. Valve block servo pressure
a Shuttle valve. Has no function.
b Solenoid valve pump unloading (Y6093)
c Shuttle valve, lift, extension, or attachment functions
d Servo valve load signal attachment (Y6002)
e Shuttle valve, lift, extension, or support jacks
f Pressure reducer
g Restriction
8. Accumulator servo pressure
9. Servo filter
10. Lift cylinder
11. Valve block lift cylinder
12. Fine filter hydraulic oil
13. Control valve lifting/lowering and extension
14. Extension cylinder
15. Valve block extension cylinder
16. Hydraulic oil filter
17. Cooler hydraulic oil
18. Electric motor (M6680–2)
20. Hydraulic oil filter
21. Breather filter hydraulic oil tank
23. Distribution block hydraulic oil pump 2
24. Pressure limiting valve 250 Bar
29. Hydraulic oil tank

E:8
OPTION TILT AND DAMPING
P C1- C2+ C1+ C2- T

2
VDRG09.01GB
B A
1 1 4
DAMPING TURNING SIDESHIFT EXTENTION TWISTLOK

12 12
P PP T T
P C1- C2+ C1+ C2- T 9 8
3 5 5
11
B A
11
1
1
9 7 OPTION:
QUICK CONNECT
COUPLINGS
10 6 6
P PP T T
E Schematics – Common hydraulics
B A B A B A B A B A B A PS

TP
T1
Hydraulic diagram top lift
P2
T2
T3
P1 PL
13
U
LS Option P 14
Pressure sensor
for load sense control
017433 (A60787.0200 ver. 03)
1. Tilt cylinder
2. Damping block tilt (product alternative controllable tilt and tilt lock)
3. Damping block tilt

5. Twistlock cylinders
6. Quick couplings for alternative attachment function
7. Valve block spreader motor
8. Spreader motor
9. Side shift cylinders
12. Brake rotation motor unit

E:10
P C1- C2+ C1+ C2- T
VDRG09.01GB
2
B A
1 1 4
DAMPING
12 Turning 12 Sideshift Extention TWISTLOK
P PP T T 3 P C1- C2+ C1+ C2- T 9

8
11
B A 11
Pileslope
1 1
14 14
9 7 5 5
OPTION
14 10 BAYONET COUPLINGS
15 14
6
16 P PP T T
B A B A B A B A B A B A PS

TP
T1
P2
T2
T3
P1 PL
U
13
LS Option P 17
Pressure sensor
Hydraulic diagram top lift, hydraulic levelling

022475 (A60787.0100 ver. 02)
1. Tilt cylinder

6. Quick couplings for alternative attachment function
8. Spreader motor
14. Levelling cylinders
15. Valve block levelling cylinders
16. Overcentre valve levelling

E:12
VDRG09.01GB
P C1- C2+ C1+ C2- T
7 7 6
2 B A
1 1 4 6
OHC HANDLING
5
7 7
DAMPING TURNING SIDESHIFT 6

12 12
P PP T T
P C1- C2+ C1+ C2- T 11 TURNING 6
3 13 9
B A
13 10 TWISTLOCK
1
1 11
14
8 8
P PP T T
PS
B
A
B
A
B
A
B
A
B
A
B
A
TP

210 210 140 140
P
P2
P2
150
150
160
120
100
PL
T2
TX
T3 T2
T3
U
LS Option P 16
PLX
LSP
Pressure sensor 15
Hydraulic diagram top lift, overheight-legs
022476 (A60787.0300 ver 03)

1. Tilt cylinder

9. Spreader motor

Hydraulic diagram combi attachment

Part 1 of 3, top lift
020211:A 020211:B 020211:C
11
11
10
020212:A
8
8
7
12
13 12
6
14
15
12
12
1
2
020212:B
16
020210 (A60787.0400 ver 02)
020212:C

1. Tilt cylinder
10. Spreader motor
12. Levelling cylinders
13. Valve block levelling cylinders
14. Overcentre valve levelling
020211:A – Reference to diagram part 2 of 3, bottom lift right side
020211:B – Reference to diagram part 2 of 3, bottom lift right side
020211:C – Reference to diagram part 2 of 3, bottom lift right side
020212:A – Reference to diagram part 3 of 3, bottom lift left side
020212:B – Reference to diagram part 3 of 3, bottom lift left side
020212:C – Reference to diagram part 3 of 3, bottom lift left side

Part 2 of 3, bottom lift right side
020210:A
2
1
3
5
6
7
8
10
020210:B
020211 (A60787.0400 ver 02)
020210:C

1. Control valve lift legs right

2. Hydraulic cylinder leg right front
3. Overcentre valve hydraulic cylinder leg right front
4. Overcentre valve hydraulic cylinder knee right front
5. Hydraulic cylinder knee and clamp right front
6. Valve operating position right front
7. Hydraulic cylinder knee and clamp right rear
8. Overcentre valve hydraulic cylinder knee right rear
9. Overcentre valve hydraulic cylinder leg right rear
10. Hydraulic cylinder leg right rear
020210:A – Reference to diagram part 1 of 3
020210:B – Reference to diagram part 1 of 3
020210:C – Reference to diagram part 1 of 3

Part 3 of 3, bottom lift left side
1 020210:A
10
020212 (A60787.0400 ver 02)
020210:C 020210:B

1. Control valve lift legs left

2. Hydraulic cylinder leg left front
3. Overcentre valve hydraulic cylinder leg left front
4. Overcentre valve hydraulic cylinder knee left front
5. Hydraulic cylinder knee and clamp left front
6. Valve operating position left front
7. Hydraulic cylinder knee and clamp left rear
8. Overcentre valve hydraulic cylinder knee left rear
9. Overcentre valve hydraulic cylinder leg left rear
10. Hydraulic cylinder leg left rear
020210:A – Reference to diagram part 1 of 3, top lift
020210:B – Reference to diagram part 1 of 3, top lift
020210:C – Reference to diagram part 1 of 3, top lift

Hydraulic diagram, spreading hydraulic cylinder
4
4
10
5
6
6
3
7
9 9
023597 (A60787.0900 ver. 01)

2

1. Tilt cylinder
5. Spreading cylinder

E:22
7 M
6 LS SLIDING CAB
VDRG09.01GB
a P 80 bar A
B
8
T T
c b
e d
ELEVATION CAB
12 M
P A
f 75 BAR
9
ACK
11 10
T
F B
5
LS
jacks
13 M
14
A1
A2
15
X1 X1 T
P
JACKS
LS
2 4

B1 15
B1 B1
B2
14
L1 L2 S L1 L2 S
1 3
16
022212 (A60532.0400 ver. 02)
Hydraulic diagram cab movement and support

5. Shuttle valve
6. Valve block servo pressure
a Shuttle valve. Has no function.
b Solenoid valve pump unloading (Y6093)
c Shuttle valve, lift, extension, or attachment functions
d Servo valve load signal attachment (Y6002)
e Shuttle valve, lift, extension, or support jacks
f Pressure reducer
7. Control valve cab movement
8. Hydraulic motor sliding cab
9. Hydraulic cylinder cab lift
10. Load control valve
11. Accumulator
12. Control valve cab movement
13. Control valve support jacks
15. Overcentre valve

E:24 E Schematics – Common electrics
Common electrics
Circuit diagrams, subdivision
Circuit diagrams are subdivided by cab, frame and attachment. The dif-
ferent parts can cover more than one machine model, it is therefore im-
portant to be observant that certain components may not be fitted on
the current machine, the same also applies to options and variants.
Circuit diagram, description

A circuit diagram is divided into circuit names (drawing numbers) and
consists of a set of numbered pages.
The circuits and their contents are governed by the following set of
rules:
• 20015.0001 circuit drawings-post designations K-standard.
• K-standard 1: norms, rules
• K-standard 2: cables, general physical
• K-standard 5: Designation and marking system, item designations
circuit drawings
The following is an explanation of symbols and texts in a circuit
diagram:
Connectors
Connectors in the wiring start with an X followed by a number and end
-X080f -X080m with f = female or m = male. If a connector is connected to a component
0301A 1 1 then the component number is inherited into the connector's number, e.
g. XB7202FRm which is the connector for Sensor, contact right front
017472
(B7202FR).
Under the connector's number the pin is specified with numbers or let-
ters depending on the connector.
Components
+CHASSIS
Components are described with component number (S220-2) and a
-S220-2 short descriptive text. Components (sensors, switches, etc.) are shown
in standby mode i.e. de-energised mode or mechanical standby mode.
P
• S indicates the type of component, see Component designations,
1 1 2 1 page E:25.
• 220 is component number and indicates the function the compo-
013018
DECLUTCH
3,0MPa nent has.
• -2 indicates that it is the second component of this type for the spe-
cific diagram.
Cable marking
The cables are colour coded in accordance with the following: Red =
battery voltage. White = ignition voltage or signal. Black = grounding.
Cable numbering is interpreted as follows:
• 0525: the number on a cable can usually be traced to a pin in a
connector, in this example, connector X052 pin 5.
• W212: cables that start with W and serial number cannot be traced
directly to a connector.
• A01012: cables that start with A are in the electronic box in the cab.
• W212D: cables that end with a capital letter are jointed in the wiring
from a main cable with the same number. Each joint will have its
own letter.
Jointed cables are only located inside the cab, outside of the cab
the joints are routed out to a separate connector with strappings.

E Schematics – Common electrics E:25
References
An arrow symbol means that the circuit continues on another page in
the circuit diagram at the specified coordinates. Sometimes there are
also references for components that can then be part of a component
whose other parts are on a different diagram. In some cases there is al-
so a help text where the cable connects.
Example: /11.5_1.D3 means page 11.5_1 coordinate D3.
Connection to control unit
Connections to control units are described as a table with two fields;
the upper one shows the type of connection, the lower one has a refer-
ence to the compilation of the control unit's connections. Together with
this there are descriptive texts that specify control unit and signal.
For more information about the different connection types on the con-
trol units, see section 11 Common electrics, group 11.5.5 Wiring.
Fuses
Fuse boxes always start with F99. Example: F9958-RD means a fuse
box with 8 fuses for battery voltage.
For most fuse boxes there is also a table and an explanation of the cir-
cuits that the various fuses protect.
Component designations
The components in circuit diagrams have a prefix and number, the pre-
fix describes the type of component, the number which component.
Component list with component number, prefix and designation is pro-
vided as an appendix after the circuit diagrams.
Prefix Description
A Control panel Drive-train/Wiper
B Converter from non-electric to electric signals or vice versa. Example: inductive sensor.
C Capacitor
D Binary element, delay unit, memory. Example: control unit.
E White light. Example: work lighting.
F Protective device. Example: fuse.
G Alternator, power supply device. Example: battery.
H Signal device. Example: horn, brake lights.
K Relay, contactor. Example: power relay ignition key lock.
M Motor. Example: electric motor.
P Measuring instrument, testing equipment. Example: hour meter.
Q Battery disconnector
R Resistor. Example: potentiometer.
S Electric switch for control circuit, selector. Example: switch.
V Diode
W Antenna
X Outlet/socket, connecting device. Example: connection terminal.
Y Electrically controlled mechanical device. Example: solenoid valve, hydraulic valve.

E:26 E Schematics – Common electrics
Circuit diagrams, compilation

Circuit diagrams are attached as an appendix in the following order.
• A55040.1800 Circuit diagram cab
• A55039.1500 Circuit diagram frame
• A67273.0100 Circuit diagram ECO efficient
• A56400.0100 Circuit diagram attachment
• A60822.0100 Circuit diagram electric heater
• List of components

1 2 3 4 5 6 7 8
B
DCG/DRG/ A
C
ECG C
not be imparted to a third party nor be used for any
written permission and the contents thereof must
unauthorized purpose. Contravention will be pro-

This document must not be copied without our
CECS 2.0
D D
secuted.
E E
Wiring CAB
hörigen användas. Överträdelse härav beivras med
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe-
stöd av gällande lag.
F F
Benämning Produkt/Product Blad/Sheet

Ref. Nr Ändring Ändring nr Datum Sign. Datum/Date Huvudnr./Project no.
E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn MLG 171220 A55032.1800 Kretsschema DCG,DRG,ECG DCG,DRG,ECG 0 1
Name
1 Sheet 9.9_1 Updated 1036053 MLG 200122 H.Grp:
6 Ritn.nr./ Drawing No. Utgåva/Issue
R
Konstr/Design
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr

MLG 190619 Klass/Class
Wiring Diagram DCG,DRG,ECG A55040.1800 08
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A A
12/24V Climate
Door switches
A55184.1200 Wipers, washers and horn

B B
C
EL-Central Accelerator
C
Eget kablage under matta

Brake pedal
Cabin floor
New harness Lever/Micro steering

A56380.0100
D 24V Ref D7901 C2p05 D
Electric mirror switch

A55185.1200
Seat
E
Interface chassi Fuse box E
harness A55186.1100
KCU A57059.0100
Electric mirrors
Ignition
MATA MED 5:1
Electric main switch
A56629.0100 Search light A59534.0100 FNR
Gnd KID #1
F Steering sensor F
Multi light
Horn
STD harness switches Indicator
Ind Panel 24V Ref C4p01 24V REF C5p01
G
KID #2 G
Radio
A55179.0100
A55190.0100 A55180.0100
Interface right
A55183.0100 Manouver panel
H
KPU-1 Joystick/levers
H
A55181.0100
24V Ref C3p09
A55182.0100
Interior light X063 to splice in
Extra KPU
Speaker Right Manouvre switch
J
24V Ref C8p01 J
A55187.0100 Rear wiper

Layout harnesses lights roof

secuted.
K
Interior light K
Speaker Left
Wiper roof
Temp ambient
L L
A55190.0100
Interface left
All red texts are linked to docment

M Ref. Ändring
Benämning Produkt/Product Blad/Sheet M
Nr Ändring nr Datum Sign. Datum/Date Huvudnr./Project no.
Sign.
Ruta
Kablage översikt DCG/DRG/ECG DCG,DRG,ECG 0.0_0 1
E³ DRAWING
Design change
Sq.
No. Change No. Date Ritad/Drawn MLG 171220 A55032.1800
Name
1 Sheet 9.9_1 Updated 1036053 MLG 200122 Konstr/Design H.Grp:
R

Harnesses overview DCG/DRG/ECG A55040.1800 08
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
A A
-D7901
Pin Number Drawing Function Type Pin Number Drawing Function Type
1:1 /9.4_4.A2 Sw. AC pressure in range=clutch active Dig In 2:1 /7.9_2.C1 Ind. unlocked TW 0,5A / Dig in
1:2 /9.4_4.A2 Sw. AC pressure >16 bar Max fan speed Dig In 2:2 /7.9_2.D1 Ind. locked TW 0,5A / Dig in
1:3 /11.6_1.B8 CAN CAN Clamp pressure ok
B 1:4 See pin K1:3 2:3 /7.9_2.D1 Ind. alignment 0,5A / Dig in B
1:5 CAN Shield / Ana In
1:6 See pin K1:3 Tilt control
1:7 See pin K1:3 2:4 /7.9_2.B1 Ind. support jacks down 0,5A / Dig in
1:8 /11.5_5.D1 Ref Air distr. / heat valve 5V Ref 2:5 /11.5_5.B1 24V Supply Lever/Micro steering 0,5A
1:9 /11.5_5.B8 Ref Sensors 0V Ref
1 2:6 /9.5_2.B1 Double wiper front left / Single wiper front 6A
1:10 /9.5_2.B8 Double wipers front left feedback Dig In 2:7 /9.3_2.C1 Lamp fasten seat belt 1,5A
1 2:8 /9.9_2.C1 Rear window heater 1,5A
Single wiper front feedback
1:11 /9.5_2.C8 Double wiper front right feedback Dig In 2:9 /9.5_2.C1 Double wipers front right 6A
1:12 /9.5_1.B8 Wiper rear feedback Dig In 2:10 /9.5_2.E1 Motor washer double/single wipers front 3A
1:13 /9.5_1.C8 Wiper roof feedback Dig In
1:14 /9.5_1.C8 Washer fluid level switch Dig In 2:11 /11.5_1.E1 Main relay ignition K3150 1,5A
1:15 2:12 /9.7_1.D1 Horn 3A
KCU D7900-1, Main C1 connector pinout
/9.4_3.B8 Climate Air Filter Ind. Pressure Sw Dig In

1:16 Cab in upper position (tilt) Dig In 2:13 /9.7_2.B1 Rotating beacon 3A
1:17 /9.3_5.B1 Seat in driving position Dig In 2:14 /9.4_5.D1 Paus heater 3A
KCU D7900-1, Main C2 connector pinout

1:18 /5.2_2.D12 Mini/Leversteering on/off Dig In 2:15 /9.5_1.E1 Motor washer front/roof 6A
C 1:19 /5.2_2.D12 Mini/Leversteering gear forward Dig In 2:16 /9.5_1.D1 Motor washer rear 6A C
1:20 /5.2_2.E12 Mini/Leversteering gear neutral Dig In 2:17 /9.5_1.B1 Wiper rear 6A
2:18 /9.6_4.A1 Extra worklight left C 6A
1:21 /5.2_2.E12 Mini/Leversteering gear reverse Dig In 2:19 /9.5_1.C1 Wiper roof/combined front/roof 6A
1:22 /5.2_2.F12 Mini/Leversteering indicator left Dig In 2:20 /9.6_2.B1 Working light reverse left 6A
1:23 /5.2_2.F12 Mini/Leversteering indicator right Dig In
1:24 /5.2_2.E12 Mini/Leversteering aut. Head light Dig In 2:21 /9.6_2.C1 Working light reverse right 6A
1:25 /5.2_2.G12 Armrest in position Dig In 2:22 /9.6_3.A1 Extra worklight left A 6A
1:26 See pin K1:3 2:23 /9.6_3.D1 Extra worklight right B 6A
1:27 See pin K1:3 2:24 /9.4_2.A1 Air distributor valve close 3A PWM
2:25 /9.4_2.A1 Air distributor valve open 3A PWM

1:28 /9.4_2.B8 Air distributor valve Dig In / Ana In

1:29 /9.4_2.C8 Heat valve(air mix) Dig In / Ana In 2:26 /9.4_2.B1 Heat valve Close 3A PWM
1:30 /11.5_4.E7 Dig In / Ana In 2:27 /9.4_2.B1 Heat valve Open 3A PWM
2:28 /9.4_2.E1 Motor, recirculation 3A PWM
1:31 /9.10_1.E8 Cab pos (tilt) Dig In / Ana In 2:29 /9.4_2.D1 Motor, recirculation 3A PWM
1:32 /9.10_1.E8 Cab moving damp sensor / Length sensor Dig In / Ana In 2:30 /9.6_1.E1 Interior light, step light PWM
1:33 /9.4_1.C8 Temp. indoor Resistance In
D 1:34 /9.4_1.C8 Temp. fan air Resistance In 2:31 /2.1.F1 Output status FWD 0,5A / Dig In D
2:32 /2.1.F1 Output status REV 0,5A / Dig In
secuted.
1:35 /9.4_1.D8 De-icing Resistance In

1:36 /9.4_1.D8 Temp. ambient Resistance In 2:33 /5.2_2.D2 Indication Mini/Leversteering on/off 0,5A / Dig in
1:37 /5.2_2.C12 Micro/Lever-Steering sensor Ch1 Dig In / Ana In 2:34 /9.3_5.C1 Seat Unlock (TDS 15/30deg) 0,5A / Dig In
1:38 /5.2_2.C12 Micro-Steering sensor Ch2 Dig In / Ana In 2:35 /11.6_1.C7 CPU power
Buzzer (OHG) 6A Dig Out CPU Power
1:39 /8.2_1.E8 Key switch override Dig In / Ana In 2:36 /9.6_4.D1 Extra worklight right D 15A PWM
1:40 1,5A/ Dig In/ Ana In Condenser roof
2:37 /9.4_2.C1 Heating fan 15A PWM
1:41 1,5A/DigIn/Ana/Freq 2:38 /11.5_1.C4 CPU Power
1:42 1,5A/DigIn/Ana/Freq
1:43 /9.6_1.D8 Steplight Dig In Start up M5: 24V See pin K1:2
1:44 /9.4_5.B7 External heater Dig In Start up M5: GND See pin K1:2
1:45 /11.5_3.C8 Door switch right Dig In Start up
1:46 /11.5_3.B8 Door switch left Dig In Start up
1:47 /11.5_3.D8 Startup hazard Dig In Start up
1:48 /11.5_3.D8 Interior light Dig In Start up
E 1:49 /11.5_3.A8 Ignition key Dig In Start up E
1:50 /9.3_1.E8 Seat switch Dig In Start up
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn MLG 171220 A55032.1800 Krets Korsreferenser DCG,DRG,ECG 0.0_1 1
Name
R
Konstr/Design

Wiring Cross References A55040.1800 08
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-D7902
Pin Number Drawing Function Type Pin Number Drawing Function Type
C1 1:1-1:2 /11.5_1.D5 Power C4 4:6 /7.10_2.C7 Opt. 1 Dig In

1:3-1:7 /11.6_1.E8 CAN-BUS Front legs down
A 1:8 Ana In A
Overheight down
1:9 /9.3_6.C8 Steering panel up/down feedback Ana In
1:10 /11.5_3.D5 Sw interior light S1160 In (Sw inside light) 4:7 /7.1_1A.C8 Sw. lock tilt / extender / Dig In
1:11 /11.5_3.D5 Sw. hazard S1090 In (Sw hazard) Sw. Tilt control
1:12 /11.5_3.D4 Supply +30 Dig In 4:8 /7.1_1A.C8 Sw. horn Dig In
4:9 /7.5_1.B8 Option 5 Supply +30
C2 2:1 5V Ref
2:2 /11.5_5.B8 Motors Console/Seat 0V Ref Spreading 40-20
2:3 /9.3_3.B8 Motor canoe fwd/rev feedback Ana In PLH-
2:4 /9.3_3.D8 Motor canoe up/down feedback Ana In Release legs
2:5 /9.3_6.B1 Steering panel up/down NPN / PNP 3A 4:10 /7.5_1.B8 Option 5 Dig In
2:6 /9.3_6.B8 Steering panel up/down NPN / PNP 3A
2:7 /9.3_3.B1 Motor canoe fwd/rev NPN / PNP 3A Spreading 20-40
2:8 /9.3_3.B8 Motor canoe fwd/rev NPN / PNP 3A PLH+
2:9 /9.3_3.C1 Motor canoe up/down NPN / PNP 3A Clamp legs
2:10 /9.3_3.C8 Motor canoe up/down NPN / PNP 3A 4:11 /9.10_1.A8 Cab moving left/reverse/Up Dig In
B 4:12 /9.10_1.B8 Cab moving right/forward/Down Dig In B
C3 3:1 /11.5_5.C1 5V ref Lever/Joystick 5V Ref 4:13 /8.2_3.A8 Dead mans grip Dig In
3:2 /11.5_5.B8 0V ref Lever/Joystick 0V Ref 4:14 /9.10_1.C8 Option 6 Dig In
3:3 /7.1_1A.D8 Sensor Lift/lower Ana In
3:4 /7.1_1A.C8 Sensor Boom in/out Ana In Cabtilt up
Sensor tilt - in/out Turible seat C.C.W
4:15 /9.10_1.C8 Option 6 Dig In
3:5 /7.1_1A.D8 Sensor Sideshift Ana In Cab tilt down
3:6 /7.1_1A.E8 Rotation Ana In
Turnible seat C.W
Spread(L) 4:16 /5.2_1.D8 Sensor steering wheel Dig In
Extension left
Clamp(L)
4:17 /7.10_1.A8 Option 7 Dig In
3:7 /7.1_1B.D8 Levelling Ana In
Support jacks up
5th function
Upper Arms Height up
C Rear legs up C
4:18 /7.10_1.B8 Option 7 Dig In
Clamp Right
Support jacks down
3:8 /7.1_1B.E8 Extension Right Ana In
Upper Arms Height down
6th function
Spread Right
Rear legs down
3:9 /7.1_1A.B1 24V Supply Island 1 0,5A C5 5:1 /11.5_5.B1 24V Supply Island 4 0,5A
3:10 /11.5_5.B1 Lever/Joystick PWM 1,5A 5:2 /4.5.B8 Sw. parking brake Dig In
5:3 /2.1.B8 Sw. forward gear Dig In
3:11 /8.2_1.B8 Sw. override safety keyswitch Dig In

5:4 /2.1.A8 Sw. neutral gear Dig In

3:12 /7.9_1.B8 Sw. lock TW Dig In

5:5 /2.1.B8 Sw. center gear Dig In
PLH on/off 5:6 /2.1.B8 Sw. reverse gear Dig In
3:13 /7.1_1A.B8 Option 1 Dig In 5:7 /9.6_1.B8 Sw. indicator right Dig In
Lock Levelling 5:8 /9.6_1.B8 Sw. indicator left Dig In
5:9 /9.6_1.C8 Sw. High Low Beam Dig In
Lock arm 1
D 5:10 /9.7_1.A8 Sw. horn Dig In D
3:14 /7.10_2.C7 Option 1 Dig In 5:11 /11.5_1.A8 Operating switch Dig In
secuted.
Front legs up 5:12 /5.2_1.B8 Sensor steering wheel Dig In

5:13 /9.2_1.A8 Start interlock device Dig In
Overheight up
5:14 /9.3_2.B8 Seat belt Dig In
Enable Clamp open
3:15 /8.2_2.B8 Override height Dig In
Override rotation C8 8:1 /11.5_5.A1 24V Supply Island 2 0,5A
Lock arm 2 8:2 Dig In
3:16 /7.5_2.B8 Aut 20-40 on-off Dig In 8:3 /1.1_1.E8 0V ref Pedals 0V Ref
8:4 /11.5_5.C1 Supply pedals 5V Ref
Differential lock 8:5 /1.1_1.D8 Throttle position B Ana In
3:17 /9.10_2.B8 Aut cab tilt on/off Dig In 8:6 /1.1_1.D8 Throttle position A Ana In
Diffrential Lock 8:7 /4.1.D8 Brake pedal pos. B Ana In
8:8 /4.1.D8 Brake pedal pos. A Ana In
3:18 /7.5_3.B8 Sw. 30-35 stop Dig In
E 3:19 /1.3_1.B8 DPF Regen Inhibit Dig In C6 6:1-6:20 Wiper & drive train control panel Ribbon cable E
3:20 /9.9_2.B8 Sw. window heater & mirror heater Dig In
C7 5:1-5:30 Climate control panel Ribbon cable
C4 4:1 /11.5_5.A1 24V Supply Island 3 0,5A C9 6:1-6:20 Light control panel Ribbon cable
4:2 /7.1_1A.B1 LED right locked levelling/opt 0,5A
4:3 /7.1_1A.C1 LED left locked tilt/opt 0,5A C10 10:1 /9.3_9.C1 Left armrest up/down NPN/PNP 3A
4:4 /7.1_1A.A8 Shift button Dig In 10:2 /9.3_9.C8 Left armrest up/down NPN/PNP 3A
10:3 /7.10_4.C7 Option Ana In
Sw. enable opening when clamped load

4:5 /7.1_1A.B8 Switch Auto clamp Dig In 10:4 /2.1.C8 Forward Dig In
10:5 /2.1.D8 Neutral Dig In
Release in lever 1 10:6 /2.1.D8 Reverse Dig In
Switch Unlock TW 10:7 /2.1.D8 Center Dig In
10:8 /7.10_4.C7 Option Dig In/Dig Out
F 10:9-10:10 /11.6_1.F8 CAN-BUS F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn MLG 171220 A55032.1800 Krets Korsreferenser DCG,DRG,ECG 0.0_2 1
Name
R
Konstr/Design

Wiring Cross References A55040.1800 08
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-X106m -XD7902-6 -XA3700f -A3700

1/20 1 1 1/20
2/20 2 2 2/20
3/20 3 3 3/20
C 4/20 4 4 4/20 C
5/20 5 5 5/20
6/20 6 6 6/20
7/20 7 7 7/20
8/20 8 8 8/20
9/20 9 9 9/20
10/20 10 10 10/20
11/20 11 11 11/20
12/20 12 12 12/20
13/20 13 13 13/20
14/20 14 14 14/20
15/20 15 15 15/20
D 16/20 16 16 16/20 D
secuted.
17/20 17 17 17/20
18/20 18 18 18/20
19/20 19 19 19/20
20/20 20 20 20/20
-D7902 -Drive_Train_Panel
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn MLG 171220 A55032.1800 Krets Manöverpanel Drive train/Wipers DCG,DRG,ECG 1.1_0 1
Name
R
Konstr/Design

Wiring Control Panel Drive Train A55040.1800 08
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
0544D D7902-804-5VRef
/4.1.B2
B 0544C D7902-804-5VRef B
/4.1.C2
-X054f -X054m
D7902-804-5VRef 7902-804 4 4 0544 -XSP544
/11.5_5.C3
C C
-XR6900m -XR6900f
RD 1 1
5V 0544B
-X054m -X054f -XD7902-8

BU 2 2 1 1 5 Ana In
Out B 0541 7902-805 C8:5
/0.0_2.E5
-D7902

Throttle position B
BK 3 3
0V 0543D
4
D 5V 0544A
D
-X054m -X054f -XD7902-8
secuted.
WH 5 5 2 2 6 Ana In
Out A 0542 7902-806 C8:6
/0.0_2.E5
-D7902
-R6900 Throttle position A

6
Speed control 0V 0543C
-X054m -X054f -XD7902-8

-XSP3 0543 3 3 7902-803 3 C8:3 0V Ref
-D7902
/0.0_2.E5
0V ref Pedals
E 0543A D7902-303-0VRef
/4.1.E7 E
0543B D7902-303-0VRef
/4.1.E7
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn MLG 171220 A55032.1800 Krets Gaspedal DCG,DRG,ECG 1.1_1 1
Name
R
Konstr/Design

Wiring Speed Control A55040.1800 08
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1049
C
A
-XS1049 -XS1049 -XS8150-4f -XS8150-4m -XD7902-3
#172 8150-47H 3 3 4 4 8150-413 13 13 7902-319 19 C3:19 Dig In
/9.9_2.B2 -D7902
1 1 8150-42G /0.0_2.E2
#172 8150-47J
B /9.10_2.B2 DPF Regen Inhibit DPF Regen Inhibit
B
D7902-302-0VRef
/9.9_2.B8
8150-42H D7902-302-0VRef
/9.10_2.C8
C C

D D
secuted.
E E
F F

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn MLG 171220 A55032.1800 Krets Regen Inhibit DCG,DRG,ECG 1.3_1 1
Name
R
Konstr/Design

Wiring Regen Inhibit A55040.1800 08
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
13101 D7902-501-24V
/9.6_1.A2
-S1310
A A
-X055m -X055f -XD7902-5
4 4 7902-504 4 C5:4 Dig In
-X055f -X055m -XS1310f -S1310 N1 -D7902
D7902-501-24V 7902-501 1 1 0551 1 1 /0.0_2.D5
/11.5_5.B3
Sw. neutral gear
N2 -S1310 -XS1310f
5 5 0554 -X055m -X055f -XD7902-5
3 3 7902-506 6 C5:6 Dig In
R -S1310 -D7902
3 3 0553 /0.0_2.D5
Sw. reverse gear
F -S1310
2 2 0552 -X055m -X055f -XD7902-5
2 2 7902-503 3 C5:3 Dig In
Q -S1310 -D7902
6 6 0555 /0.0_2.D5
Sw. forward gear
B B
-X055m -X055f -XD7902-5
/4.5.B4 5 5 7902-505 5 C5:5 Dig In
-D7902
/0.0_2.D5
Sw. center gear
Opt. Lift lever

-S1310-2 Gear selector
-XR8070-1f -XS1310-1m
F WH 7 13102 2
-XR8070-1f N1 8 1305B
D7902-309-24V 8150-17H 6
GY +
C /9.7_1.B5 BU C
N2 9 13105A 5
R 10 13103 3
-XD7902-10
GN 2 7902-1004 WH 0.75 4 C10:4 Dig In
-D7902
/0.0_2.F5
Forward
-XD7902-10
5 5 Dig In
7902-1005 WH 0.75 C10:5

-D7902
/0.0_2.F5
Neutral
-XD7902-10
Opt. Joystick 3 7902-1006 WH 0.75 6 C10:6 Dig In
-D7902
-S1310-2 /0.0_2.F5
D Gear selector D
Reverse
-XS1310-1m
secuted.
F 13102 2
Center-XD7902-10
N1 6 7902-1007 WH 0.75 7 C10:7 Dig In
-D7902
+ /0.0_2.F5
-XS1310-1f
N2 13105 5 Center
R 13103 3
13101 1 1 7902-101C 9968-BK:1

/11.5_1.D2
E E
-XD7901-2 -X036f
0,5A / Dig In C2:31 31 7901-231 3
-D7901 /8.2_7.C1
/0.0_1.D5
Output status FWD
F -XD7901-2 -X036f
0,5A / Dig In C2:32 32 7901-232 4
F
-D7901
/0.0_1.D5
Output status REV

E³ DRAWING
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No. Design change Change No. Date Ritad/Drawn MLG 171220 A55032.1800 Krets Växling DCG,DRG,ECG 2.1 1
Name
R
Konstr/Design

Wiring Gear A55040.1800 08
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
D7902-804-5VRef
/1.1_1.B4
D7902-804-5VRef
/1.1_1.B4
C C
-XR8092m -XR8092f
RD 1 1
5V 0544C
-X054m -X054f -XD7902-8

BU 2 2 5 5 7 Ana In
Out B 0545 7902-807 C8:7
/0.0_2.E5
-D7902

Brake pedal pos. B

BK 3 3
0V 0543B
4
D 5V 0544D
D
-X054m -X054f -XD7902-8
secuted.
WH 5 5 6 6 8 Ana In
Out A 0546 7902-808 C8:8
/0.0_2.E5
-D7902
-R8092 Brake pedal pos. A

6
Brake control 0V 0543A
D7902-303-0VRef
/1.1_1.E7
D7902-303-0VRef
/1.1_1.E7
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn MLG 171220 A55032.1800 Krets Broms DCG,DRG,ECG 4.1 1
Name
R
Konstr/Design

Wiring Brake A55040.1800 08
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1310
/2.1.B4
B P -S1310 -XS1310f -X056m -X056f -XD7902-5 B
4 4 0562 2 2 7902-502 2 C5:2 Dig In
-D7902
/0.0_2.D5
Sw. parking brake
C C

D D
secuted.
E E
F F

E³ DRAWING
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Sq.
No. Design change Change No. Date Ritad/Drawn MLG 171220 A55032.1800 Krets Paerkeringsbroms DCG,DRG,ECG 4.5 1
Name
R
Konstr/Design

Wiring Parking Brake A55040.1800 08
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XB7700-1f -XB7700-1m
D7902-501-24V 160031-2 1 1
/9.6_1.D2
-XB7700-2f -XB7700-2m
D7902-501-24V 160031-1 1 1 BN
/9.6_1.C2 -B7700-2 -XB7700-1m -XB7700-1f -X055m -X055f -XD7902-5
BK 3 3 0557 7 7 7902-512 12 C5:12 Dig In
B -D7902 B
/0.0_2.D5
Sensor steering wheel
BU Sensor steering wheel
-XB7700-1m -XB7700-1f -X055m -X055f -X060m -X060f -X035m -X035f
2 2 558A 0558 8 8 06012 12 12 0354 4 4 9937-00108 CHASSIS
/11.5_6.A5
-XSP9
C C
558B CHASSIS
/11.5_4.A7

BN
-B7700-1 -XB7700-2m -XB7700-2f -X055m -X055f -XD7902-4
BK 3 3 0556 6 6 7902-416 16 C4:16 Dig In
-D7902
/0.0_2.C5
Sensor steering wheel
BU Sensor steering wheel
-XB7700-2m -XB7700-2f
D 2 2 558C D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn MLG 171220 A55032.1800 Krets ministyrning DCG,DRG,ECG 5.2_1 1
Name
R
Konstr/Design

Wiring ministeering A55040.1800 08
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12
A A
B Leversteering -X066m B
WH 3
-R8250-1
-X066m -X066m
1 RD BK 2
Sensor Ch1
-X066m -X066f -X058m -X058f -X040m -X040f -XD7901-1
Microwheelsteering WH

VDRG09 01GB

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VDRG09 01GB

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Reachstackers 42-45 tonnes

Publ. no VDRG09. 01GB

9 Frame, body, cab and accessories

G Terminology and index

Workshop Manual DRG420–450 ECOefficient VDRG09.01GB

About machine version

Workshop Manual DRG420–450 ECOefficient VDRG09.01GB

Read operator's manual

Read the operator's manual

Read the Maintenance manual

Read the Maintenance manual

VDRG09.01GB Workshop Manual DRG420–450 ECOefficient

The workshop manual's contents

Function group structure

Workshop Manual DRG420–450 ECOefficient VDRG09.01GB

References between different information types

Function descriptions Hydraulic diagrams

Diagnostics Wiring diagrams

• From Function description to Component description, to enable

VDRG09.01GB Workshop Manual DRG420–450 ECOefficient

• From Component description or Function description to Diagnos-

Product alternatives and optional equipment

Optional equipment refers to options that can be added to standard

Workshop Manual DRG420–450 ECOefficient VDRG09.01GB

The machine card indicates which drawings the machine is manufac-

VDRG09.01GB Workshop Manual DRG420–450 ECOefficient

7:14 7 Lasthantering – Lyft och sänk

Lyft och sänk, funktionsbeskrivning

9 Pos Förklaring Signalbeskrivning Hänvisning

VDRG01.01SE Verkstadsmanual DRG 420–450

Example of function description

Workshop Manual DRG420–450 ECOefficient VDRG09.01GB

Symbol explanation function descriptions

VDRG09.01GB Workshop Manual DRG420–450 ECOefficient

About the documentation

Workshop Manual DRG420–450 ECOefficient VDRG09.01GB

VDRG09.01GB Workshop Manual DRG420–450 ECOefficient

Workshop Manual DRG420–450 ECOefficient VDRG09.01GB

VDRG09.01GB Workshop Manual DRG420–450 ECOefficient

A near accident is a warning!

Workshop Manual DRG420–450 ECOefficient VDRG09.01GB

VDRG09.01GB Workshop Manual DRG420–450 ECOefficient

• If the engine shall be started for work indoors then exhaust-venting

Hydraulic and brake systems, depressurising

Before the hydraulic system is opened

Workshop Manual DRG420–450 ECOefficient VDRG09.01GB

5. Depressurise the attachment.

Relief valve for top lift, the figure above shows an

VDRG09.01GB Workshop Manual DRG420–450 ECOefficient

After work is finished

8. Close the relief valve for top lift.

Relief valve for top lift, the figure above shows a

Workshop Manual DRG420–450 ECOefficient VDRG09.01GB

VDRG09.01GB Workshop Manual DRG420–450 ECOefficient

Workshop Manual DRG420–450 ECOefficient VDRG09.01GB

DEF (Diesel Exhaust Fluid)

VDRG09.01GB Workshop Manual DRG420–450 ECOefficient

Several mechanics on the same machine

Workshop Manual DRG420–450 ECOefficient VDRG09.01GB

Working under the machine

Lifting heavy components

VDRG09.01GB Workshop Manual DRG420–450 ECOefficient

Workshop Manual DRG420–450 ECOefficient VDRG09.01GB