Workshop DCT80

Empty Container Handler 8-9
tonnes
Publ. no VDCT01.03GB
Workshop Manual in original WORKSHOP MANUAL
DCT 80-90
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Workshop Manual
2 Transmission
DCT 80-90
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
G Terminology and index

A:1
A Foreword
Contents A Foreword
Foreword ............................................................................................................A:3
About the Workshop Manual........................................................................... A:3
General ...................................................................................................... A:3
Conditions .................................................................................................. A:3
Storage....................................................................................................... A:3
About machine version............................................................................... A:3
Copyright .................................................................................................... A:3
Reading instructions ....................................................................................... A:4
Warning information ................................................................................... A:4
Important information ................................................................................. A:4
Read operator's manual ............................................................................. A:4
Read the Maintenance manual .................................................................. A:4
The workshop manual's contents............................................................... A:5
Function group structure ............................................................................ A:6
References between different information types ........................................ A:7
Product alternatives and optional equipment ............................................. A:8
Machine card.............................................................................................. A:9
Function descriptions ............................................................................... A:10
About the documentation .............................................................................. A:12
The documentation's parts ....................................................................... A:12
Ordering documentation........................................................................... A:12
Feedback ...................................................................................................... A:13
Form for copying ...................................................................................... A:13
Workshop Manual DCT 80-90 VDCT01.03GB

A:2
VDCT01.03GB Workshop Manual DCT 80-90

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

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

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

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

prohibited.

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

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

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

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

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

Function group structure

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

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

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

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

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

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

References between different information types

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

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

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

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

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

Product alternatives and optional equipment

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

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

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

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

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

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

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

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

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

valves, sensors, etc.
4 B ro m s a r S e rv o b ro m s s y s te m 4 :5
4 .3 S e r v o b r o m s s y s te m
S e r v o b r o m s s y s te m , fu n k tio n s b e s k r iv n in g
1
10 14
D790-2 B
P
T
D11 D797-1
10, 13 5 9 C
Pa
11
D12 4
D9 6 2
C
2
12 Pa LB
C ACK M 8
P P
T T
7
P 3
3
9 1
015034
B 4
P os F ö r k la r in g S ig n a lb e s k r iv n in g H ä n v is n in g
8 1 H y d ra u lo lje p u m p b ro m s o c h S e try c k s k y lt p å v ä n s te r H y d ra u lo lje p u m p b ro m s o c h s ty rn in g ,
s ty rn in g p u m p a r o lja frå n ra m b a lk . b e s k riv n in g , s id a 4 :8
h y d ra u lo lje ta n k e n .
2 Ven
och
tilb lo c k
p rio rite
a c k u m u la to rla d d n in g s -
rin g s v e n til s ty r try c k till
-
5
Ven tilb lo c k b ro m s a r n ä r s ty rn in g e n
in te k rä v e r h y d ra u lk ra ft.
7 3 V e n tilb lo c k b ro m s a r le d e r o lja n
v id a re till a c k u m u la to re r o c h
-
d riv a x e lb lo c k .
4 A c k u m u la to re rn a la g ra r
h y d ra u lo lje try c k .
S e try c k s k y lt p å v ä n s te r
ra m b a lk .
A c k u m u la to r, b e s k riv n in g , s id a 4 :1 4
6
5 B ro m s v e n tile n s ty r try c k frå n - B ro m s v e n til, b e s k riv n in g , s id a 4 :1 8
a c k u m u la to re rn a till b ro m s c y lin d e rn
p ro p o rtio n e llt m o t p e d a ltry c k e t.
014621
6 D riv a x e lb lo c k e t fö rd e la r -
b ro m s try c k e t till h ju lb ro m s a rn a .
Example of function description

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

Symbol explanation function descriptions
Symbol explanation function descriptions

The following symbols are used in function descriptions. The symbols
1 2 are based on standard symbols for wiring and hydraulic diagrams.
3 4 1. Electric control signal
2. Electric force
3. Hydraulic control signal
5 6 4. Hydraulic force
5. Hydraulic motor
6. Hydraulic oil pump with variable displacement
7 8 M 7. Hydraulic oil pump with fixed displacement
8. Electric motor
9. Accumulator
9 10 10. Disc brake
11. Filter
12. Radiator
11 12 13. Bulb
14. Control and monitoring system, two control units with CAN bus
D790-1
15. Restriction
13 14
16. Adjustable restriction
D797-F
17. Inductive position sensor
18. Electrically controlled servo valve
15 16
19. Thermal bypass valve
17 18 20. Temperature-controlled switch
21. Temperature sensor
19 °C 20 °C 22. Pressure sensor
23. Pressure-controlled switch
21 °C 22 Pa
24. Hydraulic cylinder
25. Double-acting hydraulic cylinder
23 Pa 24
26. Spring brake cylinder
27. Valve block
25
28. Shuttle valve
29. Non-return valve
26 27
28 29
014726

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

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

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

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

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

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

A:14

B:1
B Safety
Contents B Safety
Safety..................................................................................................................B:3
General safety information.............................................................................. B:3
Safety concerns everyone!......................................................................... B:3
A near accident is a warning! ..................................................................... B:3
Safety instructions........................................................................................... B:4
General ...................................................................................................... B:4
Service position .......................................................................................... B:4
Hydraulic and brake systems, depressurising............................................ B:5
Oils ............................................................................................................. B:6
Fuel system ................................................................................................ B:7
Clothing, etc. .............................................................................................. B:8
Several mechanics on the same machine.................................................. B:8
Working under the machine ....................................................................... B:8
Lifting heavy components .......................................................................... B:9
Vibration ..................................................................................................... B:9
Noise ........................................................................................................ B:10
Dissolvent................................................................................................. B:10
Fire and explosion risk ............................................................................. B:11
Fluid or gas under pressure ..................................................................... B:14
Coolant ..................................................................................................... B:14
Refrigerant ............................................................................................... B:15
Air pollution .............................................................................................. B:16
Tensioned springs .................................................................................... B:17
Electrical system and electric motors ....................................................... B:17
Rotating components and tools................................................................ B:17
Tyres and rims.......................................................................................... B:18
Lifting equipment ...................................................................................... B:18
Welding .................................................................................................... B:19
Spare parts............................................................................................... B:20
Non-ionised radiation ............................................................................... B:21
Environment.................................................................................................. B:22
General .................................................................................................... B:22

B:2

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

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

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

B:4 B Safety – Safety instructions
Safety instructions
General
Read and observe the following safety instructions below before
starting to work with the machine:
• Service position, page B:4
• Hydraulic and brake systems, depressurising, page B:5
• Oils, page B:6
• Fuel system, page B:7
• Clothing, etc., page B:8
• Several mechanics on the same machine, page B:8
• Working under the machine, page B:8
• Lifting heavy components, page B:9
• Vibration, page B:9
• Noise, page B:10
• Dissolvent, page B:10
• Fire and explosion risk, page B:11
• Fluid or gas under pressure, page B:14
• Coolant, page B:14
• Refrigerant, page B:15
• Air pollution, page B:16
• Tensioned springs, page B:17
• Electrical system and electric motors, page B:17
• Rotating components and tools, page B:17
• Tyres and rims, page B:18
• Lifting equipment, page B:18
• Welding, page B:19
• Spare parts, page B:20
• Non-ionised radiation, page B:21
Service position
General
General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
Service position entails:

• The machine is parked, i.e. parking brake applied.
• Trolley and attachment in totally lowered position
• Mast tilted fully forward.
• Engine off.
• System voltage switched off (with the battery disconnector).
018741

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

1 Machine in service position, see Service position, page B:4.
2 Depressurise the hydraulic system.
Turn system voltage on, turn the starter key to position I and
activate the load handling functions several times.
3 Turn the start key to position 0 and switch off the system voltage.
4 Depressurise the brake system by opening the drain valve on the

accumulator charging valve.
NOTE
Keep the accumulator drain valve open as long as work is in
progress.
NOTE
After the work has been finished, close the drain valve and
tighten the lock ring.
014618

5 Depressurise the attachment.

Open relief valve top lift.
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
Check that the relief valve for the attachment is closed
before starting the engine.
014620
The figure above shows open valve.
Oils
The following safety instructions must be followed for work when
handling oils.
WARNING
Hot and pressurised oil.
Avoid skin contact with the oil, use protective gloves.
Hot oil can cause burn injuries, rashes and irritation!
The oil can act corrosive to eyes and skin, and mucous
membranes in the throat.
IMPORTANT
Always clean the area around components and
connections before they are loosened. Dirt in
oil systems causes increased wear, resulting in
subsequent material damage.
Always take action to avoid spills. In locations where
drainage containers cannot be used, use a pump or
hose for safe handling.
Always check that plugs are sealed tightly before
receptacles are moved.
Handle all oil as environmentally hazardous waste.
Oils freely discharged cause environmental damage
and can also be a fire hazard. Waste oils/fluids must
always be handled by an authorised company.

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

Clothing, etc.
Clothes should be in good repair. Remove loosely hanging garments
(e.g. tie, scarf). Do not wear clothes with wide sleeves, wide trouser
legs, etc.
Remove jewellery as it may conduct electricity and get caught in

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

Working under the frame
A raised vehicle may not, for any reason, be supported or raised in
parts that belong to the wheel suspension or steering. Do not support
under mudguards or tanks either. Always support under the frame or
drive axle.
Risks
Mechanical or hydraulic tools and lifting devices may fall over or
accidentally lower due to malfunctions or incorrect use.
Safety precautions
• 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

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

and forth, which can cause severe crushing injuries or material damage.
Safety precautions
Lifting with lifting device. Use lifting tools or other tools, in particular
when there are such tools available adapted for specific work
operations.
If lifting must be performed without lifting device:

• Lift near the body.
• Keep your back vertical. Raise and lower with legs and arms, do
not bend your back. Do not rotate your body while lifting. Ask for
assistance in advance.
• Wear gloves. They're often good protection to reduce crushing
and cutting injuries to fingers.
• Always use protective shoes.
Vibration
Use of vibrating tools, e.g. impact nut runner or grinder, for an extended
period of time may cause injuries as vibration is transmitted from the
tool to hands. In particular when fingers are cold.
Safety precautions
• Use heavy gloves that protect against the cold and the transfer of
vibrations.
• Switch between work duties to give the body time to rest.
• Vary your work position and grip so that your body is not affected in
only one position by the vibration.

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

damage to the central nervous system. This manifests itself in
sleeping problems, depression, nervousness, poor memory and
general tiredness. Continuous inhalation of petrol and diesel fumes is
suspected to cause cancer.
Safety precautions
• Avoid inhaling dissolvent fumes by providing good ventilation, or
wearing a fresh-air mask or respiratory device with a suitable filter
for the toxic gases.
• Never leave a dissolvent container without tight-sealing lid.
• Use dissolvents with a low content of aromatic substances. This
reduces the risk of injury.
• Avoid skin contact.
• Use protective gloves 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
fuel oil, organic solvents (paint, plastics, detergents), rust preventive
agents, welding gas, gas for heating (acetylene), high concentrations
of dust particles consisting of combustible materials. Rubber tyres that
have caught fire are difficult to extinguish and can cause fires with
explosive development.

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

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

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

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

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

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

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

Fluid or gas under pressure

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

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

hazardous to health.

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

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

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

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

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

in aerosol) when cutting, grinding or welding. May give mucous
membrane 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,
battery charging and other work when hazardous gases are
formed.
• Use suitable protective gloves and breathing protection when there
is a risk of oil mist. Make sure that the protection is oil-resistant.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eyewash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine in the workshop.
Connect extraction equipment to the exhaust pipe so that exhausts
are routed out from the workshop.

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

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

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

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

before working on the machine.
Risks
If the machine's lifting equipment is not lowered or secured, there is a
risk of crushing.
Risk of crushing is particularly great when depressurising the hydraulic

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

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

Spare parts
WARNING
For safety reasons, the following spare parts may only
be replaced with genuine spare parts:
• Brake valve
• Drive axle
• Steering valve (Orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Steering spindle
• Hub
• Rim
• Mast, carriage
• Lift cylinder incl. load control valve
• Lifting chains
• Chain tightener and shaft
• Valve block lift cylinder
• Tilt cylinder
• Twistlock
• Control breaker (for hydraulic function)
• Emergency stop
• Cab
• Frame
• Accumulator
• Main valve load handling
• Accumulator charging valve
• All control units

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

B:22 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
subjected daily to risks in connection with various forms of chemical
handling.
There are still no fully environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle, perform
service on or repair machines must use the tools, assisting devices and
methods necessary to protect the environment in an environmentally
sound manner.
By following the simple rules below, you will contribute to protecting
our environment.
Recycling
Conscientious recycling of the machine is the starting point for the life
cycle to come full circle, and for being able to recycle and make use of
material in new products. According to calculations by Cargotec, the
machine is more than 90% recyclable by weight.
Environmentally hazardous waste
Components such as batteries, oils, and various chemicals and other
items that may constitute environmentally hazardous waste must be
handled and taken care of in an environmentally safe and sound
manner.
Discarded batteries contain substances hazardous to personal health
and the environment. Therefore, handle batteries in an environmentally
safe manner and according to national regulations.
Oils and fluids
Oils freely discharged cause environmental damage and can also be a
fire hazard. Therefore, when emptying and draining oils or fuel, take
appropriate action to prevent unnecessary spills.
Waste oils and fluids should always be taken care of by an authorised
disposal company.
Pay close attention to oil leaks and other fluid leaks! Rectify leakage
immediately.
Air conditioning
The refrigerant in the air conditioning for the cab adds to the
"greenhouse effect" if released into the open air. Special training is
required for all service work on the air conditioning. Many countries
also require certification by a governing authority for such work. When
scrapping an air conditioning unit, the refrigerant shall be taken care
of by a certified company.
Working in a contaminated area
The machine must be equipped for work in contaminated areas
(environmentally polluted or health-hazardous area) before work is
started. Also, there are special local rules in force for such handling
and when servicing such a machine.
Declarations
The machine does not contain asbestos.
The machine contains lead in batteries and in electric cabling. In
certain models, there are lead castings as counterweight.
If the machine is equipped with air conditioning, refrigerant of type
R134a is used, in an amount totalling between 1-3 kg.

C:1
The information is available in the
Maintenance Manual
See Maintenance Manual DCT 80–90, section C Preventive
maintenance.
For information on how to order the Maintenance Manual, see the

section A Foreword.

C:2

0:1
0 Complete machine
Contents 0 Complete machine

Complete machine............................................................................................. 0:3
Complete machine, description ..................................................................0:3
Troubleshooting, general work instructions.................................................0:5
Troubleshooting without an error code, example ........................................0:6
Troubleshooting with an error code, example .............................................0:7
Troubleshooting cable harnesses ...............................................................0:9
Troubleshooting hydraulic hoses...............................................................0:10

0:2

0 Complete machine – Complete machine 0:3
0 Complete machine
Complete machine, description
Kalmar DCT 80-90 is a forklift truck for empty container handling. The
machine has a lifting capacity of 8-9 tonnes depending on the model.
The engine is a straight six-cylinder, four-stroke, turbocharged

low-emission diesel engine with a unit injector, air to air intercooling
and electronically controlled fuel injection.
The transmission is hydromechanical with gear wheels constantly

5 engaged and has three gears in each direction. Engine power is
transmitted using a torque converter.
The power transmission consists of a propeller shaft and one rigid

drive axle with differential and hub reduction. Drive takes place on
the front wheels.
The service brakes are wet multiple disc brakes which are attached to
the drive wheel hub. The parking brake is the disc brake type and
operates on the drive axle input shaft.
7
Steering operates on the rear wheels with a double acting hydraulic
cylinder. The steering axle is suspended in the frame with pendulum
suspension.
6 The wheels are attached to the hubs with studs and nuts. Double
wheels are fitted on the drive axle; single wheels on the steering axle.
Load handling comprises components and functions for handling loads.

The load is lifted with the side lift attachment secured to a trolley that
sits on a mast. Load handling is divided into the functions: lift and
lower, tilt, side shift, spreading and load securing.
• Lifting/lowering is the function used to raise and lower the trolley.
• Side shifting is moving the side lift attachment sideways along the
trolley.
018747
1 2 3 4 • Spreading is adjusting the width between the Twistlocks on the

side lift attachment.
1. Steering axle
• Tilt is used to angle the load in the longitudinal direction of the
2. Engine
truck with the help of the mast.
3. Frame
• Load securing is to lock the load to the side lift attachment.
4. Drive axle
The control system consists of functions for warning the operator of
5. Mast
dangerous situations and faults. The control system has diagnostic
6. Side lift attachment resources that simplify troubleshooting.
7. Cab
The frame carries the machine. The frame houses the engine,
transmission, drive axle and steering axle. Fuel and hydraulic oil tanks
are fitted to the side of the frame. The cab is located at the rear of
the frame.

0:4 0 Complete machine – Complete machine
The hydraulic system is fed by two hydraulic oil pumps. The pumps
are mounted on the transmission's power take-off. One fixed pump
feeds load handling and the other fixed pump feeds the brake system,
steering and the cooling circuit over a combined priority valve and
accumulator charging valve. The hydraulic oil tank is located on the
right side of the machine. The hydraulic oil filters are return filters fitted
in the hydraulic oil tank.
The machine's electrical system is built around control units at strategic

locations on the machine. The control units receive signals from
sensors and contacts and control components in the vicinity of each
control unit. The control units have a redundant power supply and
communicate via a redundant CAN bus. The engine and transmission
have their own control units from each supplier. These control units
communicate via the CAN bus with a control unit in the cab.

Troubleshooting, general work

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

functions. Certain faults can be identified directly using function
descriptions. Sections 0–12 contain descriptions of the various
functions of the machine.
Troubleshooting procedure
1 Check that there is battery voltage available.
• Battery disconnector, must be in position 1.
• Battery voltage, should be 24–28 V with the engine running.
• Fuses, check that they are intact.
2 Check that all oil and fluid levels are normal.
• Fuel
• Engine oil
• Transmission oil
• Hydraulic oil
• Coolant
• Washer fluid
3 Check if there are error codes.
4 If there are error codes, use the error code lists as a guide. See
Troubleshooting with an error code, example, page 0:7.
The error code lists contain recommended actions for every error
code. Error code lists are available in section D Error codes.
5 If there is no error code or the problem persists, read the
function description for the function affected in section 0–12. See
Troubleshooting without an error code, example, page 0:6
The function description contains information on which components
are involved in the function and how these components work
together. In some cases, there is information on what conditions
are required in order for it to be possible to activate the function.
Measuring points are marked with flags (C for measuring outlet,
D for diagnostic menu).

Troubleshooting without an error code,

example
1 Choose suitable section 0–12 to locate the function and
subfunction that have caused the symptom.
2 Read the function description for the function in question to get
an overall understanding of which components are affected and
how these interact.
3 Use the function description and check the signals for the function
affected in order to locate where in the function chain that the
signal or reaction is incorrect.
4 The fault is probably between the two units where the signal is
incorrect. Start by checking the component that should be sending
the signal.
5 If the component that is to send the signal seems to be intact,
check the transmission of the signal (electric cables or hydraulic
hoses).
For electric cables, see Troubleshooting cable harnesses, page
0:9.
For hydraulic hoses, see Troubleshooting hydraulic hoses, page
0:10.
6 If the cables or hoses between the components seem to be intact,
then check the component that receives the signal.

Troubleshooting with an error code,

example
Error codes are indicators of malfunctions detected by the control
system. Many error codes are connected to electrical malfunctions but
there are also error codes that interpret associations between one or
several signals that indicate a non-electrical malfunction. It is important
not to draw conclusions too hastily based on an error code.
1 Read out error codes from the display, e.g. error code 34.
2 Use the error code lists and search information about the error
code, see "Example of error code information in error code list"
below.
The error code lists are available in section D Error codes.
For detailed instructions for reading out error code, see section
D Error codes.
3 Follow the instructions in the field "Action".
4 Use diagnostic menus and circuit diagrams to determine if the
input signal to the control unit is correct; see section 8 Control
system, group 8.4 Diagnostics as well as section E Schematics.
5 Use the function group to find more information if needed.
In section 0–12 there is function description, the function's included
components and their position as well as, in certain cases, work
instructions for how components are checked, cleaned or adjusted.
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).
Sometimes 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
0:9.
For hydraulic hoses, see Troubleshooting hydraulic hoses, page
0:10.
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 to operating position.
12 Check that voltage reaches the component.

Table Example of error code information in error code list
Connec-
Cod- tions and Diagnostic Function
Description Limitation Action
e compo- menu group
nents
34 Signal error from Parking brake Check cabling D791-1/K8:5 - HYD, menu 4.1.2 Parking
parking brake cannot be between the S107, K8:13 - 5 brake control
switch, indicates released. control unit and the S107
released and component with
applied at same diagnostic menu.
time or nothing at Check component.
all.

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

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

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

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

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

1:1
1 Engine
Contents 1 Engine
1 Engine................................................................................................................. 1:3
1.1 Controls and instruments ...............................................................................1:22
1.1.1 Ignition.......................................................................................................1:22
1.1.2 Accelerator pedal ......................................................................................1:22
1.2 Fuel system....................................................................................................1:24
1.2.1 Fuel tank ...................................................................................................1:24
1.2.2 Sensor fuel level........................................................................................1:25
1.6 Air intake and exhaust outlet..........................................................................1:26
1.6.1 Air cleaning system ...................................................................................1:26
1.6.3 Exhaust system .........................................................................................1:27
1.6.4 Intercooler .................................................................................................1:28
1.7 Cooling system ..............................................................................................1:29
1.7.4 Radiator and expansion tank ....................................................................1:30
1.7.5 Cooling fan ................................................................................................1:31
1.7.7 Coolant ......................................................................................................1:32
1.9 Control system, engine ..................................................................................1:37
1.9.1 Engine control unit ....................................................................................1:37
1.11 Start/stop........................................................................................................1:38
1.11.1 Starter motor .............................................................................................1:38
1.11.2 Stopping device.........................................................................................1:38

1:2

1 Engine – Engine 1:3
1 Engine
Engine, general
Engine alternative
The machine can be equipped with one of the following engine
alternatives:
• Volvo TAD760VE (stage III according to Directive 97/68/EC)
• Cummins QSB6.7 (stage III in accordance with directive
97/68/EC)
If there are differences between engine alternatives, this is written in

brackets after headings or under figures in order to clarify what is being
shown.
Component supplier documentation
The workshop manual only describes components and work
descriptions that concern installation in the machine. For descriptions
and instructions for the engine's components and systems, refer to the
relevant supplier documentation.
References to supplier documentation are only provided in exceptional

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

1:4 1 Engine – Engine
Engine, function description (engine

alternative Volvo TAD760VE)
The Volvo TAD760VE is a straight 6-cylinder, 4-stroke turbocharged
low-emission diesel engine with unit injectors, common rail technology
and air-to-air intercooler.
Condition Reference value Reference

Engine heater Disconnected (when cable is in start immobilizer is -
activated).
˚C
. bar
0 rpm
P I kph
II
III
D5
<˚
1,5
10
D10
D1
D14 D11
3,12,14,23 11,22 2,6
D794 D790-1 D790-2
D7
D793 D797-1 D795
D19 20 17 15,18,21
D16
D12
19 D4 H2O
SENSORS D8
4 13 16
9
009685
8 M 7
The figure shows the function description for the Volvo TAD760VE.
Pos Explanation Signal description Reference

1 The ignition switch (S150) sends U = 24 V Ignition key lock, description, page 1:22
a voltage signal to cab control unit D1: Diagnostic menu, see section 8 Control
KCU (D790-1) when the start key is system, group 8.4.1.5 CAN/POWER, menu 5
turned to position 1 or the preheating and 8.4.6.4 ENGINE, menu 4
position.
2 Cab control unit KIT (D790-2) sends Checked by control See section 11 Common electrics, group
ignition on via the CAN bus. If system, error shown with 11.5.3.11 Control unit KIT (D790-2)
the key is turned to the preheating error code.
position, then preheating is also sent
on the CAN bus.
3 If preheating has been activated with U = 24 V Section 11 Common electrics, group 11.5.3.10
the start key or automatically, then Control unit, engine
the engine control unit (D794) feeds
voltage to the preheating relay and
through this also the preheating coils
(E800-1).
4 The preheating coils (E800-1) warm - D4: Diagnostic menu, see section 8 Control
each cylinder with a glow plug. system, group 8.4.6.5 ENGINE menu 5


5 The ignition switch (S150) sends a U = 24 V Ignition key lock, description, page 1:22
voltage signal to the KIT control unit D5: Diagnostic menu, see section 8 Control
(D790-2) when the start key is turned system, group 8.4.6.4 ENGINE menu 4
to start position.
6 Control unit KIT (D790-2) sends a - See section 11 Common electrics, group
start signal on the CAN bus. 11.5.3.11 Control unit KIT (D790-2)
7 The starter motor (M654) is U = 24 V Starter motor, description (engine alternative
controlled by the engine control unit Volvo), page 1:38
(D794) through starter relays and D7: Diagnostic menu, see section 8 Control
receives signals from the cab control system, group 8.4.6.5 ENGINE menu 5
unit (D790-1) via the CAN bus.
8 The starter motor (M654) cranks the - Starter motor, description (engine alternative
engine. Volvo), page 1:38
D8: Diagnostic menu, see section 8 Control
system, group 8.4.6.5 ENGINE menu 5
9 The engine's sensor sends signals - Section 11 Common electrics, group 11.5.3.10
to Control unit, engine (D794) that Control unit, engine
controls the injectors so the engine
starts.
10 The accelerator pedal (B690) sends U = 0.5-4.5 V Accelerator pedal, replacement, page 1:22
the cab control unit (D790-1) a Lower voltage than 0.5 V D10: Diagnostic menu, see section 8 Control
voltage signal proportional to the and higher voltage than system, group 8.4.6.1 ENGINE menu 1
downward press of the pedal. 4.5 V is used to detect
faults in cable harnesses
and controls.
11 Control unit, cab (D790-1) sends a Checked by control See section 11 Common electrics, group
message with the rpm request on system, error shown with 11.5.3.1 Cab control unit (D790-1)
the CAN bus. error code. D11: Diagnostic menu, see section 8 Control
12 Control unit, engine (D794) increases - Section 11 Common electrics, group 11.5.3.10
the engine speed. Control unit, engine
13 Make-contact (closing switch) U = 24 V Cooling system, description, page 1:29
coolant level sends a voltage signal
to Control unit, engine (D794) if the
coolant level is low in the expansion
tank.
14 Control unit, engine (D794) sends Checked by control Section 11 Common electrics, group 11.5.3.10
engine data and warning messages system, error shown with Control unit, engine
on the CAN bus. error code. D14: Diagnostic menu, see section 8 Control
system, group 8.4.6.6 ENGINE, menu 6, 8.4.6.7
ENGINE, menu 7 and 8.4.6.8 ENGINE, menu 8
15 Control unit KID (D795) shows - See section 11 Common electrics, group
engine data via display figures. 11.5.3.12 KID control unit (D795)
16 The fuel level sensor (B757) sends R = 0-70 ohm Sensor, fuel level, description, page 1:25
the frame control unit (D797-1) a D16: Diagnostic menu, see section 8 Control
voltage signal proportional to the fuel system, group 8.4.3.7 CAB, menu 7
level in the tank.
17 The frame control unit (D797-1) Checked by control See section 11 Common electrics, group
transmits fuel level on the CAN bus. system, error shown with 11.5.3.2 Frame control unit (D797-1)
error code.
18 The KID control unit (D795) shows - See section 11 Common electrics, group
fuel level in the operating menu for 11.5.3.12 KID control unit (D795)
engine and transmission.


19 Speed limitation - See Supplier documentation, transmission
The output shaft speed sensor D19: Diagnostic menu, see section 8 Control
(B758) sends the transmission system, group 8.4.7.6 TRANSM menu 2
control unit (D793) pulses with
frequency proportional to output
shaft rpm.
20 Control unit, transmission (D793) Checked by control See section 11 Common electrics, group
transmits the speed on the CAN bus. system, error shown with 11.5.3.9 KIT control unit (D793)
error code.
21 The KID control unit (D795) shows - See section 11 Common electrics, group
the machine's speed. 11.5.3.12 KID control unit (D795)
22 If the rotation speed of the output Checked by control See section 11 Common electrics, group
shaft is so high that it corresponds system, error shown with 11.5.3.1 Cab control unit (D790-1)
with the limit for the machine's error code.
speed limitation then Control unit,
cab (D790-1) sends reduce engine
speed on the CAN bus.
23 Control unit, engine (D794) limits the - Section 11 Common electrics, group 11.5.3.10
engine speed. Control unit, engine

Engine alternative Cummins QSB6.7 ,

function description
°C
. bar
0 rpm
P I kph
II
III
D5
1,5
10 <°
D10
D1
D14 D11
11, 19 2,6
D794 D790-1 D790-2
3, 12, 14, 20
D797-1 D795
17 15, 18
D7
D12
D16
D4 H2O
SENSORS D8
4 13 16
9
015016
8 M 7

1 The ignition key lock sends a voltage U = 24 V Ignition key lock, description, page 1:22
signal to Control unit, cab (D790-1) when D1: Diagnostic menu, see section 8 Control
the ignition key is turned to position 1 or system, group 8.4.1.5 CAN/POWER, menu
preheating mode. 5 and 8.4.6.4 ENGINE, menu 4
2 Cab control unit (D790-2) sends ignition Checked by control Section 11 Common electrics, group
on over the CAN bus. If the key is turned system, error shown 11.5.3.11 Control unit, KIT
to the preheating mode, then preheating is with error code.
also sent on the CAN bus.
3 If preheating has been activated with the U = 24 V Section 11 Common electrics, group
start key or automatically, then the engine 11.5.3.10 Control unit, engine
control unit (D794) feeds voltage to the
preheating relay and through this also the
preheating coil (E800).
4 The preheating coil heats the primary air to - D4: Diagnostic menu, see section 8 Control
the engine. system, group 8.4.6.5 ENGINE menu 5
5 The ignition key lock sends a voltage U = 24 V Ignition key lock, description, page 1:22
signal to Control unit KIT (D790-2) when D5: Diagnostic menu, see section 8 Control
the ignition key is turned to start position. system, group 8.4.6.4 ENGINE menu 4
6 Control unit KIT (D790-2) sends a start - Section 11 Common electrics, group
signal on the CAN bus. 11.5.3.11 Control unit, KIT


7 The starter motor is controlled by the U = 24 V Starter motor, description (engine
engine control unit (D794) through starter alternative Cummins), page 1:38
relays and receives signals from the cab D7: Diagnostic menu, see section 8 Control
control unit KCU (D790-1) over the CAN system, group 8.4.6.5 ENGINE menu 5
bus.
8 The starter motor cranks the engine. - Starter motor, description (engine
alternative Cummins), page 1:38
9 The engine's sensor sends signals to - Section 11 Common electrics, group
Control unit, engine (D794) that controls 11.5.3.10 Control unit, engine
the injectors so the engine starts.
10 The accelerator pedal sends a voltage U = 0.2-4.8 V Accelerator pedal, replacement, page 1:22
signal proportional the depression to Lower voltage than 0.2 D10: Diagnostic menu, see section 8
Control unit, cab (D790-1). V and higher voltage Control system, group 8.4.6.1 ENGINE
than 4.8 V is used to menu 1
detect malfunction in
cable harnesses and
controls.
11 Control unit, cab (D790-1) sends a Checked by control Section 11 Common electrics, group
message with the rpm request on the CAN system, error shown 11.5.3.1 Control unit, cab
bus. with error code. D11: Diagnostic menu, see section 8
Control system, group 8.4.6.1 ENGINE
menu 1
12 Control unit, engine (D794) increases the - Section 11 Common electrics, group
engine speed. 11.5.3.10 Control unit, engine
D11: Diagnostic menu, see section 8
Control system, group 8.4.6.1 ENGINE
menu 1
13 Make-contact (closing switch) coolant level U = 24 V Cooling system, description, page 1:29
sends a voltage signal to Control unit,
engine (D794) if the coolant level is low in
the expansion tank.
14 Control unit, engine (D794) sends engine Checked by control Section 11 Common electrics, group
data and warning messages on the CAN system, error shown 11.5.3.10 Control unit, engine
bus. with error code. D14: Diagnostic menu, see section 8
Control system, group 8.4.6.6 ENGINE,
menu 6, 8.4.6.7 ENGINE, menu 7, 8.4.6.8
ENGINE, menu 8 and 8.4.6.9 ENGINE,
menu 9
15 Control unit KID (D795) shows engine data - Section 11 Common electrics, group
via display figures. 11.5.3.12 Control unit, KID
16 Sensor fuel level (B757) sends a voltage R = 0-70 ohm Sensor, fuel level, description, page 1:25
signal proportional to the fuel level in the A warning message D16: Diagnostic menu, see section 8
tank to Control unit, frame (D797-1). appears on the display if Control system, group 8.4.3.7 CAB, menu 7
the amount of fuel in the
tank is less than 15% for
more than 40 seconds.
17 The frame control unit (D797-1) transmits Checked by control Section 11 Common electrics, group
fuel level on the CAN bus. system, error shown 11.5.3.2 Frame control unit
with error code.
18 Control unit KID (D795) shows the fuel - Section 11 Common electrics, group
level and the machine speed in the 11.5.3.12 Control unit, KID
operating menu for the engine.


19 If the rotation speed of the output shaft is Checked by control Section 11 Common electrics, group
so high that it corresponds with the limit for system, error shown 11.5.3.1 Control unit, cab
the machine's speed limitation then Control with error code.
unit, cab (D790-1) sends reduce engine
speed on the CAN bus.
20 Control unit, engine (D794) limits the - Section 11 Common electrics, group
engine speed. 11.5.3.10 Control unit, engine

Engine alternative Volvo TAD760VE,

component location
7 8 9
6
5 10
4
3
11
12
13
14
15
16
17
18
018928
19
21 20
Left-hand side (in the machine's direction of travel)
1. Sensor coolant temperature 12. Sensor fuel pressure (distribution pipe)
2. Solenoid valve EGR 13. Water pump
3. Oil dipstick, engine oil 14. Sensor oil pressure
4. Filling point engine oil 15. Oil filter
5. Crankcase ventilation 16. Sensor fuel pressure
6. Turbo 17. Fuel filter
7. Sensor charge air pressure and temperature 18. Solenoid valve proportional valve high-pressure pump
8. Injector and preheating (6 pcs.) fuel (MPROP)
9. Connection cab heating 19. Oil plug
10. Alternator 20. Electrical connection, Control unit, engine (D794)
11. Fuel pump 21. Sensor camshaft rpm

1 2
018927
6 5 4
Right-hand side (in the machine's direction of travel)
1. Thermostat housing 4. Oil plug
2. Air preheating downstream of intercooler 5. Drain point coolant
3. Starter motor 6. Sensor crankshaft rpm

Engine alternative Cummins QSB6.7,

component placement
3
1 2
5
6
018941
8
9
Engine alternative Cummins QSB6.7, left side (in machine's direction of travel)
1. Filling point engine oil 6. Connections cab heating
2. Oil dipstick engine 7. Coolant inlet
3. Outlet exhaust system 8. Oil filter
4. Outlet coolant to radiator 9. Starter motor
5. Alternator

11
10
8
3
4
5
018942
7 6
Engine alternative Cummins QSB6.7, right side (in machine's direction of travel)
1. Turbo air inlet 7. Control unit, engine (D794)
2. Turbo air outlet 8. Vibration damper (rubber)
3. Crankcase ventilation 9. Fan drive
4. Fuel filter 10. Water pump
5. Drain engine oil 11. Drive belt tensioner
6. Air inlet

Components on the machine, component

placement
0
P I
4
2 II 3 5
III
12
10
11 8
9
018946
Machine electrical components
1. Accelerator pedal (B690) 7. Control unit, engine alternative Volvo (D794)
2. Ignition key lock (S150) 8. Control unit, transmission (D793)
3. KIT cab control unit (D790-2) 9. Fuel tank
4. Control unit, KID (D795) 10. Sensor fuel level (B757)
5. Control unit, cab (D790-1) 11. Frame control unit (D797-1)
6. Control unit, engine alternative Cummins (D794) 12. Frame option control unit (D797-2)

Engine, separation (engine alternative

Volvo TAD760VE)
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.

2 Attach hoisting equipment to the engine.
3 Disconnect the requisite hoses and cables before separating
engine and transmission.
NOTE
Drain and collect liquids before detaching hoses.
4 Remove the radiator.

5 Use a jack to secure the transmission.
6 Remove the screws holding the cover plate to the flywheel.

7 Remove the nuts for the flex plate through the hole under the
cover washer.
NOTE
Rotate the engine for each nut in the flex plate that has to be
removed.
8 Take up the slack in the hoisting equipment.
NOTE
Do not lift the engine.
9 Remove the bolts between engine and transmission.

10 Remove the screws in the engine brackets.
11 Withdraw the engine rearwards to separate it from the
transmission.
NOTE
Beware of balance before the engine is lifted.
NOTE
If the flex plates are damaged during engine replacement, they
must be replaced.
12 Lift the engine away.
Assembly
13 Apply lubricating grease to the converter connection - both on the
engine and the transmission.
008301

14 Insert two studs into the flywheel housing as a guide when the
engine is installed.
15 Transfer the engine brackets to the new engine; tighten to 169
Nm (oiled screw).
007775
16 Centre a stud on the flywheel so that it aligns with the hole in the
flywheel housing.
007772
17 Lift the engine into place. Make sure that the studs on the flywheel
come into correct alignment and do not damage the flex plate.
18 Install the bolts that affix the transmission and engine, but do not
tighten the bolts fully. Leave about a millimetre between the engine
and transmission to facilitate installation of the nuts for the flex
plate/flywheel.
007776
19 Fit the nuts that fix the flex plates at the flywheel in two steps. First
fit the nuts without tightening. Then rotate the flywheel one more
revolution and torque tighten the nuts to 40 Nm (oiled screw).
NOTE
Rotate the engine for each nut in the flex plate that has to be
fitted.

20 Tighten the screws that attach transmission and engine. Tighten

the transmission in the transmission mountings. Refit the cover
plate and propeller shaft.
21 Measure and check that the engine is centred in the frame.

22 Fit the screws in the engine bracket.
Tighten to 169 Nm (oiled screw).
23 Fit the cover washer under the flywheel.
24 Remove the hoisting equipment from the engine.
25 Remove the jack from underneath the transmission.
26 Connect the requisite hoses and cables for the engine and
transmission. Check and fill fluids as required.
27 Bleed air from the engine's fuel system before starting.
007973

Engine, replacement (engine alternative

Cummins QSB6.7 )
NOTE
Safety.
Separation
2 Attach hoisting equipment to the engine.
3 Disconnect the requisite hoses and cables before separating
engine and transmission. If the engine is replaced the cooling unit
must be removed.
NOTE
Drain and collect liquids before detaching hoses.
009088
4 Remove the radiator.
5 Use a jack to secure the transmission.
6 Remove the screws holding the cover plate to the flywheel on the
left side of the engine.
008314
7 Remove the screws in the flex plate through the hole under the
cover plug.
NOTE
Turn the engine over to access each screw on the flex plate.
8 Take up the slack in the hoisting equipment.
NOTE
Do not lift the engine or transmission.
008315

9 Remove the bolts between the engine and the transmission.

10 Remove the screws in the engine brackets.
11 Carefully detach the transmission from the engine.
12 Withdraw the engine rearwards to separate it from the
transmission.
NOTE
008275
Beware of balance before the engine is lifted.
NOTE
If the flex plates are damaged during engine replacement, they
must be replaced.
13 Lift the engine away.
Assembly
14 Move the engine mount to the new engine. Tighten to a torque
of 115 Nm (oiled screw).
engine and the transmission.
008301
16 Insert a stud into one of the nuts on the flexible plate as a guide
when the engine is installed.
007769
Transmission guide stud

17 Lift the engine into place. Guide the stud through the flywheel and
out through the hole in the flywheel housing.
18 Install the screws which fix the transmission and engine, but do
not tighten the screws fully. Leave about a millimetre between
the engine and transmission to facilitate installation of the screws
for the flex plate/flywheel.
19 Remove the stud through the hole in the flywheel housing.
008319
20 Fit the screws that secure the flex plate by the flywheel in two
steps.
The first step without tightening the screws, then rotate the
flywheel a further turn.
Tighten to a torque of 35 Nm (oiled screw).
NOTE
Turn the engine over to access each screw on the flex plate.
008315
NOTE
The engine must be loosened from the engine mounts and
separated from the transmission to remove a dropped bolt.
Secure the bolt in the socket when installing.
21 Fit the bolts that secure the transmission and engine.

008275
22 Measure and check that the engine is centred in the frame.

23 Fit the screws in the engine bracket.
24 Fit the cover plug in front of the flywheel.
25 Remove the hoisting equipment from the engine.
26 Remove the jack from underneath the transmission.
27 Connect the requisite components, hoses and cables for the
engine and transmission. Check and fill fluids as required.
28 Bleed air from the engine's fuel system before starting.
007796

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

1.1.1 Ignition
Ignition key lock, description
P No function.
0 Stop position. Everything switched off, the key can be
removed.
I Operating position.
Voltage to all electrical functions. The control units for
engine and transmission are now ready to be started.
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.1.4 CAN/POWER,
menu 4.
II Preheating position (function applies to Volvo engines only).
When the switch is in the preheating position, the engine's
intake air is manually heated to a suitable temperature with
glow plugs in each cylinder on Volvo engines (Cummins
engines are heated automatically with a heating coil). The
preheating lamp is lit during preheating.
0
P I section 8 Control system, group 8.4.6.4 ENGINE, menu 4.
I- Start position.
II Engagement of starter motor for engine start.
II
NOTE
The machine is equipped with an electric restart
000317
III interlock, which prevents engagement of the starter

motor when the engine is rotating.
Condition for starter motor to engage is that the
transmission is in neutral position and that the engine
isn't already running.
section 8 Control system, group 8.4.6.4 ENGINE, menu 4.
1.1.2 Accelerator pedal

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

1 Engine – Accelerator pedal 1:23
Accelerator pedal, calibration

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

1:24 1 Engine – Fuel system
1.2 Fuel system

Fuel system, description
The fuel system distributes fuel between the cylinders and by doing so
controls the engine output power and rpm.
When the engine is started, the fuel pump draws fuel from the tank
through the fuel filter and forces it to the unit injectors. The unit injectors
spray in the fuel and atomises the fuel to the engine's combustion
chamber.
1.2.1 Fuel tank

Fuel tank, description
The fuel tank is located on the left-hand side of the machine.
3
1
019425
1. Sensor fuel level

2. Filling point fuel
3. Fuel tank

1 Engine – Sensor fuel level 1:25
1.2.2 Sensor fuel level

Sensor, fuel level, description
Fuel tank sensor (B757) is placed on the front of the fuel tank.
3 Sensor fuel level (B757) sends a voltage signal proportional to the
fuel level in the tank to Control unit, frame (D797-1). The signal can
2 be checked via the diagnostic menu. See section 8 Control system,
group 8.4.3.7 CAB, menu 7.
1
019425
1. Sensor fuel level

2. Filling point fuel
3. Fuel tank

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

1.6.1 Air cleaning system
Air cleaning system, description
The air cleaning system consists of an air cleaner with filter, filter
indicator, pipes and hoses. There are two filters in the air cleaner that
purify the air and a dust reservoir that collects larger particles. The dust
2 reservoir can be emptied without opening the air cleaner.
3
Combustion in the engine requires air. Free unobstructed flow for
fresh air and exhaust gases is essential for efficient engine operation.
Particles are collected in the filter material when the air filters clean the
air to the engine. Over time, a great deal of particle matter is collected
1 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
008040
that it is time to replace the filter.
Air cleaning system, overview As an option the machine can be equipped with a raised air intake.
1. Dust reservoir
2. Air cleaner
3. Filter indicator

1 Engine – Exhaust system 1:27
1.6.3 Exhaust system

Exhaust system, description
The exhaust system is mounted in the frame. Heat protection is fitted
between the engine and exhaust system to protect cables, etc. A flex
pipe between the turbo and silencer takes up engine movement. On
the outside of the machine, there is heat protection fitted over the
exhaust system.
WARNING
Hot exhaust system!
Risk of burn injuries!
Never touch hot components, e.g. turbo, exhaust pipe,
silencer or catalytic converters when the machine is
running or just after it has been turned off!
1
2 3
018947
1. End pipe
2. Silencer
3. Exhaust pipe

1:28 1 Engine – Intercooler
1.6.4 Intercooler
Intercooler, description
The charge air is cooled by an air-air intercooler in the upper part of
the cooling unit.
See also Cooling system, description, page 1:29.

1
4
018923
1. Intercooler
2. Radiator
3. Fuel cooler
4. Transmission oil cooler

1 Engine – Cooling system 1:29
1.7 Cooling system

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

• Coolant pump
• Expansion tank
• Thermostat
• Cooling fan
• Radiator
• Engine oil cooler
• Intercooler
Engine cooling work as follows:

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

1:30 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 placed
behind the engine.
The function of the cooling unit is to cool:

1 • Engine coolant.
• Transmission oil (cooled in its own part of the cooling unit), see
also section 2 Transmission, group 2.6.3 Oil cooler.
• Charge air (cooled in the upper part of the cooler unit), see also
Intercooler, description, page 1:28.
2
• Fuel.
4
018923
1. Intercooler
2. Radiator
3. Fuel cooler

1 Engine – Cooling fan 1:31
The coolant is filled into the system's expansion tank (position A). The
coolant level should be between the MIN and MAX markings (position
C) on the expansion tank.
A
See also Cooling system, description, page 1:29.
For more information, see supplier documentation, engine.
B
C
018642
A. Position for coolant reservoir (expansion tank)

B. Filling point
C. Level marking, MIN. and MAX.
1.7.5 Cooling fan

Cooling fan, description
The cooling fan is located on the engine water pump at the rear of the
engine. The fan is powered by the engine via the drive belt and forces
air through the cooling unit.

1:32 1 Engine – Coolant
1.7.7 Coolant
Coolant, changing (engine alternative Volvo)

Cooling efficiency is impaired due to deposits in the radiator and in
the engine's cooling ducts. Consequently, the system must always be
cleaned when replacing the coolant.
WARNING
The cooling system is pressurised. Steam or hot
coolant 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.
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid skin contact, wear protective
glasses and protective gloves. In the event of skin
contact, wash your hands.
IMPORTANT
Machines with ECC or AC are equipped with a
combined heating and cooling unit, which may result
in a risk of frost damage if the machine is operated
without coolant.
Risk of freezing and damage to the heating and cooling
unit!
The electrical connections on the AC compressor must
be disconnected when cleaning the radiator with water
or agents without antifreeze properties.
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.
NOTE
Before draining, stop the engine and remove the filler cap.

1 Engine – Coolant 1:33
Draining
2 Open the filler cap on the expansion tank carefully until a slight
resistance is felt and allow any overpressure to be vented away.
A The filler cap has a position for venting out overpressure without
the risk of the cap loosening. The position feels like a small notch
when turning the cap.
WARNING
The cooling system is pressurised. Steam or hot
coolant may jet out.
Risk or scalding or burn injuries!
Open the filler cap very carefully when the engine is
B warm. Wait until the coolant has cooled before filling.
C
3 When the overpressure has been vented away, remove the filler
cap from the cooling system's expansion tank.
4 Position a receptacle under the drain points on the radiator and
engine. For cooling system volume, see section F Technical data.
018642

B. Filling point
5 Open all drain points. Drain the coolant from the radiator and
engine block using the drainage hose.
The cock for draining the radiator is located in the lower part of the
right-hand coolant tank. Thread a hose onto the cock to route the
coolant away during draining.
The drain points are located on the underside of the radiator and
on the right-hand side of the engine block or under the oil cooler.
6 Check that all coolant drains out.
NOTE
007394
Any deposits inside the tap/plug must be cleaned away, otherwise

there is a risk that the coolant may remain and cause freezing
damage.
Drain point engine Volvo TAD760VE Let the drainage taps or plugs remain open and make sure that the
heating control is set to full heat while cleaning.
7 Insert a hose in the filler hole in the expansion tank and flush with
clean water, until the water flowing out is clear.
8 If impurities remain after flushing for a long time, it's possible to
clean with coolant. Otherwise, continue with step Filling point,
page 1:34.

Cleaning with coolant

1 Fill the cooling system, see Filling point, page 1:34. Only use
recommended coolant, see section F Technical data.
2 Drain the cooling system after 1-2 days of operation.
NOTE
Drainage should be performed quickly, within 10 minutes, without
the engine being at a standstill for a long time to prevent dissolved
material from re-entering the cooling system.
Remove the filler cap from the expansion tank and possibly a
lower radiator hose to increase the draining speed.
3 Immediately rinse the system very carefully with clean warm water
to prevent dirt from depositing again on the internal surfaces.
Rinse until the outflowing water is completely clean. Check that
the water valve in the cab is fully open when cleaning.
4 Should impurities remain after flushing for a long time, it's possible
to clean with coolant, contact Cargotec Service.
NOTE
Only use cleaning agents approved by the engine manufacturer.
Follow the instructions on the packaging carefully.
Filling point
1 When the cooling system is completely free from impurities, close
the drain points.
CAUTION
Different types of coolant may not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, the same type
of coolant must be used as was used before.
2 Start the engine.

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

1 Engine – Coolant 1:35
Coolant, replacement (engine alternative Cummins

QSB6.7)
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.

2 Open the hood.
3 Remove the cap on the expansion tank.
4 Place a receptacle under the radiator and engine. (The cooling
system holds about 40 l.)
5 Drain the cooling system.
Open the drain cock on the bottom of the radiator. Collect the
coolant in the receptacle.
014698
6 Open the drain on the engine.

7 Once all the coolant has drained out, close drain cocks.
015538
Drain point coolant.

8 Fill the new premixed coolant of the correct type in the expansion
tank. For volume and quality, see section F Technical data.
A
CAUTION
9 Switch on the system voltage and start the engine.

B
10 Set cab heating to max.
C
11 Run the engine to operating temperature so the thermostat opens
and coolant is pumped around the whole system.
12 Check the level in the expansion tank, fill if necessary.
13 Close the hood.
14 Check the coolant level again after 10 operating hours.
018642

B. Filling point

1 Engine – Control system, engine 1:37
1.9 Control system, engine

1.9.1 Engine control unit
Control unit, engine, general
See section 11 Common electrics, group 11.5.3.10 Control unit, engine
and supplier documentation, engine.

1:38 1 Engine – Start/stop
1.11 Start/stop
1.11.1 Starter motor
Starter motor, description (engine alternative Volvo)
The starter motor cranks the engine until fuel combustion begins and
the engine starts.
The starter motor is supplied with voltage directly from the start
batteries. A relay on the starter motor (solenoid) is activated by the
engine control unit (D794).
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.6.5 ENGINE, menu 5.
Starter motor, description (engine alternative

Cummins)
The starter motor cranks the engine until fuel combustion begins and
the engine starts.
The starter motor is supplied with voltage directly from the start
batteries. A relay on the starter motor (solenoid) is activated by Control
unit, engine (D797-1R).
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 can only be stopped by turning off the ignition via the
ignition key lock.
NOTE
The battery disconnector cannot and must not be used as
emergency stop!
Automatic engine shutdown is available as an option. This means

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

2:1
2 Transmission
Contents 2 Transmission
2 Transmission ..................................................................................................... 2:3
2.1 Controls and instruments ...............................................................................2:10
2.1.1 Gear selector and multi-function lever.......................................................2:10
2.2 Torque converter/Clutch system .................................................................... 2:11
2.2.1 Flex plates ................................................................................................. 2:11
2.6 Lubrication system .........................................................................................2:13
2.6.3 Oil cooler ...................................................................................................2:16
2.7 Cooling system ..............................................................................................2:17
2.7.3 Oil cooler ...................................................................................................2:17
2.8 Control system, transmission.........................................................................2:18
2.8.1 Transmission control unit ..........................................................................2:18
2.8.2 NO (normally open) switch, disengagement .............................................2:18
2.8.3 Transmission cable harness......................................................................2:18

2:2

2 Transmission – Transmission 2:3
2 Transmission
Transmission, general
and instructions for the transmission's components and systems, refer
to the relevant supplier documentation.
Transmission, function description
2
F 1
R
29 D1
5
D29 D5
34
6, 30, 35 2, 7
28
D790-1 D790-2
D794
12, 23, 25, 27, 33, 36

D793 D795 D797-1
D13 D8 D10 26 32
Pa D31
8 9 10 19 20 21
Pa Pa 31
11
4 D11
18 22
17
3 16
15 24
14
019428
13

1 Multi-function lever (S162) sends a Front: US162:F = 24 V Section 9 Frame, body, cab and
voltage signal to Control unit KIT Reverse: US162:R = 24 V accessories, group 9.1 Controls and
(D790-2). instruments
system, group 8.4.7.2, TRANSM menu 2
2 KIT control unit (D790-2) transmits the Checked by control system, Section 11 Common electrics, group
selected direction of travel (forward or error shown with error code. 11.5.3.11 KIT control unit (D790-2)
reverse) on the CAN bus. D1: Diagnostic menu, see section 8 Control
system, group 8.4.7.2, TRANSM menu 2
3 The transmission's oil pump pumps oil - -
when the engine is running.

2:4 2 Transmission – Transmission

4 The transmission's oil filter cleans the - -
oil from impurities.
5 Accelerator pedal (R690-1) sends a U = 0.5-4.5 V Section 1 Engine, group 1.1.2 Accelerator
signal to the Cab control unit (D790-1). pedal
6 Control unit, cab (D790-1) transmits Checked by control system, Section 11 Common electrics, group
the desired throttle application on the error shown with error code. 11.5.3.1 Cab control unit (D790-1)
CAN bus.
7 Control unit KIT (D790-2) sends the Checked by control system, Section 11 Common electrics, group
selected shifting program on the CAN error shown with error code. 11.5.3.11 KIT control unit (D790-2)
bus.
8 Pressure sensor gear 1/3 (B7651) Checked by Control unit, D8: Diagnostic menu, see section 8 Control
sends a voltage signal proportional transmission, error shown system, group 8.4.7.10 TRANSM menu 10
to the oil pressure to Control unit, with error code.
transmission (D793).
9 Pressure sensor gear 2 (B7652) sends Checked by Control unit, D8: Diagnostic menu, see section 8 Control
a voltage signal proportional to the oil transmission, error shown system, group 8.4.7.10, TRANSM menu 10
pressure to Control unit, transmission with error code.
(D793).
10 Sensor, engine speed (B7530) sends a Checked by Control unit, D10: Diagnostic menu, see section 8
pulse signal with frequency proportional transmission, error shown Control system, group 8.4.7.6 TRANSM
to the engine speed to Control unit, with error code. menu 6
11 Sensor, oil temperature (B7660) sends Checked by Control unit, D11: Diagnostic menu, see section 8
a voltage signal proportional to the transmission, error shown Control system, group 8.4.7.10 TRANSM
transmission oil temperature to Control with error code. menu 10
unit, transmission (D793).
12 Control unit, transmission (D793) Checked by Control unit, Section 11 Common electrics, group
supplies voltage to the solenoid and transmission, error shown 11.5.3.9 Control unit (D793)
servo valves in order to obtain the with error code.
desired function.
13 Solenoid valve drive forward (Y6300) Checked by Control unit, D13: Diagnostic menu, See section 8
14 or Solenoid valve drive reverse (Y6310) transmission, error shown Control system, group 8.4.7.7 TRANSM,
and Servo valve gear forward/reverse with error code. menu 7, 8.4.7.8 TRANSM, menu 8 and
15 (Y6096) are activated to select the 8.4.7.9 TRANSM, menu 9
16 direction of travel.
17 Solenoid valve gear selection 1/3
(Y6075) and Servo valve gear 1/3
18 (Y6067) or Servo valve gear 2 (Y6069)
are activated to select gear position.
Engine power is transferred to the
transmission's output shaft.
19 Sensor, turbine speed (B7510) sends Checked by Control unit, D10: Diagnostic menu, see section 8
Control unit, transmission (D793) a transmission, error shown Control system, group 8.4.7.6 TRANSM
pulse signal with frequency proportional with error code. menu 6
to turbine speed.
20 The drum sensor (B7520) sends the Checked by Control unit, D10: Diagnostic menu, see section 8
transmission control unit (D793) a pulse transmission, error shown Control system, group 8.4.7.6 TRANSM
signal with frequency proportional to with error code. menu 6
drum speed.
21 The output shaft speed sensor (B7580) Checked by Control unit, D10: Diagnostic menu, see section 8
sends the transmission control unit transmission, error shown Control system, group 8.4.7.6 TRANSM
(D793) a pulse signal with frequency with error code. menu 6
proportional to output shaft speed.
22 The torque converter temperature Checked by Control unit, D11: Diagnostic menu, see section 8
switch (S2210) sends the transmission transmission, error shown Control system, group 8.4.7.10 TRANSM
control unit (D793) a voltage signal if with error code. menu 10
oil temperature in the torque converter
becomes too high.


controls gear shifting according to transmission, error shown 11.5.3.9 Control unit (D793)
selected shifting program. with error code.
24 The oil cooler cools the transmission - Section 2 Transmission, group 2.6.3 Oil
oil. A thermostat senses the oil's cooler
temperature and directs the oil back to
the transmission if the oil is cold.
25 Control unit, transmission (D793) Checked by control system, Section 11 Common electrics, group
transmits temperature and speed data error shown with error code. 11.5.3.9 Control unit (D793)
on the CAN bus.
26 Control unit KID (D795) shows Checked by control system, Section 11 Common electrics, group
transmission information in operating error shown with error code. 11.5.3.12 KID control unit (D795)
menus.
27 If the signal from the output shaft speed - Section 11 Common electrics, group
sensor (B7580) indicates that machine 11.5.3.10 Engine control unit (D794)
speed exceeds the speed limitation, D28: Diagnostic menu, see section 8
the transmission control unit (D793) Control system, group 8.4.6.6 ENGINE
transmits an engine speed reduction menu 2
request on the CAN bus.
28 Control unit, engine (D794) reduces - Section 11 Common electrics, group
the engine speed. 11.5.3.10 Engine control unit (D794)
29 The declutch pedal (S220-1) sends a U = 24 V Section 9 Frame, body, cab and
voltage signal to the Cab control unit accessories, group 9.1 Controls and
(D790-1) when activated. instruments
Control system, group 8.4.7.1, TRANSM
menu 1
30 Control unit, cab (D790-1) transmits Checked by control system, Section 11 Common electrics, group
declutch drive on the CAN bus. error shown with error code. 11.5.3.1 Cab control unit (D790-1)
31 Break contact (opening switch), Brake pressure above Section 2 Transmission, group 2.8.2
declutch (S220-2) sends the Frame 0.2 MPa: Break-contact (opening switch) declutch
control unit (D797-1) a voltage signal US220-2:1 = 24 V D31: Diagnostic menu, see section 8
when the brake pressure is high Control system, group 8.4.7.1, TRANSM
enough to allow drive disengagement. US220-2:2 = 24 V
menu 1
Brake pressure below
0.2 MPa:
US220-2:1 = 24 V
US220-2:2 = 0 V
32 The frame control unit (D797-1) Checked by control system, Section 11 Common electrics, group
transmits disengagement approved on error shown with error code. 11.5.3.2 Frame control unit (D791-1)
the CAN bus.
supplies voltage to valve block transmission, error shown 11.5.3.9 Control unit (D793)
transmission control so that drive is with error code.
declutched.
34 If the operator leaves the driver's seat, U = 24 V Section 9 Frame, body, cab and
the operator-in-seat sensor (S230) accessories, group 9.3.14 Operator-in-seat
sends a voltage signal to the cab sensor
control unit (D790-1).
35 The cab control unit (D790-1) transmits Checked by control system, Section 11 Common electrics, group
go to neutral on the CAN bus. error shown with error code. 11.5.3.1 Cab control unit (D790-1)
36 Transmission control unit (D793) Checked by Control unit, Section 11 Common electrics, group
interrupts the power supply to the drive transmission, error shown 11.5.3.9 Control unit (D793)
servo valves so that the drive shifts to with error code.
neutral three seconds after the driver
has left the driver's seat.

Shifting transmission, function description
5
21
22 6 11 17
16 20
Pa Pa
7 12
23
8 13 18
27 4 3
24
25 2
26
1 1st 3rd 2nd
Rev Fwd
015548
9 10 14 15 19

1 Bottom strainer oil sump, separates particles - -
from the oil before the pumps.
2 The transmission's oil pump feeds the 92.1 l/min at 2420 rpm -
transmission with control pressure for control
of the transmission.
3 The oil filter cleans the oil. - -
4 The bypass valve in the filter bracket leads - -

the oil past the filter if the resistance through
the filter becomes too high.
5 Sensor, oil temperature (B7660) sends - Diagnostic menu, see section 8
a voltage signal proportional to the oil Control system, group 8.4.7.10
temperature to Control unit, transmission TRANSM, menu 10
(D793).
6 Servo valve gear front/rear (Y6096) controls - Diagnostic menu, see section 8
pressure to Valve travel direction, proportional Control system, group 8.4.7.7
to the desired traction. TRANSM, menu 7
7 Solenoid valve drive forward (Y6300) or - Diagnostic menu, see section 8
Solenoid valve drive reverse (Y6310) controls Control system, group 8.4.7.8
Valve travel direction for drive forward or TRANSM, menu 8 and 8.4.7.9
reverse. TRANSM, menu 9
Valve travel direction controls pressure to
drive clutch forward or drive clutch reverse,
depending on which solenoid valve is
activated.
8 The accumulator evens out the pressure. - -
9 Drive clutch reverse locks the transmission in Drive reverse: 2850-3150 kPa -
reverse drive when the clutch is pressurised.
10 Drive clutch forward locks the transmission in Drive forward: 2850-3150 kPa -
forward drive when the clutch is pressurised.
11 Servo valve gear 1/3 (Y6067) controls - Diagnostic menu, see section 8
pressure to Solenoid valve gear selection Control system, group 8.4.7.8
1/3 (Y6075) proportional to the desired TRANSM, menu 8 and 8.4.7.9
engagement force. TRANSM, menu 9
12 Solenoid valve gear selection 1/3 (Y6075) - Diagnostic menu, see section 8
pressurises Drive clutch gear 1 or Drive clutch Control system, group 8.4.7.7
gear 3. TRANSM, menu 7


14 Drive clutch gear 1 locks the transmission in Gear selected: 2850-3150 kPa -
gear position 1 when the clutch is pressurised.
16 Pressure sensor gear 1/3 (B7651) sends the - Diagnostic menu, see section 8
transmission control unit (D793) a voltage Control system, group 8.4.7.10
signal proportional to engagement pressure. TRANSM, menu 10
17 Servo valve gear 2 (Y6069) controls pressure - Diagnostic menu, see section 8
to pressurise the Drive clutch gear 2 Control system, group 8.4.7.8
proportional to the desired engagement force. TRANSM, menu 8 and 8.4.7.9
TRANSM, menu 9
20 Pressure sensor gear 2 (B7652) sends the - Diagnostic menu, see section 8
transmission control unit (D793) a voltage Control system, group 8.4.7.10
signal proportional to engagement pressure. TRANSM, menu 10
21 The pressure regulator releases pressure to Opening pressure: 2850-3150 -
the torque converter if the pressure becomes kPa
too high.
22 The safety valve leads the oil back to the Opening pressure: 900 kPa -
sump if the pressure to the torque converter
becomes too high.
23 The torque converter transmits the engine's - -
power to the transmission.
24 The torque converter temperature switch - Diagnostic menu, see section 8
(S2210) sends the transmission control unit Control system, group 8.4.7.10
(D793) a voltage signal if oil temperature in TRANSM, menu 10
the torque converter becomes too high.
25 The transmission oil cooler cools the oil. - -
26 The oil is distributed to different lubrication - -

points in the transmission.
27 The bypass valve leads surplus oil past the Opening pressure: 500 kPa -
torque converter.

Transmission, component location
7
6
5
4
1 2 3 8
9
10
11
12
13
14
15
16
17
20 19 18
019429
24 23 22 21
1. Connection transmission oil cooler 13. Servo valve gear 1/3 (Y6067)
2. Sensor rpm turbine (B7510) 14. Pressure sensor gear 1/3 (B7651)
3. Breather filter torque converter 15. Servo valve forward/reverse (Y6096)
4. Transmission oil cooler 16. Pressure sensor gear 2 (B7652)
5. Radiator inlet 17. Output shaft
6. Thermostat 18. Servo valve gear 2 (Y6069)
7. Radiator outlet 19. Sensor oil temperature (B7660)
8. Sensor engine speed (B7530) 20. Oil filter transmission
9. Sensor, drum rpm (B7520) 21. Connection transmission oil cooler
10. Solenoid valve drive forward (Y6300) 22. Temperature monitor torque converter (S2210)
11. Solenoid valve drive reverse (Y6310) 23. Connection oil filling and oil dipstick
12. Solenoid valve gear selection 1/3 (Y6075) 24. Sensor rpm output shaft (B7580)

Components on the machine, component

placement
1 2 3 4 5
11
10
9 8
018752
7
1. Accelerator pedal (B690) 7. Fuse transmission (F58-1:5)
2. Control unit KIT (D790-2) 8. Control unit, transmission (D793)
3. Control unit, KID (D795) 9. Declutch pedal (S220-1)
4. Multi-function lever (S162) 10. Make-contact (closing switch) declutch (S220-2)
5. Control unit, cab (D790-1) 11. Frame control unit (D797-1)
6. Diagnostic socket drive-train
Engine and transmission, separation

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

2:10 2 Transmission – Controls and instruments

2.1.1 Gear selector and multi-function lever
Gear selector and multi-function lever, description
F Selection of direction travel is made with the gear selector and

multi-function lever.
Selecting direction of travel:

• F - Forward
• N - Neutral
• R - Reverse
The switch is supplied with voltage by, and sends signals to, Control
002209
unit KIT (D790-2).

R
Control system, group 8.4.7.2 TRANSM, menu 2.

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

2.2.1 Flex plates
Flex plates, changing (engine alternative Volvo
TAD760VE)
For further details about separating the motor and transmission, see
section 1 Engine, group 1 Engine and transmission, separating.
2 Remove the bolts holding the flex plate to the transmission.
3 Replace the flex plate. Tighten the screws fixing the flex plate to
the transmission to 40 Nm (oiled screws).
4 Before the machine is put into operation, the transmission must
be calibrated; see .
007774
Attaching the flex plate (transmission alternative TE17

with Volvo TAD760VE engine)
Flex plates, replacement (engine alternative Cummins

QSB6.7 )
For further details about separating the motor and transmission, see
section 1 Engine, group 1 Engine and transmission, separating.
2 Remove the cover plate.
3 Remove the screws for the flex plate.
Rotate the engine for each bolt to the flex plate that has to be
removed.
4 Attach the transmission to an overhead crane.
008314
5 Remove the bolts holding together the transmission and engine.

6 Carefully separate the transmission and engine.
008275

2:12 2 Transmission – Flex plates
7 Remove the bolts holding the flex plate to the transmission.

8 Replace the flex plate. Tighten the screws fixing the flex plate to
the transmission to 40 Nm (oiled screws).
engine and the gearbox.
Insert a stud into one of the nuts on the flexible plate as a guide
when the engine is installed.
Flex plate attachment.
10 Place the screws that secure the gearbox and engine in position
without tightening the bolts.
11 Remove the stud and replace the screws that secure the flex plate
to the flywheel in two steps. The first step fit the screws without
tightening them. Now rotate the flywheel a further turn and tighten
the screws with a torque of 35 Nm (oiled screws).
NOTE
008275
The engine must be loosened from the engine mounts and

separated from the transmission to remove a dropped bolt.
Secure the bolt in the socket when installing.
12 Fit the screws that fasten the gearbox and engine and tighten them
to 52 Nm (oiled screw).

2 Transmission – Lubrication system 2:13
2.6 Lubrication system

Lubrication system, description
The transmission lubrication system has the following function:
• Lubricate gear wheels and bearings
• Apply the clutches in the transmission
• Cool down the torque converter and the transmission
• Clean the oil of any impurities with two oil filters.
During operation of the engine, the oil pump draws oil from the
transmission's oil sump through a strainer, and it then pumps it through
the oil filter to a control valve.
The control valve supplies oil at the correct pressure to the

transmission's valve housing to activate the clutch plates for
FORWARD or REVERSE and gear 1, 2 or 3. The clutch plates require
just a small amount of the oil flow supplied by the pump. The remainder
of the oil is pumped through the torque converter circuit to the oil cooler
and then returns to the transmission for lubrication.
See also supplier documentation, transmission.
Oil and oil filter transmission, changing
NOTE
Safety.
NOTE
The transmission must not be over-filled!
1 Operate and warm up the transmission oil.

3 Place a receptacle under the transmission.
4 Remove the drain plug for transmission oil and let the oil drain
into the receptacle.
NOTE
Make sure that the seal washer for the drain plug is fitted as well.
Draining transmission oil

2:14 2 Transmission – Lubrication system
5 Clean the area around the oil filter.

6 Change oil filter.
Lubricate the O-ring on the new oil filter with transmission oil.
Tighten to contact and then another two-thirds of a turn.
7 When the transmission oil has drained, fit the drain plug.
NOTE
018789
B
A
018644
Machine with Volvo TAD760VE

A. Oil dipstick transmission
B. Filling point
A B 8 Remove the transmission dipstick and fill new transmission oil

through the dipstick's hole to the marking for low level on the
dipstick.
For volume and quality, see section F Technical data.
9 Turn the main current on and start the engine and allow the engine
to idle for at least two minutes.
10 Check that the transmission oil drain plug is sealed.
018849
Machine with Cummins QSB6.7

2 Transmission – Lubrication system 2:15
11 Operate and warm up the transmission so that the display shows

an oil temperature of approx. 60-65 ºC. Use the oil temperature
operating menu to check transmission oil temperature.
a 12 Check the oil level. Fill to the MAX mark.
13 Calibrate the transmission; see .
000356
b
Operating menu, oil temperature

a. Transmission oil temperature
b. Hydraulic oil temperature
Oil level, checking
NOTE
Safety.
The transmission's oil filler pipe and dipstick are located under the
engine hood.
B
A
018644
Machine with Volvo TAD760VE

A. Oil dipstick transmission
B. Filling point
A B 1 Check the oil level with the engine at idle, transmission in neutral
position and at operating temperature (approx. 82-93 ºC in the
display). The dipstick has two markings, MAX and MIN. The oil
level should be at MAX.
Wipe off the oil dipstick before checking.
NOTE
The oil dipstick is long. Wear gloves.
2 Top up with transmission oil if necessary. For volume and quality,

see section F Technical data).
3 Fill - wait a moment - check the oil dipstick.
NOTE
018849
Work carefully when filling transmission oil to prevent other fluids

Machine with Cummins QSB6.7 or particles from contaminating the oil. Other fluids or particles in
the transmission oil means a risk of transmission damage.

2:16 2 Transmission – Oil cooler
2.6.3 Oil cooler

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

transmission oil cooling circuit, is fitted in a pipe on the underside of
1 the radiator (engine side). The valve closes when the oil starts to
reach operating temperature. This means that the oil reaches normal
operating temperature more quickly.
For more information, see supplier documentation, transmission.
4
018923
1. Intercooler
2. Radiator
3. Fuel cooler
Thermostat transmission oil cooler, replacement
NOTE
Safety.

2 Drain the oil from the transmission, see Oil and oil filter
transmission, changing, page 2:13.
3 Loosen the cover plug and remove the thermostat.
4 Check the O-ring and the spring in the bottom, replace as
necessary.
5 Fit the new thermostat, and the cover plug.
IMPORTANT
014550
It is very important that the thermostat is turned with

the temperature bulb facing out as shown.
6 Fill with transmission oil; see Oil and oil filter transmission,
changing, page 2:13.
7 Start the engine and check for leaks.
8 Check the transmission oil level, see Oil level, checking, page 2:15.

2 Transmission – Cooling system 2:17
2.7 Cooling system

2.7.3 Oil cooler
Oil cooler, description
See Oil cooler, description, page 2:16.

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

2.8.1 Transmission control unit
Control unit transmission, general
See section 11 Common electrics, group 11.5.3.9 Control unit,
transmission and supplier documentation, transmission.
2.8.2 NO (normally open) switch, disengagement

Make-contact (closing switch) declutch, description
Make-contact (closing switch) declutch (S220-2) detects whether the
wheel brakes are pressurised. The make-contact (closing switch) is
located on the distribution block for the brake system above the drive
axle's differential.
The sensor can be checked via the diagnostic menu. See section 8
Control system, group 8.4.7.1 TRANSM, menu 1.
1
10
2
1
3
3
4
5
5
9 6
8 7
019430
1. Connection brake cooling, return from wheel

brake
2. Connection brake cooling, return to radiator
and tank
3. Connection brake cooling, to wheel brake
4. Connection brake cooling, from accumulator
charging valve
5. Connection brake cylinder, to wheel brake
6. Connection brake pressure, from brake valve
7. Make-contact (closing switch), declutch
(S220-2)
8. Make-contact (closing switch), brake light
(S216)
9. Measuring outlet, brake pressure
10. Measuring outlet, back pressure brake
cooling
2.8.3 Transmission cable harness

Transmission cable harness, description
See section E Schematics.

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

3:2

3 Driveline/Axle – Driveline/Axle 3:3
3 Driveline/Axle
3.2 Propeller shaft
Propeller shaft, description
The propeller shaft transfers engine power from the transmission to the
drive axle. The propeller shaft has two joints, which means that the
engine and drive axle can move in relation to each other.
Propeller shaft, replacement

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

4 Fit the propeller shaft's attaching bolts.
Tightening torque: 98 Nm (oiled bolt). Retighten the attaching
bolts after 50h operating time.
005193

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

Drive axle, general
and instructions for the drive axle's components and systems, refer to
the relevant supplier documentation.

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 Remove the mast, see section 7 Load handling, group 7.2

Lifting/lowering.
2 Park the machine with blocks behind the steering wheels.
3 Depressurise the hydraulic systems, See section B Safety.
4 Turn the start key to position 0 and switch off the main power.
5 Insert wedges between the steering axle and the frame.

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

(position 2) from the distribution block.
NOTE
Plug all connections immediately to protect the hydraulic system
from impurities.
004501
2
1. Hydraulic hoses
2. Cables
7 Remove the cover (position 3) on the parking brake.

3
004505
3. Cover, parking brake
8 Loosen the lock nut (position 4) and screw in the screw (position
5), this compresses the brake spring. Screw until the brake pads
release from the brake disc. Refit the cover on the parking brake
(position 3).
6
9 Detach the hydraulic hose (position 6) from the parking brake.
NOTE
5 Plug all connections immediately to protect the hydraulic system
from impurities.
4
004506
4. Lock nut
5. Release screw
6. Hydraulic hose, parking brake

10 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.
11 Lift the machine so that the wheels are off the ground.
12 Remove the drive wheels from the drive axle.
13 Support the drive axle under the hubs.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away
uncontrollably.
Lifting machine
14 Remove the bolts that secure the drive axle in the frame.
15 Lift away the drive axle.
CAUTION
Crushing injury!
uncontrollably.
Attaching bolts drive axle

3 Driveline/Axle – Drive axle 3:7
16 Undo the hydraulic hoses on the drive axle.
NOTE
from impurities.
17 Transfer the couplings from the old axle to the new axle.
18 Transfer the parking brake union to the new axle.
19 Undo the distribution block bracket and move it to the new axle.
20 Connect the hydraulic hoses from the distribution block to the
drive wheels.

21 Clean contact surfaces on drive axle and frame. Also clean the
contact surface for the bolts on the underside of the drive axle.
22 Remove the nuts for attaching the drive axle, blow clean and refit
the nuts.
23 Lift the drive axle into place under the frame.
CAUTION
Crushing injury!
uncontrollably.
24 Lower the frame toward the drive axle.

25 Insert the new screws securing the drive axle in the frame. Tighten
to 1380 Nm (oiled screw).
26 Install the drive wheels on the new axle.
27 Rustproof the bolts with suitable paint.
28 Connect the hydraulic hoses (position 1) and cable harness

(position 2) to the distribution block on the drive axle.
29 Connect the hydraulic hose to the parking brake, adjust the
parking brake.
30 Connect the propeller shaft to the drive axle; see Propeller shaft,
replacement, page 3:3.
31 Check the oil level in the drive axle.
32 Start the machine and bleed the brakes, see section 4 Brakes,
group 4.3.9 Wheel brake.
1 33 Check for leaks.
004501

4:1
4 Brakes
Contents 4 Brakes
4 Brakes................................................................................................................. 4:3
4.1 Controls and instruments .................................................................................4:3
4.1.1 Brake pedal .................................................................................................4:3
4.3 Power-assisted brake system ..........................................................................4:5
4.3.1 Hydraulic oil pump.......................................................................................4:6
4.3.2 Brake oil filter ..............................................................................................4:6
4.3.3 Accumulator charging valve ........................................................................4:7
4.3.4 Accumulator ..............................................................................................4:10
4.3.5 Brake valve ...............................................................................................4:14
4.3.6 Drive axle block .........................................................................................4:17
4.3.7 Break contact (opening switch) brake pressure ........................................4:18
4.3.8 Make-contact (closing switch) brake lights................................................4:20
4.3.9 Wheel brakes ............................................................................................4:22
4.3.10 Pipes and hoses........................................................................................4:24
4.3.12 Valve block brake system..........................................................................4:25
4.5 Parking brake system ....................................................................................4:27
4.5.1 Hydraulic oil pump.....................................................................................4:28
4.5.2 Hydraulic oil filter .......................................................................................4:28
4.5.3 Solenoid valve parking brake ....................................................................4:29
4.5.4 Parking brake unit .....................................................................................4:30
4.5.5 Break contact (opening switch) parking brake ..........................................4:34
4.5.6 Pipes and hoses........................................................................................4:34
4.5.7 Valve block brake system..........................................................................4:34

4:2

4 Brakes – Brakes 4:3
4 Brakes
4.1.1 Brake pedal
Brake pedal, checking and adjustment

1 Clean the floor round the brake pedal and check that nothing is
obstructing the movement of the brake pedal.
2 Check that the brake pedal springs back adequately and that the
clearance between brake pedal and brake valve is 1-1.5 mm.
If necessary, adjust the brake pedal's stop screw to the correct
clearance.
3 Check that the pedal moves smoothly.
Stop screw for adjusting clearance between brake

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

5 Check that the rubber pad on the brake pedal is intact and that the
tread pattern is not worn away. Replace if necessary.
6 Check the brake valve; see Brake valve, checking, page 4:14.
Lubrication points, brake pedal. (The illustration

shows a loose brake pedal.)
Brake pedal, replacement
NOTE
Safety.
1 Switch off the engine and switch off the system voltage.
2 Depressurise the brake and hydraulic systems, see section B
Safety.
3 Detach the brake valve from the brake pedal.
Secure the brake valve on the cab's underside and remove the
brake valve attaching bolt.

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

Secure the steering valve on the cab's underside. Remove the
steering valve's attaching bolts. Pull down the valve slightly so that
the steering axle releases from the steering valve.
6 Detach the steering wheel shaft from the brake pedal.
Undo the bolts and pull the steering wheel shaft up slightly so that
the brake pedal can be removed.
7 Detach the declutch pedal from the brake pedal.
8 Remove the brake pedal.
Remove the brake pedal's attaching bolt and lift away the brake
pedal.
9 Transfer the pedal rubber to the new pedal.
10 Fit the new brake pedal.
Mounting of steering wheel shaft and steering valve
in pedal assembly. Fit the pedal and fit the pedal's attaching bolts.
11 Connect the steering valve to the brake pedal.
12 Connect the brake valve to the brake pedal.
13 Fit the clutch pedal to the brake pedal.
14 Close accumulator drain valve.
NOTE
Check that the accumulator drain valve is fully closed and tighten
the lock ring.
15 Lubricate and adjust the brake pedal, see Brake pedal, checking
and adjustment, page 4:3.
014619

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

Power-assisted brake system, function
description
14
D790-2 B
P
T
D11 D797-1
10, 13 5 9 C
Pa
11
D12 4
D9 6
C
2
12 Pa LB
C ACK M 8
P P
T T
7
P 3
019434
B
1 Hydraulic oil pump for the brakes See the pressure plate on the Hydraulic oil pump, general, page 4:6
and steering pumps oil from the left-hand frame beam.
hydraulic oil tank.
2 Valve block accumulator charging - Accumulator charging valve, description, page
and priority valves direct the 4:7
pressure to the Valve block brakes
when the steering does not require
hydraulic power.
3 Valve block brakes leads the oil - Valve block brake system, description, page
on to accumulators and drive axle 4:25
block.
4 The accumulators store hydraulic See the pressure plate on the Accumulator, description, page 4:10
oil pressure. left-hand frame beam.
5 The brake valve directs pressure - Brake valve, description, page 4:14
from the accumulators to the
brake cylinder proportional to the
pressure on the pedal.
6 Drive axle block distributes the - Drive axle block, description, page 4:17
brake pressure to the wheel brakes.
7 The brake cylinder compresses the See the pressure plate on the Wheel brakes, description, page 4:22
discs in the brake unit which stops left-hand frame beam.
the machine.
8 The wheel brakes brake the - Wheel brakes, description, page 4:22
machine.

4:6 4 Brakes – Hydraulic oil pump

9 Make-contact (closing switch) Brake pressure above Make-contact (closing switch) brake lights,
brake light (S216) makes the circuit 0.2 MPa: description, page 4:20
and sends the voltage signal to the Conn. 1, U = 24 V D8: Diagnostic menu, see section 8 Control
Frame control unit (D797-1) when system, group 8.4.5.4 HYD, menu 4
the brake cylinders are pressurised. Conn. 2, U = 24 V
Brake pressure below
0.2 MPa:
Conn. 1, U = 24 V
Conn. 2, U = 0 V
10 The frame control unit (D797-1) Controlled by control system, Section 11 Common electrics, group 11.5.3.2
supplies power to the brake light error shown with error code. Frame control unit
lamps.
11 Brake light lamps (H411L and U = 24 V Section 9 Frame, body, cab and accessories,
H411R) come on. group 9.6.4 Brake lights
system, group 8.4.2.8 LIGHTS, menu 8
12 Break contact (opening switch) Brake pressure above Brake pressure NC switch, description, page
brake pressure (S204) breaks the 11.5 MPa: 4:18
circuit and sends the voltage signal Conn. 1, U = 24 V D9: Diagnostic menu, see section 8 Control
to the Frame control unit (D797-1) system, group 8.4.5.4 HYD, menu 4
if the pressure in the accumulators Conn. 2, U = 24 V
is low. Brake pressure below
11.5 MPa:
Conn. 1, U = 24 V
Conn. 2, U = 0 V
13 The frame control unit (D797-1) Controlled by control system, Section 11 Common electrics, group 11.5.3.2
transmits a warning about low error shown with error code. Frame control unit
brake pressure on the CAN bus.
14 Control unit KIT (D790-2) activates Controlled by control system, Section 11 Common electrics, group 11.5.3.11
Warning lamp brake pressure. error shown with error code. Control unit, KIT
Hydraulic diagram, see section E Schematics, group 10 Common

hydraulics, Hydraulic diagram.
4.3.1 Hydraulic oil pump

Hydraulic oil pump, general
Brake system, steering and temperature control of the hydraulic oil are
fed by a common hydraulic oil pump.
See section 10 Common hydraulics, group 10.4.1 Gear pump with

fixed displacement.
4.3.2 Brake oil filter

Hydraulic oil filter, general
The return oil from the brakes, steering and load handling is filtered
through the hydraulic oil filter in the oil tank.
See section 10 Common hydraulics group 10.6.7 Hydraulic oil filter.

4 Brakes – Accumulator charging valve 4:7
4.3.3 Accumulator charging valve

Accumulator charging valve, description
The accumulator charging valve is located in the valve block
accumulator charging and priority valve that is part of the main valve,
see section 10 Common hydraulics, group 10.5.4 Main valve. The
main valve is located on the lifting beam in front of the gearbox in the
engine compartment.
The accumulator charging valve distributes the oil from the hydraulic oil
1 pump brakes and steering between pressure storage and cooling of
2 the wheel brakes. The accumulator charging valve stores pressure by
3 directing the oil to the accumulators. The wheel brakes and hydraulic
4 oil are cooled by oil being directed to the drive axle cooling circuit and
then on to the hydraulic system cooler.
5 The accumulator charging valve prioritises charging of the accumulators

above cooling. A restriction of the charging means that a small quantity
of oil also flows to cooling during accumulator charging. At idle the flow
13 6 from the pump is so small that all oil flows to pressure storage.
12 7 There are measuring points on the accumulator charging valve for

measuring control pressure (position 4), servo pressure (position
015032
11 10 9 8 9), accumulator charging pressure (position 10) and pump pressure

Valve block accumulator charging and priority valve brakes and steering (position 13). The pressure is individual for each
(a part of the main valve) machine and can be found on the pressure plate of the left front wing.
1. Feed from the hydraulic oil pump brake and
steering [P]
2. Adjuster screw control pressure
3. Return to filter [D]
4. Measuring outlet control pressure [LSM]
5. Connection brake cooling [SPOL]
6. Connection control valve, pilot pressure [LSO]
7. Feed control valve [O]
8. Adjuster screw pressure accumulator charging
9. Measuring outlet servo pressure [PPM]
10. Measuring outlet accumulator charging
pressure [ACC M]
11. Adjusting screw servo pressure
12. Connection valve block brakes, accumulator
charging [ACC]
13. Measuring outlet pump pressure brake and
steering [PM]

4:8 4 Brakes – Accumulator charging valve
Accumulator charging, checking and adjustment
NOTE
Safety.
1 Operate and warm up the machine so that the oil in the hydraulic
system reaches operating temperature, at least 50 ºC.
˚C 3 Depressurise the hydraulic systems, See section B Safety.
˚C
Operating menu, hydraulic oil temperature 000475
4 Connect a pressure gauge (0-25 MPa) to the accumulator charging

pressure measuring outlet on the accumulator charging valve.
5 Start the engine and run it at idle.
014653
Measuring outlet accumulator charging pressure

[ACC M]

014619
Close the accumulator drain valve

4 Brakes – Accumulator charging valve 4:9
7 Check that the pressure slowly rises to the specified accumulator

charging pressure on the pressure plate.
8 Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve must switch to charging at 13±0.5 MPa.
015021
Pressure plate, accumulator charging pressure
9 If necessary, adjust the accumulator charging pressure on the

valve block accumulator charging and priority valve.
Undo the lock nut and adjust the pressure by turning the adjusting
screw.
Clockwise: reduce pressure.
Anticlockwise: increase pressure.
015028
Adjusting screw, accumulator charging pressure
10 Open the accumulator drain valve so that the accumulators are

drained and the valve switches to charging. Close the valve and
check the max. pressure again.
11 Repeat steps 5–9 until the pressure is correct.
13 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
014618
Open the accumulator drain valve.

4:10 4 Brakes – Accumulator
NOTE
the lock ring.
014619
Close accumulator drain valve.
Accumulator charging valve, replacement

The accumulator charging valve is not replaced separately, in the event
of a fault replace the complete main valve, see section 10 Common
hydraulics group 10.5.4 Main valve.
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 two parallel-connected accumulators placed on the frame member
on the left-hand side of the machine.
The accumulators are of the diaphragm type. Each accumulator is

divided into two compartments by a diaphragm. One side of the
diaphragm is pressurised by nitrogen gas. The other side is pressurised
by the hydraulic oil, which compresses the nitrogen gas.
At the top of the accumulator, there is a connection for checking

nitrogen gas pressure (and for filling nitrogen gas using special filling
equipment).
When the accumulator is charged with hydraulic oil the diaphragm

is pressed upward and the nitrogen gas pressure rises. When the
hydraulic system needs feeding from the accumulator, the diaphragm
presses back the oil to the system.
Pressurised hydraulic oil from the accumulator is used for the service
009869
brake and parking brake systems, and for feeding the servo hydraulic's
reducing valve.
Brake system accumulators
NOTE
If the accumulator delivers low oil pressure, the pumps may be
damaged and the hydraulic functions may stop working.

4 Brakes – Accumulator 4:11
Accumulator, checking
NOTE
Safety.
4 The accumulators can be tested with separate test equipment or in
the machine. Primarily, separate test equipment should be used
˚C
000475
since it is faster and more accurate.
Test equipment can be ordered from Cargotec.
Operating menu, hydraulic oil temperature
• Test with test equipment: continue with step 4.
• Test in machine: continue with step 6.
Checking with test equipment

5 Remove the accumulators and test them with the test equipment
designed for the purpose.
The accumulators' gas pressure must match with the pressure
plate.
6 Continue with step 17.
015030
Pressure plate, gas pressure brake accumulators
Checking in the machine

7 Detach one of the accumulators from the distribution block. Plug
3 the connection on the distribution block with a plug that can
2 withstand high pressure. Plug the connection on the accumulator
1 to protect against impurities.
009871
1. Clamp
2. Screw
3. Distribution block

4:12 4 Brakes – Accumulator

pressure measuring outlet on the Valve block accumulator
charging and priority valve.
9 Turn on the main electric power and start the engine.
014653

[ACC M]
10 Close the accumulator charging valve and charge the accumulator

until the accumulator charging valve changes to cooling.
NOTE
the lock ring.
11 Check that the plug seals properly.

12 Switch off the engine.
13 Lower the pressure by means of braking carefully several times
while checking the pressure on the pressure gauge.
014619
When the pressure reaches approx. 10 MPa the pressure must

decrease immediately to 0 MPa.
Close accumulator drain valve. 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.
15 Mark up and disconnect the tested accumulator. Plug the
connections. Connect the other accumulator to the distribution
block.
16 Repeat steps 6-13.
Installation and final checking

18 Connect both 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.

4 Brakes – Accumulator 4:13
20 Close the accumulator drain valve so that the accumulators charge.
NOTE
the lock ring.
21 Check that the accumulators' connections are sealed tightly.

22 When the accumulators are fully charged, switch off the engine
and turn the start key to position I.
23 Check that at least 8 brake applications (pedal depressions) can
be performed before the pressure drops to 10 MPa.
014619
At 11.5 MPa the warning lamp for low brake pressure must be
switched on.
Accumulator, replacement
NOTE
Safety.

2 Switch off the engine and switch off the main electric power.
4 Detach the accumulator's clamp and remove the bolt.
3 5 Detach the accumulator from the distribution block.
2
1
NOTE
Hold the block firmly so that the other accumulator does not work
loose.
6 Bend the clamp away and remove the accumulator.

7 Fit the new accumulator.
009871
1. Clamp
NOTE
2. Screw Check that the seal is intact, clean and fitted in the correct
position.
8 Secure the accumulator's clamp and tighten the bolt.
NOTE
the lock ring.

11 Check that the accumulator's connection is sealed tightly.
12 Check precharging and function, see Accumulator, checking, page
4:11 steps 18-22.
014619

4:14 4 Brakes – Brake valve
4.3.5 Brake valve

Brake valve, description
3 The brake valve, which is located on the underside of the cab

underneath the brake pedal, controls the hydraulic pressure to the
2 brakes. A lever transfers pedal force to the valve.
1
The brake valve is a mechanically activated proportional valve. This
means that the resistance in the brake valve increases in proportion
to brake pressure. This provides optimum pedal responsiveness and
increased safety as the operator senses if no brake pressure is being
built up (no resistance in the pedal).
009872
1. Inlet from accumulator [P]

2. Return connection [T]
3. Outlet to brake cylinders [B]
Brake valve, checking
NOTE
Safety.
˚C
000475
4 Connect a pressure gauge (0–25 MPa) to the measuring outlet for

brake pressure on the distribution block on the front axle.

4 Brakes – Brake valve 4:15
NOTE
the lock ring.
6 Start the machine and run it at idle until the accumulators are
charged and the accumulator charging valve changes to cooling.
7 Press down the pedal completely and read off the pressure.
Compare with the pressure plate on the left-hand frame member.
014619
9 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.
10 Release the pedal, the brake pressure must decrease to 0 MPa
immediately. Otherwise the brake valve is not sealed and could
cause the brakes to remain applied and then overheat during
operation.
Replace the brake valve if it is not sealed.
measuring outlet.
015026
Pressure plate, brake pressure
NOTE
the lock ring.
014619

4:16 4 Brakes – Brake valve
Brake valve, replacement
NOTE
Safety.

3 Mark up and detach the hydraulic hoses from the brake valve.
B
T NOTE
P Plug all connections immediately to protect the brake system
from impurities.
4 Secure the brake valve under the cab.

009875
5 Remove the brake valve's attaching bolt.

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

B with the marking.
T NOTE
P Change the O-rings. Check that the O-rings are positioned
correctly.
10 Lubricate and adjust the brake pedal, see Brake pedal, checking
004795
and adjustment, page 4:3.

4 Brakes – Drive axle block 4:17
NOTE
the lock ring.
12 Turn on the main electric power and start the engine. Let the
engine run at idle speed.
13 Test the brakes a couple of times.
14 Check that the brake valve's connections are sealed tightly.
15 Bleed the wheel brakes' brake cylinders, see Wheel brakes,
bleeding, page 4:23.
014619
4.3.6 Drive axle block

Drive axle block, description
The drive axle block distributes oil flow and brake pressure to the right
1
10 and left-hand wheel brakes. The drive axle block is fitted on a bracket
2 above the drive axle differential.
1
3 The drive axle block has a measuring outlet for brake pressure and for
3 measuring back pressure in the disc brake's cooling circuit.
4
The drive axle block has a bypass valve which leads oil directly from
5
5 the cooling circuit intake to the cooling circuit return if the resistance
9 in the axle becomes too great. This protects the wheel brake seals,
6 e.g. when the oil is cold.
8 7 There are two contacts in the drive axle block: brake light NO switch
(216), see Make-contact (closing switch) brake lights, description, page
4:20 and disengagement NO switch, see section 2 Transmission, group
2.8.2 Normally closed (NC) switch, disengagement.
009876
1. Connection brake cooling, return from wheel

brake
2. Connection brake cooling, return to radiator
3. Connection brake cooling, to wheel brake
4. Connection brake cooling, from accumulator
charging valve
5. Connection brake cylinder, to wheel brake
6. Connection brake pressure, from brake valve
7. Make-contact (closing switch), declutch (S220)
8. Make-contact (closing switch), brake light
(S216)
9. Measuring outlet, brake pressure
10. Measuring outlet, back pressure brake
cooling

4:18 4 Brakes – Break contact (opening switch) brake pressure
4.3.7 Break contact (opening switch) brake

pressure
Brake pressure NC switch, description
Break contact (opening switch) brake pressure (S204) detects the
1 2 3 pressure in the accumulators. Break contact (opening switch) located
4 on the valve block brake system on the lifting beam in front of the
gearbox in the engine compartment. See Valve block brake system,
description, page 4:25.
5
When the pressure in the feed circuit is high enough to ensure braking
of the machine, the sensor closes an electric circuit. This is used to
11 warn for pressure-drop in the brake system. The sensor's opening
6
pressure is chosen so that there is pressure for at least another 8
brake applications without additional feed from the pump after the lamp
7 has illuminated.
10
Break contact (opening switch) brake pressure (S204) voltage fed by
9 Frame control unit (D797-1). When the pressure increases above the
8 cut-off pressure, the voltage signal to the Frame control unit (D797-1)
is cut.
Control system, group 8.4.5.4 HYD, menu 4.
015018
Valve block brake system

1. Solenoid valve, parking brake (Y642)
2. Accumulator drain valve
3. Pressure relief valve
4. Connection tank return [T]
5. Break-contact parking brake (S200)
6. Brake pressure NC switch (S204)
7. Connection, parking brake caliper [HB]
8. Connection feed from accumulator charging
and priority valve [P]
9. Connection, accumulators [ACC]
10. Connection brake valve [P]
11. Connection brake valve [T]
Brake pressure NC switch, adjusting
NOTE
Safety.
˚C
000475

4 Brakes – Break contact (opening switch) brake pressure 4:19

pressure measuring outlet on the Valve block accumulator
014653
[ACC M]
NOTE
the lock ring.
6 Start the engine and fully charge the accumulators (the

accumulator charging valve changes to cooling).
7 Stop the engine and turn the start key to position I.
8 Brake several times, stop when the warning lamp for low brake
pressure comes on.
014619
9 Read the accumulator charging pressure. The pressure should be

approx. 11.5 MPa.

4:20 4 Brakes – Make-contact (closing switch) brake lights
10 If necessary, adjust the warning level by turning the adjusting

screw in the rear edge of the sensor, between the contact pins.
NOTE
The setting is very sensitive, turn max. 1/4 turn at a time.
11 Repeat steps 6-10 until the warning lamp illuminates at 11.5 MPa.
12 Seal the adjusting screw with locking fluid.
measuring outlet.
NOTE
the lock ring.
014619
4.3.8 Make-contact (closing switch) brake lights

Make-contact (closing switch) brake lights,
description
Make-contact (closing switch) brake lights controls brake light activation
when the machine brakes. The switch is fitted on the drive axle block
which is fitted on a bracket above the drive axle differential.
Make-contact (closing switch) brake light (S216) is supplied voltage by
and sends a voltage signal to Frame control unit (D797-1). When the
pressure increases above the closing pressure, a voltage signal is sent
to Frame control unit (D797-1).
009878
Make-contact (closing switch) brake light, checking
NOTE
Safety.
˚C 3
4
Brake and check that the brake light is switched on.
Depressurise the hydraulic systems, See section B Safety.
˚C
000475

4 Brakes – Make-contact (closing switch) brake lights 4:21
5 Connect a pressure gauge (0-25 MPa) to the measuring outlet for

brake pressure on the distribution block.
Measuring outlet, brake pressure
NOTE
the lock ring.
7 Start the engine.

014619
8 Use the display, go to the diagnostic menu, see section 8 Control

DIAG HYD 4(6) system, group 8.4.5.4 HYD, menu 4.
PRESSURE SWITCHES BRAKE LIGHT PRESS. indicates status for the brake light switch.
BRAKE PRESSURE X 1 = Activated switch (brakes applied).
BRAKE LIGHT PRESS. X
000144
DECLUTCH PRESSURE X 9 Depress the brake pedal slowly until the brake light is switched on
or the status of the input signal changes. Keep the pedal in this
position and check the pressure on the pressure gauge.
The status should change and the brake light should be switched
on when the pressure is approx. 0.2 MPa.
measuring outlet.
NOTE
the lock ring.
014619

4:22 4 Brakes – Wheel brakes
4.3.9 Wheel brakes

Wheel brakes, description
The wheel brakes brake the machine during operation and are fitted on
the drive axle between the drive axle housing and hub reduction.
The wheel brake uses so-called Wet disc brakes (WDB). Wet disc
brakes require minimal maintenance and have a long service life due
to efficient cooling. Maintenance requirements are minimised since oil
circulates in the brake system and prevents corrosion.
015035
The wheel brakes have two main parts - disc pack and brake cylinder.
1 2
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

4 Brakes – Wheel brakes 4:23
Wheel brakes, bleeding
NOTE
Safety.
IMPORTANT
Both the brake cylinder and disc brake must be bled
after work which involves the brake system being
opened or after work on the wheel brake.

2 Position a ring spanner on the bleed nipple and connect a
transparent hose to the bleed nipple.
Route the other end of the hose down into a receptacle.
3 Start the machine and depress the brake pedal, keep the pedal
depressed.
4 Open the bleed nipple and allow oil to run out of it until the oil is
free of air bubbles.
NOTE
The hydraulic hose between the brake pedal and brake is long.
So allow at least two litres of oil to pass through the bleed nipple
when bleeding to ensure that no air pockets remain in the system.
5 Close the bleed nipple.

6 Move the spanner and hose and repeat steps 1-5 on the other side.
Bleed nipple, brake cylinder, on top of the drive axle
7 Check the oil level in the brake system, fill if necessary.
at the wheel hub's inner short side (left-hand side).
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
alternately to the wheel brake housing and to the hub reduction
housing. The discs are mounted on splines, which allows them to
move laterally.
Hydraulic oil circulates between the discs cooling them, thus the name
Wet Disc Brake. Hydraulic oil is the same as in other parts of the
hydraulic system and is cooled by the cooling circuit, see Section 10
Common hydraulics, group 10.6 Temperature control, cleaning and
hydraulic oil.
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

4:24 4 Brakes – Pipes and hoses
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
4.3.10 Pipes and hoses

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

4 Brakes – Valve block brake system 4:25
4.3.12 Valve block brake system

Valve block brake system, description
Solenoid valve parking brake
Solenoid valve parking brake

1 2 3
See Solenoid valve parking brake, description, page 4:29
4
Accumulator drain valve
5 The accumulator drain valve (position 2) is located on the valve block

brake system and is used to drain the pressure in the accumulators to
11 the tank. The valve opens a connection between the accumulators
6 and the wheel brake's cooling circuit. The oil is drained through the
wheel brake to the tank.
7 See section 10 Common hydraulics group 10.2.1 Accumulator drain

10 valve.
9 Pressure relief valve

8
See section 10 Common hydraulics group 10.2.4 Pressure limiting
valve.
Break contact (opening switch) parking brake
015018
See Break contact (opening switch) parking brake, description, page

4:34.
Break contact (opening switch) brake pressure
2. Accumulator drain valve See Brake pressure NC switch, description, page 4:18.

4:26 4 Brakes – Valve block brake system
Valve block brake system, replacement
NOTE
Safety.

2 Mark and disconnect the cable harness from the valve block.
3 Mark up and detach the hydraulic hoses from the valve block.
4 Move the components to the new valve and assemble the valve in
the reverse order.
NOTE
the lock ring.
014619

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

Parking brake system, function description
D1
10
1
2 9
D790-1 D790-2
D797-1
3, 8 D4
D7 13
4 5
C 7
Pa GHB
C HB
ACK M P
T
P 6
12
11
019436
P
1 Switch parking brake (S107) activates Switch activated: Section 9 Frame, body, cab and
the parking brake. Conn. 1, U = 24 V accessories, group 9.1 Controls and
The switch uses two signals, one for instruments
Conn. 7, U = 0 V
applied and one for released parking D5: Diagnostic menu, see section 8
brake. Both signals must be correct to Switch in home position: Control system, group 8.4.5.5 HYD, menu
enable release of the parking brake. Conn. 1, U = 0 V 5
Conn. 7, U = 24 V
2 The cab control unit (D790-1) transmits Controlled by control Section 11 Common electrics, group
Activate parking brake on the CAN bus. system, error shown with 11.5.3.1 Control unit, cab
error code.
3 The frame control unit (D797-1) activates U = 24 V Solenoid valve parking brake, description,
the parking brake solenoid valve (Y642). page 4:29
Control system, group 8.4.5.5 HYD, menu
5
4 Solenoid valve parking brake (Y642) acts - Solenoid valve parking brake, description,
on the valve slide which drains pressure page 4:29
in the parking brake's brake caliper to
tank.
5 The brake caliper is drained of pressure 0 MPa Parking brake unit, description, page 4:30
and the spring applies the parking brake.
6 Valve block brake system directs the - Valve block brake system, description,
hydraulic oil to the hydraulic oil tank. page 4:25
7 Break contact (opening switch) parking Applied parking brake: Break contact (opening switch) parking
brake (S200) breaks the circuit and sends Conn. 1, U = 24 V brake, description, page 4:34
the voltage signal to the Frame control D10: Diagnostic menu, see section 8
unit (D797-1) when the pressure drops. Conn. 2, U = 0 V
Control system, group 8.4.5.5 HYD, menu
Released parking brake: 5
Conn. 1, U = 24 V
Conn. 2, U = 24 V

4:28 4 Brakes – Hydraulic oil pump

8 The frame control unit (D797-1) transmits Controlled by control Section 11 Common electrics, group
Parking brake applied on the CAN bus. system, error shown with 11.5.3.2 Frame control unit
error code.
9 Control unit KIT (D790-2) activates Controlled by control Section 9 Frame, body, cab and
indicator light, parking brake (508). system, error shown with accessories, group 9.1 Controls and
error code. instruments
10 Indicator light parking brake comes on. - Section 11 Common electrics, group
11.5.3.11 Control unit, KIT
11 The hydraulic oil pump pumps hydraulic See pressure plate on left Hydraulic oil pump, general, page 4:6
oil from the hydraulic oil tank. frame beam.
12 Valve block accumulator charging and See pressure plate on left Accumulator charging valve, description,
priority valve directs oil to charging of frame beam. page 4:7
the accumulators or the brake system's
cooling circuit.
13 The accumulators store the oil pressure See pressure plate on left Accumulator, description, page 4:10
used when the parking brake is released. frame beam.


Brake system, steering and temperature control of the hydraulic oil are
fed by a common hydraulic oil pump.

fixed displacement.
4.5.2 Hydraulic oil filter

The return oil from the brakes, steering and load handling is filtered
through the hydraulic oil filter in the oil tank.
See section 10 Common hydraulics group 10.6.7 Hydraulic oil filter.

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

Solenoid valve parking brake, description
Solenoid valve parking brake (Y642) activates the parking brake. The
1 2 3 solenoid valve is fitted on the valve block brake system, which is fitted
4 on the lifting beam in front of the gearbox in the engine compartment,
see Valve block brake system, description, page 4:25.
The solenoid valve opens a connection between the accumulators and

5
the parking brake caliper on activation. This means that the parking
brake caliper is pressurised and the parking brake is released. When
11 the voltage feed to the solenoid valve is cut off, the connection between
6
the accumulators and parking brake caliper is closed. Instead, a
connection between the parking brake caliper and tank is opened and
7 the parking brake is applied. This means that the parking brake is
10 applied if the machine becomes de-energised or if the brake system
becomes depressurised.
9 8 The solenoid valve is supplied with voltage by the frame control unit
(D797-1) at activation.
015018


4:30 4 Brakes – Parking brake unit
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 the engine at idle until the warning lamp
for brake pressure goes out and the accumulator charging valve
changes to cooling.
2 Switch off the engine and turn the start key to position I.
3 Release the parking brake with the switch for the parking brake
and check that the parking brake's brake caliper releases. The
brake caliper should be able to move.
4 Activate the parking brake with the switch for the parking brake
and check that the parking brake's brake caliper is applied.
4.5.4 Parking brake unit

Parking brake unit, description
3 1 2 The parking brake unit keeps the machine stationary when parked.
The parking brake unit is fitted on the drive axle input shaft between
the propeller shaft and drive axle.
The parking brake acts on the universal drive shaft via a disc mounted
on the drive axle input shaft and a brake calliper with dry brake pads
mounted in a bracket on the drive axle.
NOTE
If the hydraulic pressure in the feed circuit drops, a warning is
activated before the pressure drops so low that the parking brake
is applied. If the parking brake is applied while the machine is in
motion, the brake disc and brake pads must be replaced.
019437
1. Cover
2. Parking brake caliper
3. Parking brake disc

4 Brakes – Parking brake unit 4:31
Parking brake unit, checking and adjustment
DANGER
Risk of crushing.
1 Start the engine and fully charge the accumulators (the

accumulator charging valve changes to cooling).
2 Switch off the engine and turn the start key to position I.
3 Release the parking brake.
4 Check that the parking brake caliper can move on the bracket.
5 Check that the brake disc is free from oil and dirt.
6 Remove the cover from the brake calliper and check for oil inside
the cover. Oil inside the cover indicates internal leakage.
7 Loosen the lock nut.

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

12 Test the function of the parking brake.

4:32 4 Brakes – Parking brake unit
4.5.4.1 Parking brake caliper

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

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

Safety.
2 Remove the cover from the brake caliper.

4 Brakes – Parking brake unit 4:33
3 Loosen the lock nut.

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

8 Clean the brake disc with methylated spirit.
9 Fit new parking brake pads.
10 Press back the attaching bolt.
11 Fit the nut and a new split pin.
12 Adjust the parking brake, see Parking brake unit, checking and
adjustment, page 4:31.
4.5.4.3 Parking brake disc
Brake disc, description

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

4:34 4 Brakes – Break contact (opening switch) parking brake
4.5.5 Break contact (opening switch) parking

brake
Break contact (opening switch) parking brake,
description
Break contact (opening switch) parking brake (S200) detects whether
1 2 3 the parking brake is applied or released. The break contact (opening
4 switch) is fitted on the valve block brake system, which is fitted on the
lifting beam in front of the transmission in the engine compartment, see
Valve block brake system, description, page 4:25.
5
Break contact (opening switch) parking brake (S200) senses the
pressure in the parking brake circuit. When the pressure is so high that
11 the parking brake is released, the sensor opens an electric circuit. This
6
is used to indicate that the parking brake is released.
Break-contact (opening switch) parking brake light (S200) is supplied

7 voltage by and sends a voltage signal to Frame control unit (D797-1).
10
When the pressure increases above the cut-off pressure, the voltage
9 signal to the Frame control unit (D797-1) is cut.
8
NOTE
015018
Gears cannot be engaged when the parking brake is applied.


4.5.7 Valve block brake system

Valve block brake system, general
See Valve block brake system, description, page 4:25.

5:1
5 Steering
Contents 5 Steering
5 Steering .............................................................................................................. 5:3
5.2 Power assisted system ....................................................................................5:3
5.2.1 Hydraulic oil pump.......................................................................................5:3
5.2.2 Priority valve................................................................................................5:4
5.2.3 Steering valve .............................................................................................5:7
5.2.4 Steering cylinder .........................................................................................5:9
5.2.5 Steering axle cradle .................................................................................. 5:11
5.2.6 Link arm .................................................................................................... 5:11
5.2.7 Wheel spindle............................................................................................ 5:11
5.2.8 Wheel hub ................................................................................................. 5:11
5.2.13 Pipes and hoses........................................................................................ 5:11

5:2

5 Steering – Steering 5:3
5 Steering
5.2 Power assisted system
Power assisted system, function description
2 C P
3
LS
C T L R
O
P
LSO
2
4
1
018760
1 Hydraulic oil pump brake and steering See the pressure plate on Section 10 Common hydraulics, group
pumps oil to the Valve block accumulator the left-hand frame beam. 10.4.1 Gear pump with fixed displacement
2 Valve block accumulator charging and Checked by control Priority valve, description, page 5:4
priority valve gives priority to the oil feed system, error shown with
to the control valve over accumulator error code.
charging and cooling to the brakes.
3 The steering wheel is turned and acts on - Steering valve, description, page 5:7
the steering valve\qs input shaft.
The control valve directs oil pressure
from the hydraulic oil pump brake and
steering to the steering cylinder.
4 The steering cylinder turns the wheels. - Steering cylinder, description, page 5:9


Steering is fed oil from the Hydraulic pump brake and steering, see
section 10 Common hydraulics, group 10.4.1 Gear pump with fixed
displacement.

5:4 5 Steering – Priority valve
5.2.2 Priority valve

Priority valve, description
The priority valve is located in the valve block accumulator charging
and priority valve that is part of the main valve, see section 10 Common
hydraulics, group 10.5.4 Main valve. The main valve is located on the
lifting beam in front of the gearbox in the engine compartment. The
priority valve divides the oil flow from the hydraulic oil pump brake and
steering so that there is always oil to the steering valve. The remaining
1 flow goes to the brake system and to the hydraulic oil's cooling circuit.
2 The priority valve is load sensing and pilot pressure compensating.
3 Load sensing means that the valve adapts the control signal to the
4 steering valve's consumption. Pilot pressure compensating means
that the priority valve compensates for the pressure drop between the
priority valve and steering valve via a separate line.
5
The priority valve has a built-in pressure limiter on the load signal. The
pressure limiter maximises the load signal's pressure.
13 6
12 7
015032
11 10 9 8
steering [P]
10. Measuring outlet accumulator pressure [ACC
M]
charging [ACC]
steering [PM]
Steering pressure, checking
NOTE
Safety.
˚C
000475

5 Steering – Priority valve 5:5
4 Connect a pressure gauge (0-25 MPa) to the measuring outlet for

steering pressure.
014651
Measuring outlet, control pressure [LSM]
5 Close the relief valve attachment and the accumulator drain valve.
6 Start the engine and increase engine speed to approx. 1200 rpm.
014619
7 Turn the steering wheel to full lock and check that the control
pressure corresponds with the pressure on the pressure plate
during the steering movement.
015020

5:6 5 Steering – Priority valve
8 If necessary, adjust the steering pressure on the valve block

accumulator charging and priority valve.
screw.
measuring outlet.
015029
Adjuster screw, control pressure
NOTE
the lock ring.
014619

5 Steering – Steering valve 5:7
5.2.3 Steering valve

Steering valve, description
The steering valve is a “closed centre, non-reaction valve” with load
signal connection to the priority valve.
The load signal provides load dependent regulation of the oil flow from
1 the priority valve to the control valve. "Closed centre" means that the
control valve is closed in neutral position. This is necessary so that
signal pressure can be connected to the steering valve.
2
5 The steering valve consists of a gear pump and a distribution valve.
When the steering wheel is turned, oil flows from the main pump over
4 3
the gear pump to the distribution valve, which directs the oil to the
steering cylinder. The gear pump ensures that the oil flow fed to the
cylinder is proportional to the steering wheel's turning angle.
The steering valve contains double shock and anti-cavitation valves.

The shock valves protect the hydraulics against pressure spikes which
can arise from impacts on the steering wheels. The anti-cavitation
valves (non-return valves) protect against negative pressure on the
piston's rear side, which may otherwise lead to cavitation.
009887
Connections control valve

1. Steering cylinder left [L]
2. Pilot pressure [LSO]
3. Steering cylinder right [R]
4. Tank return [T]
5. Pressure feed [O]

5:8 5 Steering – Steering valve
Steering valve, replacement
NOTE
Safety.

1. Water valve
2. Steering valve
4 Detach the steering valve from the brake pedal.

Remove the steering valve's attaching bolts and lower the control
valve.
5 Mark up and detach the hydraulic hoses from the steering valve.
NOTE
Plug all connections immediately to protect the brake system
from impurities.
6 Remove the steering valve.

7 Transfer the connection adapters to the new steering valve.
NOTE
Transfer one connection at a time so that the marking is not
mixed up.
8 Connect the hydraulic hoses to the steering valve in accordance

with the marking.
NOTE
Change the O-rings. Check that the O-rings are positioned
correctly.
9 Connect the new steering valve to the brake pedal.

Position the steering valve and check that the steering wheel
shaft's splines enter straight in the steering valve's slot. Fit the
attaching bolts.

5 Steering – Steering cylinder 5:9
NOTE
the lock ring.

12 Check that the connections on the steering valve are sealed tightly.
13 Steer very carefully a few times right - left, to bleed the steering
valve and steering cylinder.
014619
5.2.4 Steering cylinder

Steering cylinder, description
The steering cylinder acts on the wheels via the link arms. The steering
1 2 3 cylinder is a double-acting hydraulic cylinder.
4
009888
1. Steering cylinder
2. Shaft
3. Lock screw
4. Fastening screw (locked with locking fluid)
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.

5:10 5 Steering – Steering cylinder
4 Detach the link arms from the steering cylinder.

5 Mark up and detach the hydraulic hoses from the steering cylinder.
NOTE
Plug all connections immediately to protect the brake system
from impurities.
1. Link arm mounting

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

7 Replace the steering cylinder. Lift the steering cylinder aside.
NOTE
The steering cylinder is heavy, use lifting equipment.
8 Support the new steering cylinder so that the holes in the attaching
bolts are lined up directly opposite the holes in the steering axle.
9 Fit and lubricate the steering cylinder attaching bolts. Tighten the
bolts crosswise in steps until 680 Nm is achieved.
10 Transfer parts to the new steering cylinder.
NOTE
correctly.
009889
Attaching bolts steering cylinder.
11 Fit the link arms to the steering cylinder.

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

2. Hydraulic connection

5 Steering – Steering axle cradle 5:11
NOTE
the lock ring.
14 Start the engine and check for leaks.
014619
Hydraulic cylinders, repairs

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

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

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

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

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


5:12

6:1
6 Suspension
Contents 6 Suspension
6 Suspension ........................................................................................................ 6:3
6.2 Suspension ......................................................................................................6:3
6.2.1 Steering axle cradle ....................................................................................6:4
6.2.2 Wheel spindle..............................................................................................6:6
6.2.3 Wheel hub ...................................................................................................6:8
6.3 Tyres and rims ...............................................................................................6:13
6.3.1 Tyres .........................................................................................................6:15
6.3.2 Rim ............................................................................................................6:16
6.3.3 Nut, washer and clamp .............................................................................6:17

6:2

6 Suspension – Suspension 6:3
6 Suspension
6.2 Suspension
Bushing steering axle mounting, changing
DANGER
Steering axle and machine are very heavy.
Risk of crushing!
Technical data.

3 Support under the steering axle so that it cannot fall over.
4 Attach hoisting equipment to the rear of the machine and take up
the slack so that the steering axle's mounts are relieved.
NOTE
Do not lift so much that the wheels are off the ground.
5 Remove the shafts holding the steering axle.

6 Lift the machine so that the frame is off the steering axle.
7 Support the machine under the frame.
8 Move the steering axle so that the mountings are accessible.
NOTE
If necessary, disconnect the cable harness for the sensors on
the steering axle.
009890
The illustration shows rear mounting

6:4 6 Suspension – Steering axle cradle
9 Remove the washers that hold the bushing in place.

2 10 Press out the bushing.
1 11 Clean the bearing surfaces on the steering axle.

12 Press in the new bushing. Grease the bushing to facilitate
installation.
13 Fit the washers that hold the bushing in place.
14 Move the steering axle into place under the frame.
15 Lubricate and fit the pins at the steering axle's mounts.
3 16 Remove the lifting equipment from the machine.
010121
1. Steering axle mounting
2. Rubber bushing
3. Washers
4. Screw
6.2.1 Steering axle cradle

Steering axle cradle, description
6 The steering axle is pendulum suspended with a double-acting steering

1 2 3 4 5
cylinder. The design comprises a minimum of moving parts to minimise
service points and simplify maintenance. The frame suspension
comprises maintenance-free parts.
008047
Steering axle
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle cradle
6. Spindle bolt / - bearing

6 Suspension – Steering axle cradle 6:5
Steering axle cradle, replacement
DANGER
Steering axle and machine are very heavy.
Risk of crushing!
Technical data.
1 Clean the steering axle and its surrounding area.

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

10 Lift the machine up so that the frame is lifted away from the axle.
11 Lift out the steering axle.
CAUTION
The steering axle may start to roll.
Crushing injury!
Make sure that the steering axle does not roll away
uncontrollably.
12 Adjust the support so that the machine is secured in the new

position.
13 Lift the steering axle into place under the frame.
14 Remove the support under the frame.
15 Lower the rear of the machine.
16 Fit the pins at the steering axle mountings.
17 Connect the hydraulic hoses to the steering cylinder.
NOTE
correctly.
18 Remove the lifting equipment from the machine.

6:6 6 Suspension – Wheel spindle
6.2.2 Wheel spindle

Wheel spindle, description
The wheel spindle is the link between steering axle and wheel hubs
which means that the wheels can be turned.
3
2
4
5
1 6
8 7
9
009780
11 10
1. Wheel spindle
2. Seal ring
3. Bearing (upper)
4. Protective ring
5. Seal ring
6. Bearing (lower)
7. Circlip
8. Shim
9. Bearing cage
10. Screw
11. Lubricant nipple
Spindle bolt bearing, replacement

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 Clean the wheel spindle and its surrounding area.
5 Detach the link arm from the wheel spindle.
6 Remove the wheel hub and wheel bearing; see Wheel bearing,

6 Suspension – Wheel spindle 6:7
7 Remove the six screws holding the bearing cage to the wheel
spindle.
8 Detach the bearing cage by screwing a screw into the removal

hole.
9 Remove the bearing cage and shim from the wheel spindle.
10 Remove the wheel spindle.
11 Remove the three screws on the top of the steering axle cradle.
Press out the upper bearing's outer bearing race by screwing three
screws (about 90 mm long) into the holes.
12 Remove the inner bearing races on the upper and lower bearings
from the wheel spindle.
13 Remove the outer bearing race on the lower bearing from the
bearing cage.
14 From underneath, tap in the outer bearing race of the upper
bearing into the steering axle cradle. Use a pipe of a suitable
002419
diameter so as not to damage the bearing race.

15 Refit the three screws on the top of the steering axle cradle.
16 Fit upper bearing's inner bearing race, seal ring, guard ring and
seal ring as well as the lower bearing's inner bearing race and
circlip on the wheel spindle.
17 Fit the wheel spindle.
18 Tap the lower bearing's outer bearing race into the bearing cage.
Use a pipe of a suitable diameter so as not to damage the bearing
race.
19 Fit the bearing cage. Use a shim to get it in the right position.
Tighten the screws.
20 Check that the wheel spindle rotates smoothly and that there is no
play on the spindle bearing. If necessary, correct with shims.
NOTE
The correct number of shims have been used when it takes at
least 200 Nm to move the bearing arrangement to move laterally.
If it takes more than 400 Nm for the bearing arrangement to
move, it is too hard and the number of shims must be corrected.
21 Lubricate the wheel spindle bearings via the grease nipples.

22 Fit the wheel hub and wheel bearing; see Wheel bearing,
23 Connect the link arm to the wheel spindle.
24 Fit the wheel.
25 Remove the support and lower the steering wheel.
26 Test-operate the machine and test the steering. Check also that
the machine feels stable when driving straight ahead.

6:8 6 Suspension – Wheel hub
6.2.3 Wheel hub

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

1 Raise the machine under the steering axle at the wheel in question.
Support under the steering axle in a safe way.
2 Remove the steering wheel in question.

6 Suspension – Wheel hub 6:9
3 Clean the hub cover and its surrounding area.

4 Remove the hub cover.
5 Wipe away grease from hub cover and hub nut. Handle it as
environmentally hazardous waste.
6 Secure the hub with a lifting strap.

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

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

11 Remove the inner bearing from the wheel spindle.
12 Remove the seal from the hub.

13 Remove the bearings' outer races from the hub.
Use a drift and press out the bearing races.
14 Clean the hub and line the inside with universal grease "EP2".
15 Fit new outer races in the hub.
Use a drift and press in the bearing races. Never use 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".

6 Suspension – Wheel hub 6:11
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 250 Nm (oiled screw).
C. Rotate the hub 10 revolutions.
D. Angle tighten the nut 45°.
E. Rotate the hub 10 revolutions.
F. Angle tighten the nut 45°.

23 Apply grease onto the locking washer and fit it.

24 Fit the lock nut and tighten to at least 250 Nm (oiled screw) or
then more to engage the locking washer in the closest groove.
Lock the bearing nut and lock nut with the locking washer.
25 Fill the bearing casing with grease and fit it.

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

6 Suspension – Tyres and rims 6:13
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
conical ring and locking clips can loosen and shoot
out when the pressure is changed. With double wheel
fitting both tyres must be fully deflated!
The air 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 drilling a hole in the tyre tread. Use a drill
bit with max. Ø 5 mm. Damaged tyres may explode.
Never stand directly in front of the wheel when
deflating or inflating. The conical ring and locking
clips can loosen and shoot out when the pressure is
changed.
Never fit damaged tyres or rims.
It is 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.

6:14 6 Suspension – Tyres and rims
CAUTION
When removing wheels, the wheel nuts should be left
in place after loosening. If the wheel nuts are removed
immediately, the wheel may release from the hub.
Wheel nuts should be check-tightened after 4-5
operating hours.
Always follow the tyre manufacturer's or other
approved instructions when changing tyres.
Never use a steel hammer to fit or remove rim
components. Use a lead, brass or plastic mallet
instead.
Keep the tyre pressures at the prescribed level.
Insufficient tyre pressure impairs stability and reduces
the machine's capacity.
Remove stuck objects such as crushed glass, pieces
of wood, metal filings, etc.
Check if tyre wear is abnormal. This could indicate
a mechanical fault. Rectify faults immediately and
change damaged tyres.

6 Suspension – Tyres 6:15
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.
009892
Front wheels
009893
Rear wheels
Tyres, changing
DANGER
Changing tyres is complicated and dangerous work.
EXTREME DANGER!
Leave tyre work to authorised personnel/tyre
company.
The rims must be checked when tyres are changed. See Maintenance
manual DCT 80-90.

6:16 6 Suspension – Rim
6.3.2 Rim
Rim, description
1 2 3 4 The rim is split to make it possible to fit a tyre. The rim consists of
the following parts.
• Rim
• Rim bead seat
• Rim edge
• Lock ring
6
019431
1. Rim
2. Lock ring
3. Rim edge
4. Tapered rim
5. Wheel nut
6. Wheel bolt

6 Suspension – Nut, washer and clamp 6:17
6.3.3 Nut, washer and clamp

Nut, washer and clamp, description
1 2 3 4 The rim is attached to the wheel hub with nuts.
As an option, the rim can be equipped with nut protection.
6
019431
1. Rim
2. Lock ring
3. Rim edge
4. Tapered rim
5. Wheel nut
6. Wheel bolt

6:18 6 Suspension – Nut, washer and clamp
Wheel bolt, replacement

2 Raise the machine with a jack positioned under the steering axle.
3 Remove the steering wheel; see Maintenance manual DCT 80-90.
4 Knock out the bolt with a sledge hammer.

5 Replace the bolt.

7:1
7 Load handling
Contents 7 Load handling

7 Load handling .................................................................................................... 7:3
7.1.1 Control levers ..............................................................................................7:4
7.1.2 Switch, lock twistlock...................................................................................7:5
7.1.3 Switch, spreading 20\q-40\q........................................................................7:6
7.1.4 Switch, stop at 30\q .....................................................................................7:6
7.1.13 Switch, automatic spreading .......................................................................7:7
7.2 Lifting/lowering .................................................................................................7:8
7.2.3 Pressure reducer.......................................................................................7:10
7.2.5 Control valve, lift and tilt ............................................................................7:13
7.2.7 Lift cylinder ................................................................................................7:14
7.2.9 Mast ..........................................................................................................7:15
7.2.10 Mast position sensor .................................................................................7:24
7.2.11 Trolley........................................................................................................7:25
7.2.13 Pipes and hoses........................................................................................7:29
7.2.14 Accumulator lift..........................................................................................7:29
7.4 Side shift ........................................................................................................7:30
7.4.2 Control valve, attachment .........................................................................7:32
7.4.3 Side shift cylinder ......................................................................................7:35
7.4.5 Trolley........................................................................................................7:35
7.4.7 Relief valve, attachment ............................................................................7:37
7.4.8 Pipes and hoses........................................................................................7:37
7.4.9 Lift, tilt and attachment control valve .........................................................7:37
7.5 Spreading (positioning) ..................................................................................7:38
7.5.2 Control valve, attachment .........................................................................7:45
7.5.3 Spreading cylinder ....................................................................................7:45
7.5.4 Spreader beam .........................................................................................7:46
7.5.5 Main beam, side lift attachment.................................................................7:48
7.5.6 Position sensor, spreading ........................................................................7:53
7.5.7 Buzzer, automatic spreading 20'-40' .........................................................7:53
7.5.8 Pipes and hoses........................................................................................7:53
7.5.10 Lift, tilt and attachment control valve .........................................................7:53
7.7 Tilt ..................................................................................................................7:55
7.7.5 Control valve, lift and tilt ............................................................................7:57
7.7.6 Load holding valve ....................................................................................7:58
7.7.7 Tilt cylinder ................................................................................................7:58
7.7.8 Mast ..........................................................................................................7:58
7.7.9 Pipes and hoses........................................................................................7:59
7.8 Levelling.........................................................................................................7:60
7.9 Load carrier....................................................................................................7:61
7.9.1 Twistlocks ..................................................................................................7:61
7.10 Other functions...............................................................................................7:72
7.10.1 Container counter......................................................................................7:72

7:2

7 Load handling – Load handling 7:3
7 Load handling
Position sensor, checking and adjustment
The machine has several position sensors in the following locations.
1. Mast position sensor (B7211-2), see Mast position sensor,
2. Alignment sensors B7203L and B7203R), see Sensor, contact,
1 description, page 7:68 and Alignment sensor, checking and
adjusting, page 7:68.
3. Locked twistlocks sensors (B7205LL and B7205RL), see Sensor,
twistlocks, description, page 7:69 and Twistlocks sensor, checking
and adjusting, page 7:70.
4. Damping sensor (B769L, B769R, B777L and B777R), see Position
sensor spreading, description, page 7:53.
4
019443
Position sensor overview
Spacing check
2 Check that the sensor in question is free of damage and dirt.
3 Check that the distance between the sensor and the indicator is
5±1 mm.
C-C
5±1 mm 4 Adjust if necessary.

009632
5±1 mm
Adjusting position sensor - indicator

7:4 7 Load handling – Controls and instruments

7.1.1 Control levers
Control lever, description
The control lever (S815) is used to control the mast and attachment.
A B C The lever sends voltage signals to the Cab control unit (D790-1).
The control lever has three potentiometer-controlled functions and

three on/off functions.
A. Side shift (S815-P3)
Side shift left is activated when the potentiometer is pushed in on
the left-hand side. Side shift right is activated when the right-hand
D side is pushed in. See Side shift, function description, page 7:30.
Control system, group 8.4.9.1 ATTACH, menu 1.
B. Spreading out (S815-T1.1) and Spreading in (S815-T1.2)
Pressing the right switch activates spreading out and pressing
the left switch activates spreading in. See Spreading, function
E D C The signal can be checked via the diagnostic menu. See section 8
C. Lifting/lowering (S815-P1)
Lifting/lowering is controlled by moving the control lever forward
015080
(lowering) or rearward (lifting). See Lifting/lowering, function

The signal can be checked from the diagnostic menu, see section
8 Control system, group 8.4.8.1 ELSERV, menu 1.
D. Tilt (S815-P2)
Tilt is controlled by moving the control lever to the right (tilt out) or
left (tilt in). See Tilt, function description, page 7:55.
E. Lock/open the twistlocks (S815-T2) on full alignment
The twistlocks are alternately opened/locked when the switch
is activated if the conditions are met. See Twistlocks, function

7 Load handling – Switch, lock twistlock 7:5
Linear control levers, description
The load handling functions are controlled with fingertip-controlled

linear levers.
The control levers are supplied voltage by and send a signal to the
cab control unit (D790-1).
C A. Lift/lower (R8071-P1).
A B
Lifting/lowering is controlled by moving the control lever forward
(lowering) or rearward (lifting). See Lifting/lowering, function
D description, page 7:8.
B. Tilt (R8072-P2).
Tilt is controlled by moving the control lever forward (tilt out) or
backward (tilt in). See Tilt, function description, page 7:55.
C. Side shift (R8073-P3).
E Side shift is controlled by moving the lever forward (left) or
backward (right). See Side shift, function description, page 7:30.
014181
It is not possible to use side shift on the side lift attachment if the
attachment is in its max or min position.
D. Emergency stop switch
E. Opening locked twistlocks, attachment (S1002).
Pull the switch sideways to open the twistlocks if the conditions for
this are met. See Twistlocks, function description, page 7:61.
7.1.2 Switch, lock twistlock

Switch lock twistlocks, description (linear control
levers)
Switch (green) for locking twistlocks (S1003). The switch is momentary

in position 2.
Position 1 - Twistlocks are locked automatically when alignment with

the load occurs. The parking brake must be OFF.
009907
Position 0 - Twistlock locking not activated.
Position 2 - Twistlocks are locked manually. Button springs back.
Twistlocks are opened with the switch on the control lever, see Linear
control levers, description, page 7:5.
The switch is supplied power by and sends a voltage signal to the cab

7:6 7 Load handling – Switch, spreading 20\q-40\q
7.1.3 Switch, spreading 20\q-40\q

Switch spreading 20'-40', description (linear control
levers)
Switch (green) for spreading between 20'-40' (S1012). Spreading

stops in the position it is in when the switch is released. The switch
is momentary.
This function is used to adapt the attachment to the width of the

containers.
009910
Position 0 - Spreading not activated.
Position 1 - Spreading out activated. Spreading's outer end position

is at 40'.
Position 2 - Spreading in activated. Spreading's inner end position
is at 20'.
7.1.4 Switch, stop at 30\q

Switch stop at 30', description (linear control levers)
The switch (green) for spreading stop for the attachment at 30' (S1004)
activates the 30-foot stop. When the switch is depressed, the function
5
changes from spreading from 20'–40' to stop at 30'.
3
30-
009909

7 Load handling – Switch, automatic spreading 7:7
7.1.13 Switch, automatic spreading

Switch automatic spreading, description (linear
control levers)
Switch (green) for automatic spreading between 20'-40' (S1004).

When the switch is pressed down spreading automatically goes to
the next position (20, 30 or 40 feet) if spreading is activated with the
control lever.
This switch is used to activate automatic spreading.
009908
Position 0 - Automatic spreading not activated.
Position 1 - Automatic spreading activated. Spreading is activated with

the switch for spreading 20'-40'.
The switch is supplied with voltage from and sends a voltage signal to
the cab control unit (D790-1) when the switch is activated.
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.

7:8 7 Load handling – Lifting/lowering
7.2 Lifting/lowering
Lifting/lowering, function description
Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop
switch voltage
Twistlocks Locked or unlocked, not Twistlocks, description, page 7:61
intermediate position
Contact Mast down: no contact Sensor, contact, description, page 7:68
1b 1a D3
D1
2, 3, 5 6
D790-1 D794
D797-1
7, 15
4
D7
D14 14
8
C
12, 16 12, 16
P2
9 A
10
13
019444
11

1a The lifting/lowering control lever U = 0.5-4.5 V Linear control levers, description,
(R8071-P1) sends the cab control unit Lower: U = <2.5 V page 7:5
(D790-1) a voltage signal proportional D1: Diagnostic menu, see section
to lever movement. Lift: U = 2.5 V
8 Control system, group 8.4.8.1
0.5 V is the fastest lowering ELSERV, menu 1
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.
1b The control lever (S815-P1) sends the US815-P1 = 0.5-4.5 V Lower: Control lever, description, page 7:4
cab control unit (D790-1) a voltage US815-P1 = <2.5 V D1: Diagnostic menu, see section
signal proportional to lever movement. Lift: US815-P1 = >2.5 V 8 Control system, group 8.4.8.1
0.5 V is the fastest lowering ELSERV, menu 1
speed and 4.5 V is the fastest lift
speed. Lower voltage than 0.5
V and higher voltage than 4.5 V
is used to detect faults in cable
harnesses and controls.
2 The cab control unit (D790-1) sends the Checked by control system, error Section 11 Common electrics, group
frame control unit (D797-1) a lift/lower shown with error code. 11.5.3.1 Control unit, cab
request via the CAN bus.
3 Cab control unit (D790-1) voltage feeds U = 24 V Section 11 Common electrics, group
the control breaker relay lifting and 11.5.3.2 Frame control unit
lowering (K3007). D3: Diagnostic menu, see section
CAN/POWER, menu 6

7 Load handling – Lifting/lowering 7:9

4 Control breaker relay lifting and lowering - Section 11 Common electrics, group
(K3007) makes the ground connection 11.5.1.4 Emergency stop switch
between Frame control unit (D797-1) voltage (15E)
and Solenoid valve lift (Y6005) and
Solenoid valve lower(Y6004).
5 Control unit, cab (D790-1) transmits a Checked by control system, error Section 11 Common electrics, group
request for increased engine speed on shown with error code. 11.5.3.1 Control unit, cab
the CAN bus.
6 Control unit, engine (D794) increases Checked by control system, error Section 11 Common electrics, group
the engine speed. shown with error code. 11.5.3.10 Control unit, engine
7 The frame control unit (D797-1) controls I = 380–650 mA Section 11 Common electrics, group
the current proportionally to the lever 11.5.3.2 Frame control unit
movement to the solenoid valve lift mast D7: Diagnostic menu, see section
(Y6005) or the Solenoid valve lower 8 Control system, group 8.4.8.3
(Y6004). ELSERV, menu 3 and 8.4.8.4
ELSERV, menu 4
8 Solenoid valve lift (Y6005) or Solenoid - Lift, tilt and attachment control valve,
valve lower (Y6004) pressurises lift, tilt description, page 7:13
and the attachment control valve's lift
spool with servo pressure.
9 Hydraulic oil pump load handling feeds See the pressure plate on the Section 10 Common hydraulics,
the lift, tilt and attachment control valve left-hand frame beam. group 10.4.1 Gear pump
with hydraulic pressure.
10 The lift, tilt and attachment control - Lift, tilt and attachment control valve,
valve's lift spool change position and description, page 7:13
then pressurise the lift cylinders and
accumulator lifting/lowering.
11 Accumulator lift equalizes the pressure - Accumulator lift, description, page
surges that occur in the lift cylinders 7:29
when the machine is running.
12 The lift cylinders are pressurised and the - Lift cylinder, description, page 7:14
mast is lifted or lowered.
Lift
The oil is led by a non-return valve
past the restrictor to the lifting cylinders'
piston side.
Lower
The oil passes through a restrictor back
to the lift, tilt and attachment control
valve.
13 The oil filter cleans the return oil from - Section 10 Common hydraulics
the lift cylinders before it is collected in group 10.6.7 Hydraulic oil filter.
the hydraulic oil tank.
14 Damping UB771/1 = 5 V Mast position sensor, description,
When the mast is approx. 50 cm from its UB771/2 = 0 V page 7:24
topmost position, damping is activated. UB771/3 = 0.5-4.5 V Section 11 Common electrics, group
The mast position sensor (B7211-2) 11.5.3.3 Frame control unit
sends the frame control unit (D797-1) D14: Diagnostic menu, see section
a voltage signal proportional to the lift 8 Control system, group 8.4.8.15
height. The control unit then transmits a ELSERV, menu 15.
damping request on the CAN bus.
15 The frame control unit (D797-1) reduces - Section 11 Common electrics, group
the control current to the lift solenoid 11.5.3.2 Frame control unit
valve (Y6005) or the lower solenoid D7: Diagnostic menu, see section
valve (Y6004). 8 Control system, group 8.4.8.3
ELSERV, menu 3 and 8.4.8.4
ELSERV, menu 4
16 Lift speed decreases. - Lift cylinder, description, page 7:14

7:10 7 Load handling – Hydraulic oil pump

hydraulics, Hydraulic diagram

fixed displacement.
7.2.3 Pressure reducer

Pressure reducer, description
The pressure reducer is located in the valve block accumulator charging
and priority valve that is part of the main valve, see section 10 Common
hydraulics, group 10.5.6 Main valve. The main valve is located on the
lifting beam in front of the gearbox in the engine compartment. The
pressure reducer reduces the oil pressure from the Hydraulic oil pump
brake and steering to the servo pressure lift, tilt and attachment control
1 valve, see Lift, tilt and attachment control valve, description, page 7:13.
2
3
4
13 6
12 7
015032
11 10 9 8
steering [P]
10. Measuring outlet accumulator pressure [ACC
M]
charging [ACC]
steering [PM]

7 Load handling – Pressure reducer 7:11
Servo pressure, check
NOTE
Safety.
1 Operate and warm up the machine so that the hydraulic oil reaches
operating temperature, 50 °C.
˚C
000475
4 Connect a pressure gauge (0-25 MPa) to the measuring outlet

for servo pressure.
014652
Measuring outlet, servo pressure [PPM]
014619

7:12 7 Load handling – Pressure reducer
7 Check that the servo pressure corresponds with the pressure on

the pressure plate.
015022
Pressure plate, servo pressure
8 If necessary, adjust the servo pressure on the valve block

accumulator charging and priority valve.
screw.
measuring outlet.
015027
Adjusting screw, servo pressure
NOTE
the lock ring.
014619

7 Load handling – Control valve, lift and tilt 7:13
7.2.5 Control valve, lift and tilt

Lift, tilt and attachment control valve, description
Lift slide
1 Lift, tilt and attachment control valve controls the speed and direction
of the lift and tilt and feeds pressure to the attachment control valve.
2 Control valve lift, tilt and attachment is a part of the main valve, see
section 10 Common hydraulics, group 10.5.4 Main valve. The main
3 valve is located on the lifting beam in front of the gearbox in the engine
compartment.
The valve has three sections, one for the lift function, one for the
tilt function and one to pressurise the control valve attachment. The
sections have many similarities, but are described separately under the
respective function. For tilt, see Lift, tilt and attachment control valve,
description, page 7:57, for attachment see Lift, tilt and attachment
4 control valve, description, page 7:37. Electric solenoid valves control
the flow from the valve.
The control valve is proportionally controlled by solenoid valves. This

means that both volume and direction of the flow from the valve can be
015081
adjusted and that the valve also sends control signals to the variable
pumps.
1. Solenoid valve, lower (Y6004)
Electrically controlled pressure reducing valves (solenoid valves)
2. Solenoid valve, lift (Y6005)
convert electric current into a low hydraulic pressure that is proportional
3. Connection left lift cylinder to the current, so-called servo pressure. The servo pressure acts on
4. Connection right lift cylinder the spring-centred control slide in the control valve for the function in
question and thereby controls the main flow.
The speed of the function is controlled by means of the flow being

regulated in proportion to the lever movement.
Lift slide
The lift slide controls the direction and flow of the oil to the lift cylinder.
Lift solenoid valve
The valve is controlled electrically with the Solenoid valve, lift (Y6005),
which is activated by the frame control unit, (D797-1). The servo valve
directs servo pressure to the lift slide which is proportional to the control
current to the solenoid valve.
The signals can be checked from the diagnostic menu, see section 8
Control system, group 8.4.8.3 ELSERV, menu 3.
Lower solenoid valve
The valve is controlled electrically with the Solenoid valve, lower
(Y6004), which is activated by the frame control unit, (D797-1). The
servo valve directs servo pressure to the lift slide which is proportional
to the control current to the solenoid valve.
The signals can be checked from the diagnostic menu, see section 8

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

Lift cylinder, description
The lift cylinders lift and lower the inner mast which runs in the outer
mast. The lower part of the lift cylinders is fastened to the outer mast,
while its upper part is fastened to the inner mast, one on the right and
one on the left side of the mast.
The lift cylinder is fastened in the mast with nuts in the bottom and a
washer and screw in the top.
The lift cylinders are connected in parallel and are fed from one section
of the lift, tilt and attachment control valve, see Lift, tilt and attachment
control valve, description, page 7:13.
019448 On the piston side there is a built-in load control valve. The load control
valve consists of a restrictor and a non-return valve. The non-return
valve directs oil past the restrictor when lifting and forces the oil to pass
through the restrictor when lowering. This limits the lowering speed.


7 Load handling – Mast 7:15
7.2.9 Mast
Mast, description
The mast which has a clear view design lifts the load. The trolley runs
1 in the mast, which in turn holds the side lift attachment.
The lower part of the mast is fastened to the frame with two shafts in
2 both of the double lugs on the front of the frame. The mast is also
fastened in the frame with two tilt cylinders.
The mast consists of an outer mast and an inner mast manufactured

in high-strength steel with a minimum number of welds to provide
3
maximum strength. The inner mast runs in the outer mast and is lifted
and lowered with the lift cylinders. Between the inner and outer masts
are mast wheels and slide plates that guide the inner mast in the outer
mast and reduces the friction between the mast parts.
4 The lower part of the lifting cylinders is fastened to the outer mast, while
its upper part is fastened to the inner mast. When the oil is pushed into
the lift cylinders the cylinders' piston rods are pushed out and the inner
mast is lifted. The chain, which is attached to the trolley (and in the
outer frame), runs over chain wheels in the top of the inner mast. In
this way even the trolley is lifted at the same time as the inner mast.
Hydraulic hoses and cables for the trolley and side lift attachment
functions run along the left side.
CAUTION
The mast and its component parts are tested under
harsh operating conditions and environments to
009918
ensure a long and trouble-free life.

Despite these efforts, problems can arise due
1. Inner mast to neglected maintenance, improper handling,
2. Lifting eye malfunction or damage to a mast wheel, mast or trolley.
For example, lamination or pitting could occur on the
3. Outer mast mast beam flange. This most often occurs on the inner
4. Lift cylinder mast, but could also occur on the outer mast.
Repairs to the mast may only by performed on the
flanges on the outer and inner mast beams according
to special instructions, see Flanges on outer and inner
mast beam, repair, page 7:22.
Mast, removing
NOTE
Safety.
NOTE
It is possible to remove the trolley and the side lift attachment
as a unit.
1 Remove the side lift attachment; see Side lift attachment,

removing, page 7:48.
2 Remove the trolley; see Trolley, removing, page 7:25.

7:16 7 Load handling – Mast
3 Connect the lifting equipment to the lifting lugs at the top of the
mast in a secure manner.
4 Start the engine and tilt the mast forwards as far as possible.
6 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
009974
8 Mark up and disconnect the hydraulic connections of the lift

cylinders.
NOTE
from impurities.
9 Mark up and detach the electrical connections of the mast.

009980
10 Mark up and release the hydraulic connections on the front plate

on the mast. Let the oil drain out.
NOTE
from impurities.
009981
11 Undo the electrical connectors for the mast.

Undo the connectors and protect the terminals by lubricating them
with contact grease. Then loosely insert the connectors.

12 Fasten one of the tilt cylinders in the lifting equipment (overhead

crane).
13 Release the tilt cylinder from the mast.
Remove the cylinder shaft. If necessary, use the threaded hole
and a puller to press the shaft out.
Start the engine and retract the cylinder so that it comes loose
from the mounting in the mast. Switch off the engine.
Save the circlips. Refit the shaft in the tilt cylinder.
Lower the cylinder onto a block of wood. Then slacken and remove
the lifting equipment (overhead crane).
Repeat the procedure for the other cylinder.
009984 14 Undo the nuts and bolts and remove the shafts which fix the mast
to the frame.
009979
15 Release the mast from the chassis.
WARNING
The mast can swing out when it is released from the
machine.
Risk of personal injury!
009983

16 Lift aside the mast.
009985
17 Place the mast on the ground and detach the lifting equipment
(overhead crane).
009975

Mast, installing
NOTE
Safety.

4 Connect lifting equipment to the mast in a secure manner so the
mast does not tip when lifted.
009975
5 The shafts and bearing surfaces must be checked before the mast
is refitted for deep grooves/scratches, fibres must not protrude
above the bearing surface. If there are signs of damage, the
shaft/bearing must be replacement.
NOTE
The mast is attached to the machine's frame with strong shafts
which run in maintenance-free bearings.
It is extremely important that bearing surfaces are absolutely
clean when the mast is installed.
The shafts and bearings mentioned above must NEVER be
009977
lubricated with oil or grease.
Check that seals are intact and clean.

6 Lift the mast into place. It is important that the lifting equipment is
connected to the mast's lifting lugs in a secure manner.
009976

7 Suspend the mast vertically. Align the mast and position the shafts
in the mast mountings.
009978
8 Fasten the shafts with bolts and lock nuts.

9 Start the engine and tilt the mast forwards as far as possible.
009979
13 Lift the tilt cylinders with lifting equipment (overhead crane) and
align the tilt cylinders with the mast.
009982
14 Connect the tilt cylinders to the mast.

If necessary, adjust the cylinders' stroke so that the cylinders pull
the mast straight. This is done by slackening the screws and
turning the piston with a hook spanner. Tighten the screws to
136 Nm.
Fit the shafts and lock with circlips.
009996

15 Lubricate the connectors with contact grease and join them up.
16 Remove the plugs and connect the mast's hydraulic hoses on the
machine's front panel.
009981
17 Remove the plugs and connect the hydraulic hoses to the lift
cylinders.
18 Turn on the power supply and start the engine.
19 Check that the hydraulic connections are sealed tightly.
20 Check the mast functions.
21 Fit the trolley; see Trolley, installing, page 7:26.
22 Fit the side lift attachment; see Side lift attachment, installing,
page 7:51.
009980

Flanges on outer and inner mast beam, repair
NOTE
Safety.
If the surface of the flanges has started to break down into small
flakes, this can be repaired so that the mast can still be used. This is
rectified by first grinding down the attacked surfaces and then "run-in"
the surface.
3 Removing the mast, see Mast, removing, page 7:15.
4 Separate the outer and inner mast.
5 Clean the mast components.
6 Grind the affected surfaces with a belt sander until the surface is
smooth and bright. Start with grit size 36-40 and finish with 60-80.
Grind in the longitudinal direction of the beam.
Check the internal measurement between the beam's front and
250 mm
rear flange. If the measurement exceeds 252 mm for a beam that

is supposed to be 250 mm, contact Cargotec.
7 Apply a thin layer of slide grease to the sliding surfaces of the
outer mast and reassemble the inner and outer masts.
010127C
8 Apply a thin layer of slide grease to the sliding surfaces of the

inner mast and fit the mast on the machine; see Mast, installing,
Mast beam size 250 mm. page 7:19.
9 Fit the trolley; see Trolley, installing, page 7:26.
10 Lift and lower the mast as follows to check its function.
Lift and lower the mast 20 times with 50% of the maximum load at
the right centre of gravity distance.
Lift and lower the mast 20 times with 75% of the maximum load at
the right centre of gravity distance.
Lift and lower the mast 20 times with the maximum load at the
right centre of gravity distance.
11 Check that contact surfaces look normal. If not, contact Cargotec.

Slide plates in inner mast, adjusting
NOTE
If the slide plate extends less than 3 mm from the holder, replace
it.
1 Lubricate the inner sliding surfaces of the outer mast with a thin
layer of slide grease.
2 Lift the inner mast 200 mm.
3 Adjust the slide plate in the bottom part of the outer mast so that it
lies against or has no more than 0.5 mm play to the outer mast.
Use a suitable number of shims in the rear and front of the slide
plate so that the slide plate lies evenly against the entire sliding
surface.
4 Raise the mast to its end position and check that the slide plates
do not pinch too hard against the sliding surface.
010152
Slide plates in outer mast, adjusting
NOTE
If the slide plate extends less than 3 mm from the holder, replace
it.
1 Lubricate the outer sliding surfaces of the inner mast with a thin
2 Lower the inner mast to its bottom position.
3 Lift the inner mast 200 mm.
4 Adjust the slide plate in the top part of the outer mast so that it lies
against or has no more than 0.5 mm play to the inner mast.
Use a suitable number of shims in the rear and front of the slide
plate so that the slide plate lies evenly against the entire sliding
surface.
5 Raise the mast to its end position and check that the slide plates
do not pinch too hard against the sliding surface.
010130

7:24 7 Load handling – Mast position sensor
Mast wheel, adjusting

1 Use a drift to tap out the spring pin (position 4) from the inside.
1
NOTE
2 Check that the cover washer is centred on the clamping screw.
3 2 Screw in the clamping screw (position 5) so that the wheel is

completely locked.
NOTE
4
Rotate the mast wheel while tightening the clamping screw.
5
3 Loosen the clamping screw until the wheel rotates, slightly slowly.
Turn the clamping screw so that the next hole for the tubular pin
fits.
6
7 NOTE
Check that there is clearance between the mast wheel and the
mast beam.
4 Lock the clamping screw with the spring pin.

010126
1. Impeller
2. Circlip
3. Cover washer
4. Spring pin
5. Clamping screw
6. Inner bearing
7. Outer bearing
7.2.10 Mast position sensor

Mast position sensor, description
Mast position sensor (B7211-2) activates damping when lifting when
the mast approaches its upper end position.
The position sensor sends a signals to the Frame control unit (D797-1)
when the mast approaches the end position.
The signal can be checked from the diagnostic menu, see section 8
For checking and adjusting, see Position sensor, checking and

adjustment, page 7:3.

7 Load handling – Trolley 7:25
7.2.11 Trolley
Trolley, description
The trolley holds the side lift attachment and runs along the inner mast
with slide plates and mast wheels. The attachment can be shifted
sideways ±600 mm with a hydraulic cylinder that sits between the
2
attachment and trolley.
1 Also located on the trolley are the Attachment control unit (D791-1),
attachment control valve and buzzer automatic spreading 20'-40' ( )
See also Side shift cylinder, description, page 7:35.

3
4013589
1. Side shift cylinder

2. Control valve, attachment
3. Slide plates
4. Mast wheels
Trolley, removing
NOTE
Safety.
1 Remove the side lift attachment; see Side lift attachment,

removing, page 7:48.
2 Connect lifting equipment to the trolley in a secure manner.
3 Disconnect the main power supply.
4 Disconnect the trolley cable by undoing the lock plate screws.
009995

7:26 7 Load handling – Trolley
5 Mark up and disconnect the carriage's hydraulic connections. Let

the oil run out.
NOTE
from impurities.
6 Raise the carriage with the lifting equipment (overhead crane) to

slacken the chains.
009987
7 Undo the nuts and remove the chain tensioners.

8 Start the engine and tilt the mast rearwards.
9 Raise the mast enough for the carriage to release from the mast.
10 Lower the mast again.
11 Lift aside the trolley. Put it on blocks and supports to prevent
damage to the cylinders.
12 Undo the lifting equipment (travelling crane).
013591
Trolley, installing
NOTE
Safety.
1 Park the machine with the mast vertical.

2 Raise the mast high enough to position the carriage in the inner
mast and lift it into place.
3 Run down the mast so the trolley fastens in the inner mast. Stop
the mast in a position where the chains can be attached to the
trolley. Fit the chain tensioners and adjust and fasten with the nuts.
4 Lower the carriage as far as possible.
013591

7 Load handling – Trolley 7:27
8 Remove the plugs and connect the mast's hydraulic hoses and
the carriage wiring.
009987
9 Connect the trolley cable.
Lubricate the connectors with contact grease and connect them
Fasten the wiring with the lock plate.
10 Fit the side lift attachment; see Side lift attachment, installing,
page 7:51.
13 Check the trolley functions.
009995

Slide plates in trolley, adjusting and, if necessary,

replacing
NOTE
Minor adjustment to the clearance between the trolley and inner
mast is possible without removing the trolley.
2 If the slide plate extends less than 3 mm from the holder, replace it.
A 3 Use a gauge in the centre of the beam to measure the interior
width of the inner mast.
B
013593
Measure the interior width of the inner mast (A and B)
4 Use a sliding calliper to measure the external measurements

between the trolley slide plates.
D
013648
Measure the exterior measurements between the

trolley slide plates (C and D).

7 Load handling – Pipes and hoses 7:29
5 Adjust trolley clearance by removing the screws and adding or

removing shims.
a. If the width at A and B is the same:
2
Adjust C and D to be equal to or max. 0.5 mm more than A.
1 b. If A is greater than B:
Adjust C to be equal to or max. 0.5 mm more than A.
Adjust D to be equal to or max. 0.5 mm more than B.
c. If A is less than B:
Adjust C to be equal to or max. 0.5 mm more than A.
Adjust D to be equal to or max. 0.5 mm less than B.
6 Lubricate the inner sliding surfaces of the inner mast with a thin
013649
1
2 7 Fit the trolley; see Trolley, installing, page 7:26.
1. Screws 8 Lift the trolley all the way up and check that the slide plates do not
clamp too hard against the sliding surfaces.
2. Shim
Mast wheel, adjusting

For mast wheel adjustment, see Mast wheel, adjusting, page 7:24.

7.2.14 Accumulator lift

Accumulator lift, description
1 2
Accumulator lift is connected in parallel with the lift cylinders and
takes up pressure surges that occur in the lift cylinder when operating.
The piston-type accumulator is located below the main valve on the
hydraulic plate in front of the transmission.
019450
1. Accumulator brake system

2. Accumulator lift

See section 10 Common hydraulics group 10.6.7 hydraulic oil filter.

7:30 7 Load handling – Side shift
7.4 Side shift

Side shift, function description
Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage
1a
1b D1
2
D790-1
D797-1 D791-1
3 7
D7
D3
C 4 8
P2
P2
5 11 A 9
6 T2 A B
10
015076
1a The side shift control lever U = 0.5-4.5 V Linear control levers, description, page 7:5
(R8073-P3) sends the cab control unit Left: U = <2.5 V D1: Diagnostic menu, see section 8 Control
(D790-1) a voltage signal proportional system, group 8.4.9.1 ATTACH, menu 1
to lever movement. Right: U = 2.5 V
0.5 V is the highest left side
shift speed and 4.5 V is
the highest right side shift
speed. Lower voltage than
0.5 V and higher voltage
than 4.5 V is used to detect
and controls.
1b The control lever (S815-P3) sends US815-P3 = 0.5-4.5 V Control lever, description, page 7:4
the cab control unit (D790-1) a Right: US815-P3 = <2.5 V D1: Diagnostic menu, see section 8 Control
voltage signal proportional to lever system, group 8.4.9.1 ATTACH, menu 1
movement. Left: US815-P3 = >2.5 V
0.5 V is the highest right
side shift speed and 4.5 V
is the highest left side shift
speed. Lower voltage than
0.5 V and higher voltage
than 4.5 V is used to detect
and controls.
2 Control unit, cab (D790-1) transmits Checked by control Section 11 Common electrics, group 11.5.3.1
side shift left or right on the CAN bus. system, error shown Control unit, cab
with error code.
3 The frame control unit (D797-1) U = 24 V Section 11 Common electrics, group 11.5.3.2
activates the solenoid valve for main Frame control unit
pump relief (Y6062-2). D3: Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6

7 Load handling – Hydraulic oil pump 7:31

4 Solenoid valve, relief main pump - Lift, tilt and attachment control valve,
(Y6062-2) pressurises the attachment description, page 7:37
spool in the lift, tilt and attachment
control valve with servo pressure.
5 Hydraulic oil pump load handling See the pressure plate on Section 10 Common hydraulics, group 10.4.1
feeds the lift, tilt and attachment the left-hand frame beam. Gear pump with fixed displacement
control valve with hydraulic pressure. -
6 The control valve lift, tilt and - Lift, tilt and attachment control valve,
attachment's attachment slide description, page 7:37
changes position and pressurises the
control valve attachment.
7 The attachment control unit (D791-1) U = 24 V Section 11 Common electrics, group 11.5.3.5
activates the solenoid valve for side Control unit, attachment
shift left (Y6020) or the solenoid valve D7: Diagnostic menu, see section 8 Control
for side shift right (Y6021). system, group 8.4.9.11 ATTACH, menu 11 and
group 8.4.9.12 ATTACH, menu 12
8 The solenoid valve for side shift left - Attachment control valve, description, page
(Y6020) or the solenoid valve for side 7:32
shift right (Y6021) pressurises the
side shift spool in the attachment
control valve.
9 The control valve's side shift slide - Attachment control valve, description, page
changes position and pressurises the 7:32
side shift cylinder.
10 The side shift cylinder pushes in the - Side shift cylinder, description, page 7:35
main beam sideways in relation to
the trolley.
11 The oil filter cleans the return oil from - Section 10 Common hydraulics group 10.6.7
the lift cylinders before it is collected Hydraulic oil filter.
in the hydraulic oil tank.


fixed displacement.

7:32 7 Load handling – Control valve, attachment
7.4.2 Control valve, attachment

Attachment control valve, description
Side shift slide
Control valve attachment controls the hydraulic functions on the

3 4
2 attachment. The control valve is located up on the trolley. Solenoid
1 valves control the flow from the valve.
The control valve is an electro-hydraulically controlled, proportional and

5 pressure-compensated directional control valve. Electrically controlled
solenoid valves convert current to servo pressure. The servo pressure
controls the spring-centred valve slides that control pressure and flow
10 for the function in question. The valve slides have a flow limit so that
several functions can be used simultaneously. This enables them to
6 control the main flow.
9 The control valve has a built-in supply of pilot pressure. This means
7 that the valve has a built-in pressure reduction that converts feed
8 pressure to servo pressure for the various functions. The supply of pilot
pressure is common for all functions. This reduces pressure variations
due to long hoses and reduces the number of hoses to the valve.
The attachment control valve is fed by lift, tilt and attachment control
valve, see Lift, tilt and attachment control valve, description, page 7:37.
The control valve has the following sections:

• Side shift
019451
• Spreading right extension beam, see Attachment control valve,

description, page 7:45
1. Solenoid valve, side shift right (Y6021)
• Spreading left extension beam, see Attachment control valve,
2. Solenoid valve, lock twistlock (Y6040)
description, page 7:45
3. Solenoid valve spreading in left (Y6019L)
• Twistlocks, see Attachment control valve, description, page 7:64
4. Solenoid valve spreading in right (Y6019R)
Side shift slide
5. Solenoid valve spreading out right (Y6018R)
6. Solenoid valve spreading out left (Y6018L) The valve slide controls the direction and speed of side shift. The
valve spool is controlled by a solenoid valve for side shift right and a
7. Solenoid valve, open twistlock (Y6039)
solenoid valve for side shift left.
8. Solenoid valve, side shift left (Y6020)
Solenoid valve, side shift left
9. Connection, feed from hydraulic oil pump (P)
10. Connection return to tank (T) The solenoid valve for side shift left controls pressure to the side shift
spool so that the side shift spool opens and pressurises the side shift
cylinder.
Solenoid valve, side shift left is controlled electrically by Solenoid valve,

side shift left (Y6020), which is activated by Control unit, attachment
(D791-1). The solenoid valve directs servo pressure to the side shift
slide in proportion to the control current to the solenoid valve.
Solenoid valve, side shift right
The solenoid valve for side shift right controls pressure to the side shift
spool so that the side shift spool opens and pressurises the side shift
cylinder.
Solenoid valve, side shift is controlled electrically by Solenoid valve,

side shift right (Y6021), which is activated by Control unit, attachment
(D791-1). The solenoid valve directs servo pressure to the side shift
slide in proportion to the control current to the solenoid valve.

7 Load handling – Control valve, attachment 7:33
Control valve attachment, replacement
NOTE
Safety.

3 Remove the attaching bolts and lift away the plate fitted over the
control valve.
4 Mark and disconnect the hydraulic hoses from the control valve.
NOTE
from impurities.
5 Mark and disconnect the cable harness from the control valve.
013595
6 Remove the attaching bolts and lift away the valve. Place the valve
on a clean and protected surface.
7 Transfer the connection adapters to the new control valve.
NOTE
correctly.
NOTE
013596
mixed up.
8 Mark up the solenoid valves on the new control valve.

9 Lift the valve into place and fit the attaching bolts.
10 Connect the cable harness to the control valve according to the
marking.
11 Connect the hydraulic hoses to the control valve in according to
the marking.
NOTE
correctly.

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

7:34 7 Load handling – Control valve, attachment
15 Check the oil level in hydraulic oil tank with all hydraulic cylinders
in the retracted position. The oil level should be at the top of the
sight glass. Top up if necessary.
CAUTION
Do not overfill!
Leakage and environmental damage!
Check the hydraulic oil level with all hydraulic
cylinders fully retracted.
Control valve attachment, checking hydraulic

pressure
NOTE
Safety.
1 Operate and warm up the machine so that the hydraulic oil reaches
operating temperature, at least 50 °C.
˚C 3 Machine in service position, see section B Safety.
˚C
000475
4 Connect a pressure gauge (0-25 MPa) to the feed pressure

measuring outlet on the control valve attachment.
015085
Measuring outlet, feed pressure control valve,

attachment

7 Load handling – Side shift cylinder 7:35
5 Start the engine and run at max. revs. Activate a hydraulic function
on the attachment and read the pressure gauge. The pressure
must correspond with the pressure plate.
measuring outlet.
015025
7.4.3 Side shift cylinder

Side shift cylinder, description
The side shift cylinder sits between the trolley and the side lift
attachment. It shifts the main beam laterally in relation to the trolley.
013598

7.4.5 Trolley
Trolley, description
See Trolley, description, page 7:25.

Slide plates between trolley and attachment,

adjustment
1 Park the machine with the attachment lowered as far as possible
and spreading run all the way in.
1 2 Switch off the engine and switch off the main electric power.
3 Clean and measure the thickness of the lower slide plates.
NOTE
The thickness of the slide plate should be at least 10 mm.
4 Replace the lower slide plates, if necessary, by loosening the

attachment's mounting.
5 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 side lift attachment or inserting wedges to alter
the position of the side lift attachment in the trolley.
6 Remove the slide plate and fit a new one. Repeat with the other
lower slide plates (4 plates).
7 Reassemble the attachment's mounting.
3
2
013681
3
The illustration shows the slide plates between the
attachment and trolley.
1. Upper slide plates
2. Lower slide plates
3. Attachment's fastening
8 Clean and measure the thickness of the upper slide plates.

1 2 3
The upper slide plates can be replaced and adjusted using shims
when the attachment is in position in the trolley.
NOTE
The thickness of the slide plate should be at least 10 mm.
9 Remove the counterhold.

10 Loosen the slide plate's attaching bolt slightly so that the slide
plate releases from the carriage.
4
11 Insert the required number of shims to remove the play between
attachment and carriage. Alternatively replace the slide plate.
12 Refit the counterhold and tighten the attaching bolt that secures
the slide plate.
13 Check the play between side lift attachment and the trolley. The
play should be less than 1 mm with all slide plates fitted.
013682
Use more shims to adjust any play.

The illustration shows the slide plates between the
trolley and attachment. NOTE
1. Upper slide plates Do not use too thick shims. Too little play increases wear on the
2. Shim slide plates.
3. Counterhold
4. Screw NOTE
Check that the attaching bolts for all slide plates are tightened.
14 Check that the sliding surface is clean and lubricate the sliding
surface on the side lift attachment.

7 Load handling – Relief valve, attachment 7:37
15 Start the machine and side shift the attachment to its end positions.
Check that the play between the trolley and the attachment is
sufficient along the whole attachment and that no metallic contact
occurs. Adjust as necessary, using the shims.
7.4.7 Relief valve, attachment

Relief valve attachment, description
See section 10 Common hydraulics, group 10.2.3 Relief valve
attachment.

7.4.9 Lift, tilt and attachment control valve

Attachment slide
Lift, tilt and attachment control valve controls the speed and direction
1 of the lift and tilt and feeds pressure to the attachment control valve.
Control valve lift, tilt and attachment is a part of the main valve, see
valve is located on the lifting beam in front of the gearbox in the engine
compartment.
The attachment control valve is fed through a separate section in the

lift, tilt and attachment control valve. The solenoid valve hydraulic
pressure attachment (Y6062-2) is also activated when attachment
functions are activated. See also Lift, tilt and attachment control valve,
Attachment slide
2 When activating the Solenoid valve hydraulic attachment (Y6062-2) the

attachment slide is pressurised and controls the direction and flow of
015083
the oil from the hydraulic oil pumps to the attachment control valve.
Solenoid valve hydraulic pressure attachment
1. Solenoid valve hydraulic pressure attachment
(Y6062-2) Solenoid valve hydraulic pressure attachment (Y6062-2) is activated
2. Connection feed pressure control valve, by the frame control unit (D797-1). The solenoid valve directs servo
attachment pressure to the attachment slide which is proportional to the control
current to the solenoid valve.


7:38 7 Load handling – Spreading (positioning)
7.5 Spreading (positioning)

Spreading, function description
Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage
Twistlocks Unlocked or bypass Twistlocks, description, page 7:61
activated Section 8 Control system, group 8.2.2 Bypass
1b 1a
D1
2
D790-1
D797-1 D791-1
3 7, 14, 19
D3
4 D13 D8 D9
C
8, 15 9, 20
C
P2 D18
P2 10,
5 23 A 16,
6 T2 B A A B 21
13 18
015077
11, 17 12, 22

1a The switch for spreading 20'-40' U = 24 V Switch spreading 20'-40', description (linear
(S1012) sends a voltage signal to control levers), page 7:6
the cab control unit (D790-1). D1: Diagnostic menu, see section 8 Control
system, group 8.4.9.3 ATTACH, menu 3
1b The control lever (S815-T1.1 and Spreading: US815-T4 = 24 V Control lever, description, page 7:4
S815-T1.2) sends a voltage signal Out: US815-T1.2 = 24 V D1: Diagnostic menu, see section 8 Control
to the cab control unit (D790-1). system, group 8.4.9.3 ATTACH, menu 3
In: US815-T1.1 = 24V
2 The cab control unit (D790-1) Checked by control Section 11 Common electrics, group 11.5.3.1
transmits spreading in or out on the system, error shown Control unit, cab
CAN bus. with error code.
3 The frame control unit (D797-1) U = 24 V Section 11 Common electrics, group 11.5.3.2
activates the solenoid valve for main Frame control unit
pump relief (Y6062-2). D3: Diagnostic menu, see section 8 Control
4 Solenoid valve, relief main - Lift, tilt and attachment control valve,
pump (Y6062-2) pressurises the description, page 7:37
attachment spool in the lift, tilt and
attachment control valve with servo
pressure.
5 Hydraulic oil pump load handling See the pressure plate on Section 10 Common hydraulics, group 10.4.1
feeds the lift, tilt and attachment the left-hand frame beam. Gear pump with fixed displacement
control valve with hydraulic pressure. -

7 Load handling – Spreading (positioning) 7:39

6 The control valve lift, tilt and - Lift, tilt and attachment control valve,
attachment's attachment slide description, page 7:37
changes position and pressurises
the control valve attachment.
7 The attachment control unit I = 350–600 mA Section 11 Common electrics, group 11.5.3.5
(D791-1) activates the Solenoid Control unit, attachment
valve spreading out left (Y6018L) D8–D9: Diagnostic menu, see section 8 Control
and Solenoid valve spreading system, group 8.4.9.17 ATTACH, menu 17 –
out right (Y6018R) or Solenoid 8.4.9.20 ATTACH, menu 20
spreading in left (Y6019L) and
Solenoid valve spreading right
(Y6019R).
8 The solenoid valve for spreading - Attachment control valve, description, page
out left (Y6018L) or the solenoid 7:32
valve for spreading in left (Y6019L) D8: Diagnostic menu, see section 8 Control
pressurises the left spreader spool system, group 8.4.9.17 ATTACH, menu 17 and
in the attachment's control valve. 8.4.9.18 ATTACH, menu 18
9 The solenoid valve for spreading - Attachment control valve, description, page
out right (Y6018T) or the solenoid 7:32
valve for spreading in right (Y6019T) D9: Diagnostic menu, see section 8 Control
pressurises the right spreader spool system, group 8.4.9.19 ATTACH, menu 19 and
in the attachment's control valve. 8.4.9.20 ATTACH, menu 20
10 The control valve's spreader slides - Attachment control valve, description, page
change position and direct pressure 7:32
to the spreading cylinders.
11 Left spreading cylinder pushes left - Spreading cylinder, description, page 7:45
spreader beam in or out in the
attachment.
12 Right spreading cylinder pushes - Spreading cylinder, description, page 7:45
right spreader beam in or out in the
attachment.
13 The sensor for end position 20'-40' Sensor directly opposite Position sensor spreading, description, page
left (B769L) sends a voltage signal indicator plate: U > 24 V 7:53
to the attachment control unit D13: Diagnostic menu, see section 8 Control
(D791-1). system, group 8.4.9.6 ATTACH, menu 6
14 The attachment control unit (D791-1) - Section 11 Common electrics, group 11.5.3.5
reduces the control current to the Control unit, attachment
solenoid valve for spreading out left D8: Diagnostic menu, see section 8 Control
(Y6018L) or the solenoid valve for system, group 8.4.9.17 ATTACH, menu 17 and
spreading in left (Y6019L). 8.4.9.18 ATTACH, menu 18
15 The solenoid valve for spreading - Control valve attachment, replacement, page
out left (Y6018L) or the solenoid 7:33
valve for spreading in left (Y6019L) D8: Diagnostic menu, see section 8 Control
reduces the pressure to the left system, group 8.4.9.17 ATTACH, menu 17 and
spreader spool in the attachment's 8.4.9.18 ATTACH, menu 18
control valve.
16 The control valve's spreading slide - Attachment control valve, description, page
left changes position and lowers 7:32
the pressure on the left spreading
cylinder.
17 Spreader speed decreases. - Spreading cylinder, description, page 7:45
18 The sensor for end position 20'-40' Sensor directly opposite Position sensor spreading, description, page
right (B769R) sends a voltage indicator plate: U = 24 V 7:53
signal to the attachment control unit D18: Diagnostic menu, see section 8 Control


19 The attachment control unit (D791-1) - Section 11 Common electrics, group 11.5.3.5
reduces the control current to the Control unit, attachment
solenoid valve for spreading out D9: Diagnostic menu, see section 8 Control
right (Y6018R) or the solenoid valve system, group 8.4.9.19 ATTACH, menu 19 and
for spreading in right (Y6019R). 8.4.9.20 ATTACH, menu 20
20 The solenoid valve for spreading out - Control valve attachment, replacement, page
right (Y6018R) or the solenoid valve 7:33
for spreading in right (Y6019R) D9: Diagnostic menu, see section 8 Control
reduces the pressure to the right system, group 8.4.9.19 ATTACH, menu 19 and
spreader spool in the attachment's 8.4.9.20 ATTACH, menu 20
control valve.
21 The control valve's spreading slide - Attachment control valve, description, page
right changes position and lowers 7:32
the pressure on the right spreading
cylinder.
22 Spreader speed decreases. - Spreading cylinder, description, page 7:45
23 The hydraulic oil filter cleans the - Section 10 Common hydraulics group 10.6.7
return oil from the lift cylinders Hydraulic oil filter.
before it is collected in the hydraulic
oil tank.


30-foot stop, function description

voltage
Twistlocks Unlocked or Twistlocks, description, page 7:61
bypass activated Section 8 Control system, group 8.2.2 Bypass
D1 D2
2b 2a 1
35
30-
3
D790-1
D791-1
4,7,9,11 D5
D8 30' 30'
014803
4,7 4,7 5 6 8 10

1 The switch for stop at 30' (S1004) sends Switch in on position: Switch stop at 30', description (linear control
a voltage signal to the cab control unit Conn. 1: U = 0 V levers), page 7:6
(D790-1). D1: Diagnostic menu, see section 8 Control
Conn. 5: U = 24 V
Switch in off position:
Conn. 1: U = 24 V
Conn. 5: U = 24 V
2a The switch for spreading 20'-40' U = 24 V DC Switch spreading 20'-40', description (linear
(S1012) sends a voltage signal to the control levers), page 7:6
cab control unit (D790-1). D2: Diagnostic menu, see section 8 Control
2b The control lever (S815-T1.2) sends a Spreading: US815-T4 = 24 V Control lever, description, page 7:4
voltage signal to the Cab control unit Out: US815-T1.2 = 24 V D2: Diagnostic menu, see section 8 Control
In: US815-T1.1 = 24V
3 Control unit, cab (D790-1) sends Checked by control Section 11 Common electrics, group
spreading 30' on the CAN bus. system, error shown 11.5.3.1 Control unit, cab
with error code.
4 Spreading is activated in the same way - Spreading, function description, page 7:38
as the normal spreading steps 3–14.
5 When the left spreader beam Sensor directly opposite Position sensor spreading, description, page
approaches the 30' mark, the sensor indicator plate: U = 24 V 7:53
for 30' end position left (B777L) sends a D5: Diagnostic menu, see section 8 Control
voltage signal to the attachment control system, group 8.4.9.6 ATTACH, menu 6
unit (D791-1).
6 When the right spreader beam Sensor directly opposite Position sensor spreading, description, page
approaches the 30' mark, the sensor for indicator plate: U = 24 V 7:53
30' end position left (B777R) sends a D5: Diagnostic menu, see section 8 Control
voltage signal to the attachment control system, group 8.4.9.6 ATTACH, menu 6
unit (D791-1).


7 The attachment control unit (D791-1) - Spreading, function description, page 7:38
dampens the speed in the same way as
in normal spreading, steps 17–22.
8 When the left spreader beam is at the Sensor directly opposite Position sensor spreading, description, page
30' mark, the sensor for 20'-40' end indicator plate: U = 24 V 7:53
position (B769L) sends a voltage signal D8: Diagnostic menu, see section 8 Control
to the attachment control unit (D791-1). system, group 8.4.9.5 ATTACH, menu 5
9 The attachment control unit (D791-1) U=0V Attachment control valve, description, page
cuts off the current to the solenoid 7:32
valve for spreading out left (Y6018L) or
the solenoid valve for spreading in left
(Y6019L).
10 When the right spreader beam is at the Sensor directly opposite Position sensor spreading, description, page
30' mark, the sensor for 20'-40' end indicator plate: U = 24 V 7:53
position (B769R) sends a voltage signal D8: Diagnostic menu, see section 8 Control
to the attachment control unit (D791-1). system, group 8.4.9.5 ATTACH, menu 5
11 The attachment control unit (D791-1) U=0V Attachment control valve, description, page
cuts off the current to the solenoid valve 7:32
for spreading out right (Y6018R) or the
solenoid valve for spreading in right
(Y6019R).


Automatic spreading 20-40 foot, function

description

voltage
Twistlocks Unlocked or bypass Twistlocks, description, page 7:61
activated
Doors Closed Section 9 Frame, body, cab and accessories, group 9.10.2 Doors
Parking brake Released Section 4 Brakes, group 4.5 Parking brake system
2
D1 D2
1b 1a
3 7
D790-1 D795
D791-1 D9
D10 D8 D11 4, 5, 8 9 D13 D12
10 8 11 6 13 9 12
009347
D5

1a. The switch for spreading 20'-40' U = 24 V DC Switch spreading 20'-40', description (linear
(S1012) sends a voltage signal to control levers), page 7:6
the cab control unit (D790-1). D1: Diagnostic menu, see section 8 Control
1b The control lever (S815-T1.1 and Spreading: US815/T4 = 24 V Control lever, description, page 7:4
S815-T1.2) sends a voltage signal to Out: US815/T1.2 = 24 V D1: Diagnostic menu, see section 8 Control
the cab control unit (D790-1). system, group 8.4.9.3 ATTACH, menu 3
In: US815/T1.1 = 24 V
2 The switch for automatic spreading Switch in on position: Switch automatic spreading, description (linear
20'-40' (S1012-2) sends a voltage US199-2/2 = 0 V control levers), page 7:7
signal to the cab control unit D2: Diagnostic menu, see section 8 Control
(D790-1). US199-2/5 = 24 V
Switch in off position:
US199-2/2 = 24 V
US199-2/5 = 24 V
3 The cab control unit (D790-1) Checked by control Section 11 Common electrics, group 11.5.3.1
transmits "automatic spreading out" system, error shown Control unit, cab
or "automatic spreading in" on the with error code.
CAN bus.
4 The attachment control unit (D791-1) - Spreading, function description, page 7:38
activates spreading the same way as
in steps 3-14 of normal spreading.
5 The attachment control unit (D791-1) Buzzer active: U = 24 V Buzzer automatic spreading 20'-40',
activates the automatic spreading description, page 7:53
buzzer (H9003). D5: Diagnostic menu, see section 8 Control


6 Buzzer automatic spreading (H9003) Buzzer active: U = 24 V Buzzer automatic spreading 20'-40',
generates acoustic warning signal. description, page 7:53
7 When automatic spreading is active, - Section 11 Common electrics, group 11.5.3.12
the KID control unit (D795) activates Control unit, KID
the Automatic Spreading event
menu.
8 When the left spreader beam Sensor directly opposite Spreading, function description, page 7:38
approaches the 20', 30' ( ) or 40' indicator plate: U = 24 V 30-foot stop, function description, page 7:41
mark, the sensor for 20'–40' end
position left (B769L) sends a voltage D8: Diagnostic menu, see section 8 Control
signal to the attachment control unit system, group 8.4.9.6 ATTACH, menu 6
(D791-1), which activates damping
for the left spreader beam the same
way as in steps 16-22 of normal
spreading.
9 When the right spreader beam Sensor directly opposite Spreading, function description, page 7:38
approaches the 20', 30' ( ) or indicator plate: U = 24 V 30-foot stop, function description, page 7:41
40' mark, the sensor for 20'–40'
end position right (B769R) sends D9: Diagnostic menu, see section 8 Control
a voltage signal to the attachment system, group 8.4.9.6 ATTACH, menu 6
control unit (D791-1), which activates
damping for the right spreader beam
the same way as in steps 16-22 of
normal spreading.
10 When the left spreader beam is Sensor directly opposite Position sensor spreading, description, page
at the 20', 30' ( ) or 40' mark, indicator plate: U = 24 V 7:53
the sensor for end position 30' left D10: Diagnostic menu, see section 8 Control
(B777L) sends a voltage signal to system, group 8.4.9.6 ATTACH, menu 6
the attachment control unit (D791-1).
11 The attachment control unit (D791-1) I = 0 mA Section 11 Common electrics, group 11.5.3.5
cuts off the current to the solenoid Control unit, attachment
valve for spreading out left (Y6018L) D11: Diagnostic menu, see section 8 Control
or the solenoid valve for spreading system, group 8.4.9.17 ATTACH, menu 17 and
in left (Y6019L). 8.4.9.18 ATTACH, menu 18
12 When the right spreader beam is Sensor directly opposite Position sensor spreading, description, page
at the 20', 30' ( ) or 40' mark, the indicator plate: U = 24 V 7:53
sensor for end position 30' right D12: Diagnostic menu, see section 8 Control
(B777R) sends a voltage signal to system, group 8.4.9.6 ATTACH, menu 6
the attachment control unit (D791-1).
13 The attachment control unit (D791-1) I = 0 mA Section 11 Common electrics, group 11.5.3.5
cuts off the control current the Control unit, attachment
solenoid valve for spreading out right D13: section 8 Control system, group 8.4.9.19
(Y6018R) or the solenoid valve for ATTACH, menu 16 and 8.4.9.20 ATTACH,
spreading in right (Y6019R). menu 20


fixed displacement.

7 Load handling – Control valve, attachment 7:45
7.5.2 Control valve, attachment

Spreader slide
Spreading is controlled by two identical sections in the attachment

3 4
2 control valve, one for the right spreader beam and one for the left
1 spreader beam. Both beams are controlled in the same way, which is
why they are described together below. For a more detailed description
of the valve and component locations, see Attachment control valve,
5 description, page 7:32.
Spreader slide
10 The valve slides control the direction and speed of the spreading. Each
6 valve slide is controlled by two solenoid valves, one for spreading out
and one of spreading in.
9 Solenoid valve for spreading out
7
The solenoid valves for spreading out control the pressure to the
8
spreader slides so that they open and pressurises the spreader
cylinders.
Solenoid valve, spreading out left (Y6018L) and solenoid valve,
spreading out right (Y6018R) are activated by the attachment control
unit (D791-1). The solenoid valve controls the servo pressure to
spreader slide proportionally toward the control current.
The signal can be checked with diagnostic menu.
019451
• Left: section 8 Control system, group 8.4.9.17 ATTACH, menu 17

1. Solenoid valve, side shift right (Y6021) • Right: section 8 Control system, group 8.4.9.19 ATTACH, menu 19
2. Solenoid valve, lock twistlock (Y6040) Solenoid valve for spreading in
3. Solenoid valve spreading in left (Y6019L) The solenoid valves for spreading in control the pressure to the
4. Solenoid valve spreading in right (Y6019R) spreader slides so that they open and pressurises the spreader
5. Solenoid valve spreading out right (Y6018R) cylinders.
6. Solenoid valve spreading out left (Y6018L) Solenoid valve, spreading in left (Y6019L) and solenoid valve,
7. Solenoid valve, open twistlock (Y6039) spreading in right (Y6019R) are activated by the attachment control unit
(D791-1). The solenoid valve controls the servo pressure to spreader
slide proportionally toward the control current.
10. Connection return to tank (T) The signal can be checked with diagnostic menu.
• Left: section 8 Control system, group 8.4.9.18 ATTACH, menu 18
• Right: section 8 Control system, group 8.4.9.20 ATTACH, menu 20

See Control valve attachment, replacement, page 7:33.
7.5.3 Spreading cylinder

Spreading cylinder, description
The spreading cylinders move the spreader beams in and out of
the attachment's main beam. The attachment control unit (D791-1)
sends a signal to the attachment control valve which pressurises the
spreading cylinders.
The spreader cylinders are fastened in the spreader beams and the
main beam.
Openings in the sides of the spreader beams and the attachment's
main beam make it possible to access the spreader cylinders for
maintenance purposes.
014816

7:46 7 Load handling – Spreader beam
7.5.4 Spreader beam

Spreader beam, description
The spreader beams are the part of the attachment that grips the
container Two spreader beams run in the main beam. The spreader
beams are pushed in and out by the hydraulic cylinders.
The spreader beam houses twistlocks. See Twistlocks, function

014737
Spreader beam slide plates, adjusting/replacing

1 Park the machine with the attachment lowered as far as possible
and spreading extended approx. 1000 mm.
1000 mm
013683
3 Unscrew the nuts and bolts (position 1) that secure the slide plates.
1
013684

7 Load handling – Spreader beam 7:47
013685
Right side
4 Remove the slide plates and shims from the main beam.
Lift the extension section slightly so that the slide the plates are
unloaded.
013686
Left side
013687
Right side

7:48 7 Load handling – Main beam, side lift attachment
5 Refit the slide plates, add a sufficient number shims under the
slide plates so that the play between the slide plates and the main
beam is 1-3 mm both laterally and vertically. This corresponds
to the measurements X + (1-3) mm and Y + (1-3) mm internally
between the slide plates.
NOTE
Do not use too thick shims. Too little play increases wear on the
slide plates.
NOTE
Check that the attaching bolts for all slide plates are tightened.
6 Start the machine and check the spreading functioning. Try to lift a
container and then check the spreader beams' play again on the
attachment's main beam.
013688
Left side
7.5.5 Main beam, side lift attachment

Side lift attachment's main beam, description
The main beam side lift attachment is fastened to the trolley by the
hydraulic cylinders. The main beam contains equipment for spreading
(spreader beams, hydraulic cylinders, slide plates and sensors).
014817
Side lift attachment, removing
NOTE
Safety.
NOTE
It is possible to remove the trolley and the side lift attachment
as a unit.
1 Park the machine with the mast vertical and the attachment in
its lowest position.

7 Load handling – Main beam, side lift attachment 7:49
3 Connect lifting equipment (overhead crane) to the attachment in

a secure manner.
4 Start the engine and lift slightly with the lifting equipment (overhead
crane). Let the machine stand with the ignition on for a while.
014819
6 Detach the side shift cylinder from the attachment.
Remove the cylinder's shaft from the bracket on the trolley. If
necessary, use the threaded hole and a puller to press the shaft
out.
Start the engine and retract the cylinder so that it comes loose
from the mounting in the trolley. Switch off the engine.
Save the circlips. Refit the shaft in the cylinder.
013654
7 Fasten the side shift cylinder.

009997
10 Mark up and detach hydraulic connections from the side lift

attachment and the side shift cylinder.
NOTE
from impurities.
009952

11 Detach the cable harness of the attachment from the attachment

control unit.
Remove the cable harness clamping ring.
12 Loosen the attachment's mounting unit in the trolley.

13 Lift aside the side lift attachment. Position so as not to damage
the twistlocks.
013680

7 Load handling – Main beam, side lift attachment 7:51
Side lift attachment, installing
NOTE
Safety.
1 Park the machine with the mast vertical.

2 Lower the trolley to its lowest position.
6 Lift the side lift attachment into place.
Lifting points side lift attachment
7 Fit the lifting carriage's front panels to fix the side lifting attachment
in position.
8 Check that the side lift attachment runs correctly in the trolley; see
Slide plates between trolley and attachment, adjustment, page
7:36.
013680
9 Clean and apply a layer of lubricating grease to the side shift

cylinder shaft prior to installation.
10 Connect the side shift cylinder to the side lift attachment.
Align the side shift cylinder, press in the shaft and secure with
the circlips.
NOTE
Use an anti-recoil plastic or copper mallet.
If necessary, detach the hydraulic connections on the side shift

cylinder to make it possible to adjust cylinder length.
013654

11 Attach the cable harness of the attachment to the attachment

control unit.
Lubricate the connectors with contact grease and join them up.
Fasten the wiring with clamps.
12 Remove plugs and connect hydraulic hoses for the side lift
attachment and side shift cylinder using the markings as a guide.
15 Check the functions of the side lift attachment.
009952
16 Check the oil level in hydraulic oil tank when all hydraulic cylinders
are in the retracted position. The oil level should be at the top of
the sight glass. Top up if necessary.
CAUTION
Do not overfill!

7 Load handling – Position sensor, spreading 7:53
7.5.6 Position sensor, spreading

Position sensor spreading, description
The spreading position sensors indicate the position of the spreader
3 4 5
beams. The position sensors are used to control spreading so that the
twistlocks fit the container. The position sensors are located under the
protective plate at the rear of the attachment's main beam.
Sensor end positions 20' and 40' (B769R and B769L) indicate the
end positions for 20 and 40-feet containers. The sensors detect the
spreader beams' end positions by means of two indicator plates on top
1 2 of the spreader beams. The sensor is used to activate damping.
With the 30 feet stop option, two extra sensors are fitted, Sensor end
5 4 3
position 30' (B777R and B777L), and two indicator plates. The sensor
is used to activate 30-foot stop.
The sensors are supplied power by and send a 24 V signal to Control

unit, attachment (D791-1) when the indicator plates pass the sensor.
Indicator plates on the spreader units are fitted so that the sensors
generate a signal when the spreader unit passes the sensor. The
indicator plates and the position of the sensors are designed so that
013676
2 1 the distance between the spreaders becomes 20', (30') and 40'.
1. Sensor, end position 20' and 40' The signals can be checked via the diagnostic menu. See section 8
2. Sensor end position 30' Control system, group 8.4.9.6 ATTACH, menu 6.
3. Indicator plate 20'

Position sensor, checking and adjustment

See Position sensor, checking and adjustment, page 7:3.
7.5.7 Buzzer, automatic spreading 20'-40'

Buzzer automatic spreading 20'-40', description
The buzzer for automatic spread 20'-40' (H9003) sits on the underside
of the trolley on machines with automatic spreading 20'-40'. The buzzer
is activated during automatic spreader movement.


attachment.
7.5.10 Lift, tilt and attachment control valve

Lift, tilt and attachment control valve, general
See Lift, tilt and attachment control valve, description, page 7:37.

7:54 7 Load handling – Hydraulic oil filter


7 Load handling – Tilt 7:55
7.7 Tilt
Tilt, function description
voltage
1b 1a D3
D1
2, 3
D790-1
D797-1
4 5
D5
6 9
C
P2
10
7 11 A B 8 9
019453
10

1a The tilt control lever (R8072-P2) sends U = 0.5-4.5 V Linear control levers, description, page 7:5
the cab control unit (D790-1) a voltage Out: U = <2.5 V D1: Diagnostic menu, see section 8 Control
signal proportional to lever movement. system, group 8.4.8.1 ELSERV, menu 1
In: U = >2.5 V
0.5 V is the highest tilt
out speed and 4.5 V is
the highest tilt in speed.
Lower voltage than 0.5 V
and higher voltage than
4.5 V is used to detect
and controls.
1b The control lever (S815-P2) sends the US815-P2 = 0.5-4.5 V Control lever, description, page 7:4
cab control unit (D790-1) a voltage In: US815-P2 <2.5 V D1: Diagnostic menu, see section 8 Control
signal proportional to lever movement. system, group 8.4.8.1 ELSERV, menu 1
Out: US815-P2 = >2.5 V
0.5 V is the highest tilt
in speed and 4.5 V is
the highest tilt out speed.
Lower voltage than 0.5 V
and higher voltage than
4.5 V is used to detect
and controls.
2 The cab control unit (D790-1) transmits Checked by control Section 11 Common electrics, group 11.5.3.1
tilt in or tilt out on the CAN bus. system, error shown with Control unit, cab
error code.
3 Cab control unit (D790-1) voltage feeds U = 24 V Section 11 Common electrics, group 11.5.3.2
control breaker relay tilt (K3002). Frame control unit
system, group 8.4.1.6 CAN/POWER, menu 6


4 Control breaker relay tilt (K3002) makes - Section 11 Common electrics, group 11.5.1.4
the ground connection between Frame Emergency stop switch voltage (15E)
control unit (D797-1) and to Solenoid
valve tilt in (Y6011) and Solenoid valve
tilt out (Y6010).
5 The frame control unit (D797-1) controls I = TDB mA Section 11 Common electrics, group 11.5.3.2
the current proportionally to the lever Frame control unit
movement to Solenoid valve tilt in D5: Diagnostic menu, see section 8 Control
(Y6011) or Solenoid valve tilt out system, group 8.4.8.5 ELSERV, menu 5 and
(Y6010). 8.4.8.6 ELSERV, menu 6
6 The solenoid valve for tilt in (Y6011) or - Lift, tilt and attachment control valve,
the solenoid valve for tilt out (Y6010) description, page 7:57
pressurises the tilt spool in the lift, tilt
and attachment control valve.
7 The hydraulic oil pumps pump oil from See the pressure plate on Section 10 Common hydraulics, group
the hydraulic oil tank. the left-hand frame beam. 10.4.1 Gear pump with fixed displacement
8 The control valve's tilt spool changes - Lift, tilt and attachment control valve,
position and pressurises the load description, page 7:57
retention valve.
9 The load holding valve opens and directs - Load holding valve, description, page 7:58
the pressure on to the tilt cylinders.
10 The tilt cylinders angle the mast in - Tilt cylinder, description, page 7:58
relation to the frame. Mast, description, page 7:15
the lift cylinders before it is collected in Hydraulic oil filter.


fixed displacement.

7 Load handling – Control valve, lift and tilt 7:57
7.7.5 Control valve, lift and tilt

Tilt slide
Lift, tilt and attachment control valve controls the speed and direction
1 of the lift and tilt and feeds pressure to the attachment control valve.
2 Control valve lift, tilt and attachment is a part of the main valve, see
valve is located on the lifting beam in front of the gearbox in the engine
compartment.
Tilt is controlled by a separate section of the lift, tilt and attachment

control valve. See also Lift, tilt and attachment control valve,
For more information about tilting, see Tilt, function description, page
7:55.
Tilt slide
4 When the solenoid valves are activated, the tilt spool is pressurised
and controls the direction and flow of oil from the hydraulic oil pumps
015082
3 to the tilt cylinders.

1. Solenoid valve, tilt in (Y6011) Solenoid valve, tilt out
2. Solenoid valve, tilt out (Y6010)
On machines with electric servo, the solenoid valve tilt out is controlled
3. Connection rod side tilt cylinders electrically with Solenoid valve tilt out (Y6010) which is activated by the
4. Connection piston side tilt cylinders Frame control unit option (D797-1). The solenoid valve directs servo
pressure to the tilt spool which is proportional to the control current to
the solenoid valve.
Solenoid valve, tilt in
On machines with electric servo, the solenoid valve tilt in is controlled
electrically with Solenoid valve tilt in (Y6011) which is activated by the
Frame control unit option (D797-1). The solenoid valve directs servo
pressure to the tilt spool which is proportional to the control current to
the solenoid valve.

7:58 7 Load handling – Load holding valve
7.7.6 Load holding valve

Load holding valve, description
Load retention valves are located on the tilt cylinders by the hydraulic
connection to the rod side. The load retention valve prevents the tilt
cylinders from moving faster than the supplied pressure from the lift, tilt
and attachment control valve. This prevents unwanted tilting forward
that can occur with heavy loads and or high lifting. The load retention
valve also makes the tilt movement more controlled.
009929
Load holding valve
7.7.7 Tilt cylinder

Tilt cylinder, description
The tilt cylinders sit between the mast and the frame and angle the
mast in relation to the machine.
2
019454
3
1. Tilt cylinder
2. Mast
3. Lower mast mounting in frame

7.7.8 Mast
Mast, description
See Mast, description, page 7:15.

7 Load handling – Pipes and hoses 7:59



7:60 7 Load handling – Levelling
7.8 Levelling
Mechanical levelling, function description
Mechanical levelling means that the twistlock fasteners can spring out
and adjusts the height of the twistlocks according to the incline of the
container to be lifted. This means that the machine can handle loads
on an uneven surface, up to ± 3° angle.
014021

7 Load handling – Load carrier 7:61
7.9 Load carrier

7.9.1 Twistlocks
Twistlocks, description
The container is held in place on the side lift attachment with two
twistlocks.
Twistlocks are controlled with Switch twistlocks. A section of the

attachment control valve pressurises two parallel-connected cylinders,
one on each side of side lift attachment. Each hydraulic cylinder
actuates a linkage that turns a twistlock. Four position sensors, two on
each side of the side lift attachment, detect the position of the linkage
and indicates whether the twistlocks are open or locked. Indicator
lamps on the side lift attachment and in the cab, and a mechanical
indicator on the side lift attachment shows the status of the twistlocks.
A contact pin and a sensor by each twistlock indicates when the

attachment is in contact with the container. This is used to control
when the twistlocks can be activated. An indicator light on the side lift
attachment and one in the cab indicate when the side lift attachment is
fully aligned. An event menu shows which twistlocks is aligned (1 - 2).
Both twistlocks must be aligned in order to actuate the twistlocks.
Twistlocks, function description

switch voltage
Contact Full contact or bypass activated Twistlocks, description, page 7:66
Section 8 Control system, group 8.2.2 Bypassing
1
D1
2b
2a
7, 20
D2 3 6, 19
D790-1 D790-2 D795
D8 D797-1 D791-1 D5
8 5, 12, 18
9 D17
D12 17 4
C
13
C 16
P2
P2 A
10 21 A
11 T2 B
14 15 16
D17 4
17
015078
D4

7:62 7 Load handling – Twistlocks

1 The switch for locking the twistlocks U = 24 V Switch lock twistlocks, description (linear
(S1003) (automatic mode) sends a control levers), page 7:5
voltage signal to the cab control unit D1: Diagnostic menu, see section 8 Control
2a The switch for opening the twistlocks U = 24 V Switch lock twistlocks, description (linear
(S1002) sends a voltage signal to the control levers), page 7:5
cab control unit (D790-1) for twistlock D2: Diagnostic menu, see section 8 Control
opening. system, group 8.4.9.5 ATTACH, menu 5
If the "lock twistlocks" switch (S1003) is
in the manual position, a signal from the
"open twistlocks" switch (S1002) is not
needed to open the twistlocks.
2b The control lever (S815-T2) sends a US815/T2 = 24 V Control lever, description, page 7:4
voltage signal to the cab control unit D2: Diagnostic menu, see section 8 Control
(D790-1) for twistlock opening. system, group 8.4.9.3 ATTACH, menu 3
If Switch, lock twistlocks (S1003) is
in manual position then no signal is
required from the control lever to open
twistlocks.
3 Control unit, cab (D790-1) transmits Checked by control Section 11 Common electrics, group 11.5.3.1
"open twistlocks" or "lock twistlocks" on system, error shown with Control unit, cab.
the CAN bus. error code.
4 The alignment left sensor (B7203L) and Sensor directly opposite Sensor, contact, description, page 7:68
alignment right sensor (B7203R) detect indicator plate: U = 24 V D4: Diagnostic menu, see section 8 Control
position and send a voltage signal to the system, group 8.4.9.6 ATTACH, menu 6
attachment control unit (D791).
activates the alignment indicator light Control unit, attachment
on the mast's lamp panel and sends D5: Diagnostic menu, see section 8 Control
alignment on the CAN bus. system, group 8.4.9.10 ATTACH, menu 10
6 Control unit KID (D795) activates the - Section 11 Common electrics, group
event menu for alignment. 11.5.3.12 Control unit, KID
7 Control unit KID (D790-2) activates the - Section 11 Common electrics, group
indicator light for alignment on the cab's 11.5.3.11 Control unit, KIT
light panel.
8 The frame control unit (D797-1) activates U = 24 V Section 11 Common electrics, group 11.5.3.2
the solenoid valve for main pump relief Frame control unit
(Y6062-2). D8: Diagnostic menu, see section 8 Control
9 Solenoid valve, relief main pump - Lift, tilt and attachment control valve,
(Y6062-2) pressurises the attachment description, page 7:37
spool in the lift, tilt and attachment
control valve with servo pressure.
10 The load handling hydraulic oil pump See the pressure plate on Section 10 Common hydraulics, group 10.4.2
pumps oil from the hydraulic oil tank to the left-hand frame beam. Axial piston pump with variable displacement
the lift, tilt and attachment control valve
with hydraulic pressure.
11 The control valve lift, tilt and attachment's - Lift, tilt and attachment control valve,
attachment slide changes position and description, page 7:37
pressurises the control valve attachment.
activates the "open twistlocks" solenoid Control unit, attachment
valve (Y6039) or the "lock twistlocks" D12: Diagnostic menu, see section 8 Control
solenoid valve (Y6040). system, group 8.4.9.9 ATTACH, menu 9
13 The "open twistlocks" solenoid valve - Attachment control valve, description, page
(Y6039) or the "lock twistlocks" solenoid 7:64
valve (Y6040) pressurises the twistlock
spool with servo pressure.

7 Load handling – Twistlocks 7:63

14 The twistlock spool of the control valve - Attachment control valve, description, page
changes position and pressurises the 7:64
lock cylinders via the overcentre valve.
15 The overcentre valve prevents the - Twistlock overcentre valve, description, page
uncontrolled opening or closing of the 7:65
twistlocks.
16 The lock cylinders rotate the twistlocks. - Lock cylinder, description, page 7:65
17 The "unlocked twistlocks" sensor (B7204 Sensor directly opposite Sensor, twistlocks, description, page 7:69
L and R) or the "locked twistlocks" sensor indicator plate: U = 24 V D17: Diagnostic menu, see section 8 Control
(B7205 L and R) sends a signal to the system, group 8.4.9.7 ATTACH, menu 7
attachment control unit (D791-1).
voltage feeds the unlocked twistlocks Control unit, attachment
indicator light (H562) or the locked D5: Diagnostic menu, see section 8 Control
twistlocks indicator light (H563) on system, group 8.4.9.10 ATTACH, menu 10
the mast's lamp panel and sends
unlocked twistlocks or locked twistlocks
information on the CAN-bus.
19 Control unit KID (D795) activates the Checked by control Section 11 Common electrics, group
event menu for twistlocks. system, error shown with 11.5.3.12 Control unit, KID
error code.
20 Control unit KIT (D790-2) supplies Checked by control Section 11 Common electrics, group
voltage to Indicator light "unlocked system, error shown with 11.5.3.11 Control unit, KIT
twistlocks" or Indicator light "locked error code.
twistlocks" on the cab lamp panel.
the lift cylinders before it is collected in Hydraulic oil filter.

7.9.1.1 Hydraulic oil pump

fixed displacement.

7.9.1.2 Control valve, attachment

Twistlocks slide, description
The twistlocks function is controlled by a separate section in the

3 4
2 attachment's control valve. For a general description of the valve and
1 component locations, see Attachment control valve, description, page
7:32.
5 Twistlocks slide, description

The valve spool controls the direction of the lock cylinder. The valve
spool is controlled by the "lock twistlocks" solenoid valve (Y6040) and
10 the "open twistlocks" solenoid valve (Y6039).
6
"Lock twistlocks" solenoid valve, description
9 The "lock twistlocks" solenoid valve directs pressure to the twistlock
7 spool so that the spool opens and pressurises the lock cylinders.
8
Solenoid valve locked twistlocks (Y6040) is activated by the attachment
control unit (D791-1). The solenoid valve guides servo pressure to
the twistlock spool.
"Open twistlocks" solenoid valve, description
019451
The "open twistlocks" solenoid valve directs pressure to the twistlock

spool so that the spool opens and pressurises the lock cylinders.
1. Solenoid valve, side shift right (Y6021)
2. Solenoid valve, lock twistlock (Y6040) Solenoid valve open twistlocks (Y6039) is activated by the attachment
control unit (D791-1). The solenoid valve guides servo pressure to
3. Solenoid valve spreading in left (Y6019L)
the twistlock spool.
4. Solenoid valve spreading in right (Y6019R)
5. Solenoid valve spreading out right (Y6018R) The signal can be checked via the diagnostic menu. See section 8
6. Solenoid valve spreading out left (Y6018L)
7. Solenoid valve, open twistlock (Y6039)
10. Connection return to tank (T)

See Control valve attachment, replacement, page 7:33.

7.9.1.3 Twistlock overcentre valve
Twistlock overcentre valve, description

The overcentre valve prevents the uncontrolled opening or closing of
the twistlocks. The valve is located to the left of the attachment control
valve on the trolley.
019455
7.9.1.4 Lock cylinder
Lock cylinder, description

The lock cylinder activates the lock mechanism so that the twistlocks
are rotated. Two parallel-connected locking cylinders, one on the
right and one on the left spreader beam actuate a linkage that turns
a twistlock.
014806


7.9.1.5 Lock mechanism
Lock mechanism, description
1 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 in
3 2 the corner box.
The lock mechanism consists of a rotary plate with a linkage bearing

at which the lock cylinder is attached. The rotary plate rotates the
twistlocks.
014807
1. Linkages
2. Rotary plate
3. Lock cylinder mount
7.9.1.6 Twistlocks
Twistlocks, description
1 2 3
WARNING
Dropped load.
Extreme danger!
Twistlocks hold the load during load handling and
therefore it is of the utmost importance that twistlocks
are checked according to instructions and are replaced
at the slightest sign of damage or wear.
014716
5 4
Twistlocks secure the load and are located out in the corners of the
1. Unlocked twistlock sensor spreader beam's longitudinal section.
2. Sensor, contact Twistlocks are manufactured from high-strength steel in accordance
3. Locked twistlock sensor with international standards. The lift pins are marked with serial
numbers.
4. Lift pin
5. Contact pin Twistlocks are connected pairs via a linkage system to a hydraulic
cylinder which in turn is controlled via a section in the attachment's
control valve. Inductive sensors send signals when the twistlocks are
locked and unlocked, respectively.

Twistlocks, replacement
3 Clean the twistlocks and the surrounding area.
4 Slacken the screws on the clamp holding the twistlocks in place.
5 Hold the twistlocks while removing the clamp halves.
WARNING
Dropped component.
Risk of pinch injury or product damage.
Twistlock weighs approx. 30 kg.
014821
6 Remove the clamp halves and lift away the twistlock.

7 Fit a new twistlock and secure it with the clamp halves.
NOTE
Remember the washer.
8 Check the positions of the parts and that the twistlocks can move.
9 Tighten the screws of the clamp halves.
10 Lubricate the twistlocks and lock mechanism with lubricating
grease.
11 Check that the twistlock mechanism can move.
12 Turn on the main electric power and start the machine.
13 Check that the twistlocks are working.
014821

7.9.1.7 Sensor, contact
Sensor, contact, description

The alignment sensors (B7203L and B7203R) detect when the
attachment has contact with the container. Two inductive position
sensors are used to indicate alignment.
The sensor senses the position of a spring pin which is pressed in

when the attachment has contact up against the container. The sensor
is located behind the pin. The position of the sensor can be adjusted
so that it gives a signal when the pin is pressed in and the head is level
with the lower edge of the spreader beam. The clearance between the
attachment and the container's corner boxes means the sensors stop
sending signals when the attachment is lifted.
The sensors are supplied power and send a 24 V signal to the

attachment control unit (D791-1) when the indicator pin is pressed in.
014813
1 2
1. Sensor, contact
2. Contact pin
Alignment sensor, checking and adjusting

1 Check that the alignment pins in the corner boxes can move up
and down freely. The alignment pins must spring down when they
are not loaded.
2 Check that the sensor is free of damage and dirt.
3 Turn the start key to position I and check that the LED on the
sensor is unlit.
4 Lower the attachment onto a container and check that the
alignment indicator light comes on.
5 Lift the container a little bit so that the alignment indicator light
goes out.
6 With the container lifted, check how much alignment pin movement
014717
1 2 is needed to detect contact (LED on the sensor lights). The

movement should be 3–4 mm.
Right side
1. Sensor, contact
2. Contact pin

7 If necessary, slacken the lock nut and screw the sensor in/out until
the distance between the sensor and the alignment pin is 5±1 mm.
014718
2 1
Left side
1. Sensor, contact
2. Contact pin
7.9.1.8 Sensor twistlocks
Sensor, twistlocks, description

Twistlock sensors (B7204L, B7204R, B7205L and B7205R) detect
when the twistlocks are locked or unlocked. Four inductive position
sensors, two in each spreader beam, detect the position of the lock
mechanism.
Both sides function in the same way independently of one another. An

indicator plate is fitted on the lock mechanism by the lock cylinder.
When the lock mechanism is in the position that locks the twistlocks,
one of the sensors sends a signal to Control unit, attachment (D791-1).
When the lock mechanism is in the position that unlocks the twistlocks,
the second sensor sends signal to Control unit, attachment (D791-1).
No signals are sent if the lock mechanism stops midway.
The sensors are supplied power by and send a 24 V signal to Control

unit, attachment (D791-1) when the indicator plate is in front of the
sensor.
014809
1 2
1. Unlocked twistlock sensor
2. Locked twistlock sensor

Twistlocks sensor, checking and adjusting

1 Check that the sensors are free of damage and dirt.
2 Turn the start key to position I and check that the LED on the
"unlocked twistlock" sensor is lit.
If necessary, slacken the lock nut and screw the sensor in/out until
the distance between the sensor and the indicator plate is 5±1 mm.
3 Check that the "twistlocks open" indicator light is lit.
4 Lower the attachment over a container and lock the twistlocks.
5 Check that the LED on the "locked twistlock" sensor is lit.
If necessary, slacken the lock nut and screw the sensor in/out until
the distance between the sensor and the indicator plate is 5±1 mm.
014719
1 2
Right side
6 Check that the "twistlocks locked" indicator light is lit.

014720
2 1
Left side

7.9.1.10 Pipes and hoses

7.9.1.11 Relief valve, attachment

attachment.
7.9.1.12 Lift, tilt and attachment control valve
Lift, tilt and attachment control valve, general

See Lift, tilt and attachment control valve, description, page 7:37.
7.9.1.13 Hydraulic oil filter


7:72 7 Load handling – Other functions
7.10 Other functions

7.10.1 Container counter
Container counter, function description
The container counter tracks the number of containers lifted. The

counter has two counters that can be reset separately.
The container counter uses the alignment sensors and the twistlock
sensors to determine when a container is lifted. The container counter
counts lifting when alignment is broken with locked twistlocks and
twistlocks are not opened again within eight seconds.

switch voltage
D1
1, 4, 7
10
D790-1 D795
D797-1 D791-1
3,6,9 D5
D2
2,8 5
015086
1 The attachment is positioned over - Lifting/lowering, function description, page 7:8
a container with the functions 7.2 Side shift, function description, page 7:30
Lifting/lowering, 7.4 Side shift and 7.5
Spreading Spreading, function description, page 7:38
system, group 8.4.8.1 ELSERV, menu 1 and
8.4.8.1 ELSERV, menu 2.
2 Alignment sensors left and right (B7203L Sensor directly opposite Sensor, contact, description, page 7:68
and B7203R) voltage signal to the indicator plate: U = 24 V D2: Diagnostic menu, see section 8 Control
attachment control unit (D791-1). system, group 8.4.9.7 ATTACH, menu 7
3 Control unit, attachment (D791-1) sends Checked by control Section 11 Common electrics, group 11.5.3.5
alignment on the CAN bus. system, error shown Control unit, attachment
with error code.
4 Twistlocks are rotated to the locked - Twistlocks, function description, page 7:61
position and are closed with the 7.9.1
Twistlocks function.
5 The sensor for locked twistlocks Sensor directly opposite Sensor, twistlocks, description, page 7:69
left (B7205L) and sensor for locked indicator plate: U = 24 V D5: Diagnostic menu, see section 8 Control
twistlocks right (B7205R) send a voltage system, group 8.4.9.8 ATTACH, menu 8
signal to the attachment control unit
(D791-1).

7 Load handling – Container counter 7:73

locked twistlocks on the CAN bus. system, error shown Control unit, attachment
with error code.
7 The container is lifted with the function - Lifting/lowering, function description, page 7:8
7.2 Lifting/lowering.
8 Alignment sensors left and right (B7203L U=0V Sensor, contact, description, page 7:68
and B7203R) make and send a voltage D2: Diagnostic menu, see section 8 Control
signal to the attachment control unit system, group 8.4.9.7 ATTACH, menu 7
(D791-1).
no alignment on the CAN bus. system, error shown Control unit, attachment
with error code.
10 If the twistlocks remain locked for 8 - Section 11 Common electrics, group 11.5.3.1
seconds then Control unit, cab (D790-1) Control unit, cab
adds one lift to the container counter.

7:74

8:1
8 Control system
Contents 8 Control system

8 Control system .................................................................................................. 8:3
8.1.10 Error code menu .........................................................................................8:4
8.2 Monitoring ........................................................................................................8:7
8.2.2 Bypass ........................................................................................................8:7
8.2.3 Speed limitation...........................................................................................8:7
8.2.4 Service indicator..........................................................................................8:8
8.4 Diagnostics ......................................................................................................8:9
8.4.1 CAN/POWER ............................................................................................8:12
8.4.2 LIGHTS .....................................................................................................8:25
8.4.3 CAB ...........................................................................................................8:36
8.4.4 CLIMATE ...................................................................................................8:44
8.4.5 HYD...........................................................................................................8:50
8.4.6 ENGINE ....................................................................................................8:54
8.4.7 TRANSM ...................................................................................................8:59
8.4.8 ELSERV ....................................................................................................8:70
8.4.9 ATTACH ....................................................................................................8:77
8.4.10 OLS ...........................................................................................................8:90
8.4.11 EXTRA ......................................................................................................8:90
8.5 Setup..............................................................................................................8:96
8.5.1 Initialization ...............................................................................................8:96
8.5.2 Calibration ............................................................................................... 8:114

8:2

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

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

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

been detected.
Diagnostics comprise a tool for performing service and troubleshooting

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

8:4 8 Control system – Controls and instruments

8.1.10 Error code menu
Error code menu, description
The control and monitoring system's display is divided into four fields
C where the information is shown (see figure to the left).
• Field B: Error code level is shown with a symbol.
D E
• Field C: Shows error code.
B
000389
• Field D: Shows type of error.
• Field E: Indicates which function is affected by error code.
• Book symbol means that information is available in the operator's
manual.
Field B: Error code level
The control and monitoring system gives error code information in three
levels which are indicated with a symbol in the lower left corner (B)
on the display unit.
• Stop
C Indicates a serious malfunction that may jeopardise the operator's
safety or cause machine failure. The error code must be attended
D E to immediately. Stop working with the machine and contact service
immediately.
000350
The error code is shown automatically on the display.
• Warning
C Indicates malfunction in machine that should be taken care of as
soon as possible. After the finished work shift with the machine,
D E contact service as soon as possible.
000351
• Information
C Information to the operator that something should be rectified, e.g.
broken bulb. Take action to rectify the cause of the error code as
D E soon as possible. See section 6 Inspection and maintenance in
the operator's manual.
The error code is stored in the error code list under operating
000352
menu for service.

8 Control system – Error code menu 8:5
Field C: Error code number

The control and monitoring system gives error codes from three
sub-systems:
• Machine:
C Shown with error code number XXX on display.
D E
000389
• Engine:
XX/YY Shown with error code number XXX/YY on display.
D
NOTE
B If several error codes come from the engine, the error code level is
001343
shown for the most serious error code.
• Transmission:
XXX/YY Shown with error code number XX/YY on display.
B
001344
Field D: Type of error

1. Temperature too high/too low.
1 2 3
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
5. Incorrect signal from control.
4 5 6
6. Incorrect signal to bulb.
7. Incorrect signal, for example, open circuit.
7
000396

8:6 8 Control system – Error code menu
Field E: Affected function

1. Attachment
1 2 3
2. Rotation of attachment
3. Side shift, attachment
4. Length adjustment attachment
4 5 6 5. Levelling
6. Twistlocks
7. Forks up/down
8. Tilt forks
7 8 9
9. Side shift forks
10. Spreading forks
11. Rotation forks
10 11 12 12. Overload protection
13. Hydraulic functions
14. Brake system
15. Steering
13 14 15 16. Engine
17. Transmission
18. Central lubrication
16 17 18 19. Control unit
20. Hardware-related error
21. Cab
22. Air conditioning
19 20 21 23. Fuel system
24. Headlights
25. Windscreen wipers
22 23 24 26. Battery voltage
27. Bulb for lighting
25 26 27
010153

8 Control system – Monitoring 8:7
8.2 Monitoring
8.2.2 Bypass
Bypass, description
Bypassing is activated with the bypass switch.
By-passing the safety system allows:

• locking and opening of twistlocks without complete contact
• 20'-40' spreading with locked twistlocks
• lowering a load with alignment on side lift attachment.
• manual control of the recirculation damper for ECC or ECH.
• release of parking brake in the event of parking brake switch
malfunction
• output signal to solenoid valves with active error codes.
• the machine shifts to neutral as no one is sitting in the driver's seat.
DANGER
Bypassing the safety systems results in a risk of
tipping. Use at your own risk.
damage!
Only use the bypass of safety systems in emergency
situations.
8.2.3 Speed limitation

Speed limitation, description
Speed limitation prevents the machine's speed from exceeding the

preset value by limiting gear position and engine speed.
Machine speed is limited when:

• the control breaker is activated.
• load not in transport position during transport. Maximum speed
is 5 km/h.
• constant speed limitation is set.
Speed limitation is set via the initiation menu, see section 8 Control
system, group 8.5.1.4 INIT DRIVE-TRAIN, menu 9.

8:8 8 Control system – Service indicator
8.2.4 Service indicator

Service indicator, resetting

2 Navigate first to the service menu and press Enter.
000056
3 Enter the code to reset the service indicator.

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

Diagnostic test, Initiation or Calibration).
4 Reset the service indicator by pressing Enter. NEXT SERVICE is

SERVICE INTERVALL changed to indicated interval.
NEXT SERVICE XXXXh To change duration of the service interval, set the desired interval
SERVICE INTERVALL with the plus or minus key.
STORED XXXXh
004908
PRESENT XXXXh

8 Control system – Diagnostics 8:9
8.4 Diagnostics
Diagnostic test, general
The machine has built-in functions for troubleshooting called diagnostic
DIAGNOSIS test. The diagnostic test consists of several menus shown on the
CAN/POWER LIGHTS CAB display. The menus are grouped for faster access. The following pages
CLIMATE HYD ENGINE describe the content of the menu figures and which functions can be
TRANSM ELSERV ATTACH controlled.
005263
OLS EXTRA
The diagnostic test is divided into the following groups:
• Voltage feed and communication for the Control system,
CAN/POWER, description, page 8:12.
• Lighting, LIGHTS, description, page 8:25.
• Cab functions, CAB, description, page 8:36.
• Air conditioning, CLIMATE, description, page 8:44.
• Hydraulic functions, HYD, description, page 8:50.
• Engine ENGINE, description, page 8:54.
• Transmission, TRANSM, description, page 8:59.
• Functions for electric servo, ELSERV, description, page 8:70.
• Attachment functions, ATTACH, description, page 8:77.
• Optional functions, EXTRA, description, page 8:90
– Optional functions, OPT, description, page 8:91

8:10 8 Control system – Diagnostics
Diagnostic menu, description
1 Diagnostic tests show how the control units interpret input signals as
2 3 4
well as which signals that the control units send.
7 DIAG CAB 2(X)

FRONT WIPER
SWITCH (1-3) 2
6 OUTPUT 11 5
008873
FEEDBACK 0
1. DIAG = Diagnostic menus

2. Menu group
3. Menu number
4. Total number of menus in the loop. The
number of menus depends on the equipment
fitted to the machine. For this reason, number of
menus is indicated with (X) in this manual.
5. Signal value
6. Variable
7. Menu heading
DIAG Indicates that diagnostic tests are selected.

CAB Indicates which menu group is selected, these groups are:
CAN/POWER, description, page 8:12.
LIGHTS, description, page 8:25.
CAB, description, page 8:36.
CLIMATE, description, page 8:44.
HYD, description, page 8:50.
ENGINE, description, page 8:54.
TRANSM, description, page 8:59.
ELSERV, description, page 8:70.
ATTACH, description, page 8:77.
OLS, description, page 8:90.
EXTRA, description, page 8:90.
2 Number of current menu. Every menu group consists of several menus in a loop.
(X) Total number of menus in the group. The number of menus depends on the equipment fitted to the
machine. For this reason, number of menus is indicated with (X) in this manual.
Variable The signal that is measured. Different signals are designated in different ways:
SWITCH: a digital input signal, e.g. a switch.
OUTPUT: a digital output signal, e.g. feed to a motor.
INPUT: an analogue input signal, e.g. from a sensor.
REFERENCE: status for an analogue output signal.
REQUIRED: triggered output signal for a control current
FEEDBACK: either feedback signal from a motor or measured current on the minus side for an analogue
output signal.

8 Control system – Diagnostics 8:11
Signal value Measurement value or status for the signal for variable. On the same row there are different types
that are interpreted in different ways.
SWITCH: 1 or 0 where 1 means closed circuit.
OUTPUT: two characters where the first number is 1 if the output signal is active. The second number is
status for the circuit, 1=circuit OK, 0=open circuit or short circuit.
INPUT: numerical value corresponding to the signal.
REFERENCE: two characters where the first number is 1 if the input signal is active. The second number
is status for the circuit, 1=circuit OK, 0=open circuit or short circuit.
REQUIRED: numerical value corresponding to the signal.
FEEDBACK: numerical value corresponding to the signal.
Menu heading Description of the function for which the menu reads signals.

8:12 8 Control system – CAN/POWER
8.4.1 CAN/POWER
CAN/POWER, description
This group handles redundant voltage feed to control units and CAN
DIAGNOSIS bus communication.
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE Confirm selections with function key for Enter.
TRANSM ELSERV ATTACH
005263
OLS EXTRA
8.4.1.1 CAN/POWER, menu 1
PRESENT REDCAN STATUS, COMMUNICATION MODE

Description: Indicates communication status for the redundant CAN
DIAG CAN/POWER 1(X) bus.
PRESENT REDCAN STATUS
COMMUNICATION MODE X Circuit diagram: Circuit CANBUS ground group 11.6_1
NUMBERS OF UNITS X
005266
SEGMENT ERROR X Contact: -
Function: 11.6.2 Redundant CAN bus
Signal value:
3 OK.
2 Segment check.
0 Error.
PRESENT REDCAN STATUS, NUMBER OF UNITS

Description: Indicates the number of control units, excluding Cab
DIAG CAN/POWER 1(X) control unit (D790-1) which should be on the current machine. The
PRESENT REDCAN STATUS number is dependent on the installed options.
COMMUNICATION MODE X
NUMBERS OF UNITS X Circuit diagram: Circuit CANBUS ground group 11.6_1
005266
SEGMENT ERROR X
Contact: -
Signal value:
X Number of nodes that should be in the machine. Number

of nodes depends on installed options.

8 Control system – CAN/POWER 8:13
PRESENT REDCAN STATUS, SEGMENT ERROR

Description: Indicates if there is open circuit on the redundant CAN bus
DIAG CAN/POWER 1(X) and if there is, where the first open circuit is. If there is open circuit, it is
PRESENT REDCAN STATUS indicated with a number that corresponds to the defective segment on
COMMUNICATION MODE X the redundant CAN bus.
NUMBERS OF UNITS X
005266
SEGMENT ERROR X Circuit diagram: Circuit CANBUS ground group 11.6_1
Contact: -
Signal value:
0 No open circuits.
>0 If X is separated from 0, the first segment is indicated
as missing contact. A 1 means that the first segment
is defective, that is, that contact between first and
second control unit is cut off.
To see which control units are installed on the
machine along with their order, use diagnostic menu
CAN/POWER, menu 2, see PRESENT REDCAN
STATUS, CONNECTED CITIES, page 8:13.
PRESENT REDCAN STATUS, CONNECTED CITIES

Description: Indicates which control units are in contact with the cab
DIAG CAN/POWER 2(X) control unit (D790-1) via the redundant CAN bus.
PRESENT REDCAN STATUS
CONNECTED CITIES Circuit diagram: Circuit CANBUS ground group 11.6_1, Attachment
D797-1 D797-2 XX DCF90-100/45E 11.6_1
005267
D795 D791-1 XX
Contact:
D795: K1:10, K1:11, K1:12 and K1:13
D797-1, D791-1: K2:2, K2:3, K2:4 and K2:5
Function: 11.5.3.2 Frame control unit (D797-1), 11.5.3.5 Attachment

control unit, 11.5.3.12 KID control unit, 11.6.2 Redundant CAN bus.
Signal value:
1 Communication with the node is OK.

0 No communication and/or there is some node error.

PRESENT OPTION KDU

Description: Indicates which optional control units should be present
DIAG CAN/POWER 3(X) on the machine and if they have working communication with the cab
PRESENT OPTION KDU KCU control unit (D790-1).
KDU D797-2 XY Circuit diagram: Circuit CANBUS ground group 11.6_1, Circuit
007183
KDU D791-1 XY Attachment DCF90-100/45E 11.6_1
Contact: -
Signal value:
00 The control unit is not installed on the machine.

10 The control unit is installed on the machine but there is
no communication with the cab control unit (D790-1).
11 The control unit is installed on the machine and there is
communication with the cab control unit (D790-1).
PRESENT DRIVE-TRAIN CAN BUS STATUS, ENGINE

Description: Indicates status for engine in the drive-train's CAN bus.
DIAG CAN/POWER 4(X)
PRESENT DRIVE-TRAIN Circuit diagram: Engine circuit group 1.0, CAN bus circuit group 11.6.
CAN BUS STATUS
ENGINE X Contact:
005269
TRANSMISSION X Volvo TWDTAD760VE: CAN J1939 from D790-1/K13:1 and K13:2

to D794/1 and 2
Cummins QSB6.7 : CAN J1939 from D790-1/K13:1 and K13:2
to D794/46 and 37
Function: 11.6.3 CAN bus drive-train
Signal value:

NOTE
The cable harness for CAN bus drive-train is common to the
engine and transmission from the cab electronic box to the frame
electronic box. The cable branches in the frame electronic box. If
communication with both the engine and transmission is cut off, start
troubleshooting at the cable harness between the cab electronic
box and the frame electronic box. If there is communication (either
engine or transmission), this rules out a fault in the cable harness
between the cab electronic box and the frame electronic box.

PRESENT DRIVE-TRAIN CAN BUS STATUS,

TRANSMISSION
Description: Indicates status for transmission in the drive-train's CAN
DIAG CAN/POWER 4(X) bus.
PRESENT DRIVE-TRAIN
CAN BUS STATUS Circuit diagram: Circuit CAN-BUS ground group 11.6_1, circuit Dana
ENGINE X TE17FF group 2.0
005269
TRANSMISSION X
Connection: CAN J1939 from D790-1/K13:1 and K13:2 to D793/L2
and M2
Function: 11.6.3 CAN bus drive-train
Signal value:

NOTE
The cable harness for CAN bus drive-train is common to the
engine and transmission from the cab electronic box to the frame
electronic box. The cable branches in the frame electronic box. If
communication with both the engine and transmission is cut off, start
troubleshooting at the cable harness between the cab electronic
box and the frame electronic box. If there is communication (either
engine or transmission), this rules out a fault in the cable harness
between the cab electronic box and the frame electronic box.
IGNITION, KEY IN
Description: Indicates if ignition is switched on (key in ignition key lock).
DIAG CAN/POWER 5(X)
IGNITION Circuit diagram: Circuit power group 11.5_3
KEY IN X
RELAY K315-1 XY Connection: signal from S150/15 to digital in D790-1/K11:1
007126
RELAY K315-2 XY Function: 11.5.1.3 Ignition voltage
Signal value:
1 Input signal active.

0 No signal.

IGNITION, RELAY K315-1

Description: Control current to Relay, ignition voltage (K315-1),
DIAG CAN/POWER 5(X) 15-voltage.
IGNITION
KEY IN X Circuit diagram: Circuit power 11.5_3
RELAY K315-1 XY
007126
RELAY K315-2 XY Connection: output signal from D790-1/K10:10 to K315-1
Function: 11.5.1.3 Ignition voltage (15)
Signal value:
00 No output signal and open circuit in the circuit.

01 Normal mode function off.
No output signal, circuit OK. It can also be a short circuit
as this is only detected when the output signal is active.
10 Output signal active, short-circuiting.
11 Normal mode function on.
Output signal active, circuit OK. It can also be an open
circuit as this can only be detected when the output
signal is missing.
IGNITION, RELAY K315-2

Description: Control current to Relay, ignition voltage (K315-2)
DIAG CAN/POWER 5(X) (15-voltage).
IGNITION
KEY IN X Circuit diagram: Circuit power 11.5_3
RELAY K315-1 XY
007126
RELAY K315-2 XY Connection: output signal from D790-1/K10:16 to K315-2
Signal value:

10 Output signal active, short-circuiting.
signal is missing.
EMERGENCY STOP, SW
Description: Indicates if switch, emergency stop switch, is activated.
DIAG CAN/POWER 6(X)
EMERGENCY STOP, SW X Circuit diagram: Circuit power control breaker group 11.5_6
RELAY K3009-1 XY
FEEDBACK X Connection: signal from S250/2 to digital in D790-1/K8:4
007127
RELAY K3009-2 XY Function: 11.5.1.4 Emergency stop switch voltage (15E)
Signal value:

0 No signal.

EMERGENCY STOP, RELAY K3009-1

Description: Status for control current to relay K3009-1, for emergency
DIAG CAN/POWER 6(X) stop switch voltage, 15E voltage.
EMERGENCY STOP, SW X
RELAY K3009-1 XY Circuit diagram: Circuit power control breaker group 11.5_6
FEEDBACK X
007127
RELAY K3009-2 XY Connection: signal from D790-1/K10:11 to K3009-1/86
Function: 11.5.1.4 Emergency stop switch voltage (15E)
Signal value:

10 Output signal active, short circuit.
signal is missing.
EMERGENCY STOP, FEEDBACK

Description: Feedback signal from control breaker relay (K3009-1),
DIAG CAN/POWER 6(X) indicates that relay is working normally.
EMERGENCY STOP, SW X
RELAY K3009-1 XY Circuit diagram: Circuit power control breaker group 11.5_6
FEEDBACK X
007127
RELAY K3009-2 XY Contact: Signal from K3009-1/87 via F58-3/8 to digital in D790-1/K11:13
Signal value:

0 No signal.
EMERGENCY STOP, RELAY K3009-2

Description: Status of the control current to the control breaker relay
DIAG CAN/POWER 6(X) (K3009-2), Control breaker relay lifting/lowering (K3007) and Control
EMERGENCY STOP, SW X breaker relay tilt (K3002),15E-voltage.
RELAY K3009-1 XY
FEEDBACK X Circuit diagram: Circuit power control breaker group 11.5_6
007127
RELAY K3009-2 XY
Contact: signal from D790-1/K10:12 to K3009-2/86, K3002/86 and
K3007/86.
Signal value:

signal is missing.


790-1 CAB, POWER
Description: Ignition voltage (15) to Control unit, cab (D790-1).
DIAG CAN/POWER 7(X)
790-1 CAB Circuit diagram: Circuit power group 11.5_1, 11.5_4
POWER XX.XXV
Connection: 15-voltage from K315-1/87 via F54/4 and F58-5/1, F58-5/2
5V REF X.XXV
to D790-1/K1:2, D790-1/K1:3 and D790-1/K1:4
005271
Function: 11.5.1 Voltage feed
Signal value: XX.XXV = voltage on the connection. The signal value

should be 22-30 V (battery voltage).
790-1 CAB, 5V REF

Description: Reference voltage 5 V to controls in cab.
DIAG CAN/POWER 7(X)
790-1 CAB Circuit diagram: Circuit climate group 9.4_1, 9.4_2 (contact 1, 2),
POWER XX.XXV Circuit drivetrain engine group 1.0_1 (contact 3), Circuit electric servo
5V REF X.XXV levers 7.0_1 (contact 4), Circuit electric servo joystick 7.0_2 (contact 5)
005271
Contact:
1. signal from digital out D790-1/K4:5 to Y672/10 and Y673/10
2. signal from digital out D790-1/K5:11 to S118/1, S139/1 and S117/1
3. signal from digital out D790-1/K5:13 to B690-1/1
4. signal from digital out D790-1/K7:2 to R8071/1, R8072/1,
R8073/1
5. signal from digital out D790-1/K7:2 to S815/P1, S815/P2
Function: 9.4 Heating, ventilation and air conditioning (contact 1 and

2); 1 Engine and 2 Transmission (contact 3); 7 Load handling (contact
4 and 5)
Signal value: X.XXV = 5.00 V, Important that the signal value is stable
(not varying).

790-1 CAB, 24V SENSOR SUPPLY
Description: 24 V voltage feed to components in cab.
DIAG CAN/POWER 8(X)
790-1 CAB Circuit diagram:
24V SENSOR SUPPLY XY 1. Circuit wiper group 9.5_1
24V SUPPLY,RPM>500 XY
2. Circuit drivetrain transmission group 2.0_1, Circuit extra equipment
005275
group 9.1_1, Circuit seat heating group 9.3_1, Circuit working

lights 20-40 group 9.6_1, Circuit working lights truck 9.6_2, Circuit
working lights mast 9.6_3, Circuit lighting group 9.6_4 and Circuit
wiper group 9.5_1
3. -
4. -
5. Circuit twistlock group 7.9_1, circuit 20-40, 30-35 stop group 7.5_1,
circuit over height group 7.9_4, circuit horn servo panel group
9.7_4, circuit power control breaker group 11.5_6, circuit brake
system group 4.0_1, circuit 20-40 opt. group 7.5_3, circuit bypass
group 8.2_1 and circuit extra equipment group 9.1_1
6. -
7. -
8. Circuit alarm, audible signals group 9.7_1
9. Circuit wiper group 9.5_1
10. Circuit wiper group 9.5_1

Contact:
1. signal from digital out D790-1/K4:14 to M650-1/53a
2. signal from digital out D790-1/K5:1 to S105-1/5, S105-2/5,
S105-3/5, S143/5, S100/5, S110/5, S199-1/5, S199-3/5, S199-4/5
and S220-1/1
3. signal from digital out D790-1/K6:13 not connected
5. signal from digital out D790-1/K8:16 to S1002/2, S1003/4, S1003/3,
S1004/5, S149-3/2, S250/1, S107/5, S1012/3, S1012-2/5,
S1031/3, S1005/5, and S199-2/5
8. signal from digital out D790-1/K11:12 to S230/2
Function:
1. 9.5.5 Wiper motor front
2. 2.0 Transmission, 9.3 Seat, 9.6 Lighting
3. -
4. -
5. 11.5.1.4 Emergency stop switch voltage; 4.5 Parking brake system;
8.2.2 Bypassing; 9.10.4 Tiltable cab/Hydraulic sliding cab; 7.5
Spreading; 7.8 Levelling; 7.9.1 Twistlocks
6. -
7. -
8. 9.3.14 Sensor operator in seat
9. 9.5.7 Wiper motor rear
10. 9.5.6 Wiper motor roof
Signal value:

No output signal. It can also be a short circuit in the
circuit as errors can only be detected when the output
signal is active.
10 Output signal active, short circuit. It can also be an open
circuit as this cannot be detected.
Output signal active, circuit OK or open circuit. Open
circuit cannot be detected.

790-1 CAB, 24V SUPPLY, RPM>500

Description: Voltage feed when engine speed is higher than 500 rpm.
DIAG CAN/POWER 8(X)
790-1 CAB Circuit diagram: Circuit hour meter group 9.1_2, Circuit air suspension
24V SENSOR SUPPLY XY seat group 9.3_2
24V SUPPLY,RPM>500 XY
005275
Connection: signal from digital out D790-1/K10:9 to P708/+ and
K358/86
Function: 9.3.6 Compressor air-suspension seat, 11.1.1 Hour meter
Signal value:

signal is missing.
795 DISPLAY, RED. POWER

Description: Redundant voltage to Control unit KID (D795).
DIAG CAN/POWER 9(X)
795 DISPLAY Circuit diagram: Circuit canbus ground group 11.6_1
RED.POWER LE X RI X Contact:
005276
LE: redundant feed from D790-1/K11:10 to D795/K1:8

RI: redundant feed from D790-1/K11:8 to D795/K1:7
Function: 11.5.1.2 Redundant voltage feed of control units
Signal value:
1 Feed active.
0 No feed.
797-1 FRAME, POWER

Description: Ignition voltage (15) to the frame control unit (D797-1).
DIAG CAN/POWER 10(X)
797-1 FRAME Circuit diagram: Circuit power group 11.5_1 and 11.5_4
POWER XX.XXV
RED.POWER LE X RI X Connection: 15 voltage from K315-1/87 via F54/4 and F58-2/1 to
005277
POWER 2 X D797-1/K2:1, D797-1/K2:9 and D797-1/K2:10
Signal value: XX.XXV = voltage on connection. The signal value


797-1 FRAME, RED. POWER

Description: Redundant voltage to frame control unit (D797-1).
797-1 FRAME Circuit diagram: Circuit canbus ground group 11.6_1
POWER XX.XXV
RED.POWER LE X RI X Contact:
005277
POWER 2 X • LE: redundant feed from D790-1/K11:7 to D797-1/K2:7
• RI: redundant feed from D790-1/K11:9 to D797-1/K2:8
Signal value:
1 Feed active.
0 No feed.
797-1 FRAME, POWER 2

Description: Battery voltage to the frame control unit (D797-1).
797-1 FRAME Circuit diagram: Circuit power group 11.5 and 11.5_4
POWER XX.XXV
RED.POWER LE X RI X Connection: 15-voltage from K315-1/87 via F54/4 and F58-2/1 to
005277
POWER 2 X D797-1/K2:11
Signal value:
1 Feed active.
0 No feed.
NOT USED
This menu is not used.
XXXXXXX X(X)
NOT USED
008793
793 TRANSMISSION, POWER

Description: Battery voltage (30) to Control unit, transmission (D793).
793 TRANSMISSION Circuit diagram: Circuit CAN-BUS KDU group 11.6, Circuit Dana
POWER XX.XXV TE17FF group 2.0
IGNITION POWER XX.XXV
005279
SENSOR SUPPLY XX.XXV Connection: 30-voltage from F54/2 via F58-1/5 to D793/A1
Function: 11.5.1.1 Battery voltage (30)


793 TRANSMISSION, IGNITION POWER

Description: Ignition voltage (15) to Control unit, transmission (D793).
793 TRANSMISSION Circuit diagram: Circuit CAN-BUS KDU group 11.6, Circuit Dana
POWER XX.XXV TE17FF group 2.0
IGNITION POWER XX.XXV
005279
SENSOR SUPPLY XX.XXV Connection: 15E-voltage from K315/87 via F54/4 and F58-2/5 till
D793/S2

793 TRANSMISSION, SENSOR SUPPLY

Description: Voltage feed to sensors on transmission, reference
DIAG CAN/POWER 12(X) voltage of 5 V.
793 TRANSMISSION
POWER XX.XXV Circuit diagram: Circuit CAN-BUS KDU group 11.6, Circuit Dana
IGNITION POWER XX.XXV TE17FF group 2.0
005279
SENSOR SUPPLY XX.XXV

Connection: 5V analogue Ref from D793/M1 to S2210/1, B7651/B,
B7652/B
Function: 2.8 Control system, transmission

should be 5 V, stable (not varying).
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793

791-1 ATTACHMENT, EME POWER

Description: Voltage feed to Control unit, attachment (D791-1).
791-1 ATTACHMENT(OPT) Circuit diagram: Attachment DCF90/100-45E group 11.5_1, Circuit
EME POWER XX.XXV power control breaker group 11.5_6
RED.POWER LE X RI X
005282
EME POWER 2 X Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1 to
D791-1/K2:1, K2:9, K2:10, K2:11
Signal value:
XX.XXV = Voltage on the connection. The signal value should be
22-30 V (battery voltage).
791-1 ATTACHMENT, RED. POWER

Description: Redundant voltage feed to Control unit, attachment
DIAG CAN/POWER 15(X) (D791-1).
791-1 ATTACHMENT(OPT)
EME POWER XX.XXV Circuit diagram: Circuit CANBUS ground group 11:6_1, Circuit
RED.POWER LE X RI X CANBUS KDU opt. group 11.6_2B, Attachment DCF90/100-45E group
005282
EME POWER 2 X 11.6_1
Contact:
LE: redundant voltage feed to D791/K2:7
RI: redundant voltage feed to D791/K2:8
Signal value:
1 Feed active.
0 No feed.
791-1 FRAME, EME POWER 2

Description: Emergency stop switch voltage (15E) to attachment
DIAG CAN/POWER 15(X) control unit (D791-1).
791-1 ATTACHMENT(OPT)
EME POWER XX.XXV Circuit diagram: Circuit 11.5_5
RED.POWER LE X RI X
005282
EME POWER 2 X Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1
to D791-1/K2:11
Signal value:
1 Feed active.
0 No feed.

791-1 ATTACHMENT (OPT), 24V SENSOR SUPPLY

Description: Voltage feed to sensors connected to the attachment
DIAG CAN/POWER 16(X) control unit (D791-1).
791-1 ATTACHMENT (OPT)
24V SENSOR SUPPLY XY Circuit diagram: Circuit diagram: Attachment DCF90/100-45E group
5V REF X.XXV 7.5_3, 7.9_2, 11.5_2
005283
Connection: digital out from 791-1/K1:10 to B769L, B769R, B777L,
B777R, B7203L, B7203R, B7204L, B7204R, B7205LL and B7205LR
Function: 7.5.6 Spreading position sensor, 7.9.1.7 Alignment position

sensor, 7.9.1.8 Twistlocks sensor
Signal value:

signal is missing.
791-1 ATTACHMENT (OPT), 5V REF

This menu row is not used.
791-1 ATTACHMENT (OPT)
24V SENSOR SUPPLY XY
5V REF X.XXV
005283
REDCAN STATUS CHECK

Description: Control function from the redundant CAN bus. Cab control
DIAG CAN/POWER 17(X) unit (D790-1) performs a segment check to verify that all control units
REDCAN STATUS CHECK are in contact and are connected in the correct order. The control
PRESS ENTER system indicates the fault by numbering the cables between the control
units (segments) from 1 onwards. Segment 1 is always between cab
005284
SEGMENT ERROR X control unit (D790 -1) and the next Control unit. The last segment is
always between Control unit KID (D795) and Control unit, cab (D790-1).
The segments in between vary depending on machine configuration.
Circuit diagram: Circuit CANBUS ground group 11.6_1, Circuit diagram

D790-1 D791 D797-1 attachment DCF90/100-45E group 11.6_1
CAN L CAN R CAN L CAN R CAN L CAN R
1 2 Contact: -
4 3
CAN R CAN L
D795 Signal value:

015052
Segment numbering with maximum number of control 0 No errors.

units. >0 X > 0, digit denotes incorrect segment. Use the circuit
diagram to find the defective segment.

8 Control system – LIGHTS 8:25
8.4.2 LIGHTS
LIGHTS, description
This group covers lighting.
DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selections with function key for Enter.
CLIMATE HYD ENGINE
005285
OLS EXTRA
8.4.2.1 LIGHTS, menu 1
MAIN LIGHT, SWITCH

Description: Signal from headlights switch.
DIAG LIGHTS 1(X)
MAIN LIGHT Circuit diagram: Circuit lighting group 9.6_4
SWITCH X
Connection: signal from S100/1 to digital in D790-1/K6:5
005286
Function: 9.6.1 Headlights.
Signal value:

0 No signal.
PRESENT OUTPUT SIGNAL, SIDE LIGHTS

Description: Voltage feed to side running lights.
DIAG LIGHTS 2(X)
PRESENT OUTPUT SIGNAL Circuit diagram: Circuit lighting group 9.6_5 and 9.6_6
SIDE LIGHTS XY Connection: digital out from D797-1/K1:2 to H416-1, H416-2, H417-1
005287
REAR LIGHTS XY and H417-2
Function: 9.6.2 Running lights
Signal value:

signal is missing.

8:26 8 Control system – LIGHTS
PRESENT OUTPUT SIGNAL, REAR LIGHTS

Description: Voltage feed to tail lights.
DIAG LIGHTS 2(X)
PRESENT OUTPUT SIGNAL Circuit diagram: Circuit lighting group 9.6_6
SIDE LIGHTS XY Connection: digital out from D797-1/K1:33 to H412L and H412R
005287
REAR LIGHTS XY Function: 9.6.3 Tail lights
Signal value:

signal is missing.
HEAD LIGHTS, SWITCH

Description: Lighting headlights front, switch.
DIAG LIGHTS 3(X)
HEAD LIGHTS Circuit diagram: Circuit lighting group 9.6_4
SWITCH X
HEAD LE/RI XY Connection: from S162:56A to digital in D790-2/K3:9
005288
DIMMED LE/RI XY Function: 9.6.1 Headlights
Signal value:

0 No signal.
HEADLIGHTS, HEAD LE/RI

Description: Voltage feed to headlights, high beam.
DIAG LIGHTS 3(X)
SWITCH X
HEAD LE/RI XY Connection: digital out from D797-1/K1:15 to E402L-1 and E402R-1
005288
Signal value:

signal is missing.

HEADLIGHTS, DIMMED LE/RI

Description: Voltage feed to headlights, low beam.
DIAG LIGHTS 3(X)
SWITCH X
HEAD LE/RI XY Connection: digital out from D797-1/K1:28 to E400L and E400R
005288
Signal value:

signal is missing.
PRESENT INPUT SIGNAL, HAZARD SWITCH

Description: Signal from switch, flashing hazard lights (Hazard).
DIAG LIGHTS 4(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit blinkers & hazard group 9.6_7
HAZARD SWITCH X
FLASH.SW. LE X RI X Connection: signal from S109/1 to digital in D790-1/K5:6
005289
Function: 9.7 Signalling system
Signal value:

0 No signal.
PRESENT INPUT SIGNAL, FLASH.SW.

Description: Signal from switch, direction indicators.
DIAG LIGHTS 4(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit blinkers & hazard group 9.6_7
HAZARD SWITCH X
FLASH.SW. LE X RI X Contact:
005289
• LE: signal from S161/6 to digital in D790-2/K8:8

• RI: signal from S161/1 to digital in D790-2/K8:9
Function: 9.6 Lighting system
Signal value:

0 No signal.


PRESENT OUTPUT SIGNAL HAZARD/FLASHER, LEFT
F/R
Description: Voltage feed to direction indicator, left-hand side.
DIAG LIGHTS 5(X)
PRESENT OUTPUT SIGNAL Circuit diagram: Circuit blinkers & hazard group 9.6_7
HAZARD/FLASHER Connection: digital out from D797-1/K1:30 to H422 and H426
LEFT F/R XY
005290
RIGHT F/R XY Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
(Hazard)
Signal value:

signal is missing.
PRESENT OUTPUT SIGNAL HAZARD/FLASHER,

RIGHT F/R
Description: Voltage feed to direction indicator, right-hand side.
DIAG LIGHTS 5(X)
PRESENT OUTPUT SIGNAL Circuit diagram: Circuit blinkers & hazard group 9.6_7
HAZARD/FLASHER Connection: digital out from D797-1/K1:31 to H423 and H427
LEFT F/R XY
005290
RIGHT F/R XY Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
(Hazard)
Signal value:

signal is missing.

ROTATION BEACON, SWITCH
Description: Signal from switch, revolving beacon.
DIAG LIGHTS 6(X)
ROTATION BEACON Circuit diagram: Circuit lighting group 9.6_4
SWITCH X Connection: from S110/1 to digital in D790-1/K6:4
OUTPUT XY
005291
Function: 9.6.8 Revolving beacon
Signal value:

0 No signal.

ROTATION BEACON, OUTPUT

Description: Voltage feed to revolving beacon.
DIAG LIGHTS 6(X)
ROTATION BEACON Circuit diagram: Circuit lighting group 9.6_4
SWITCH X
OUTPUT XY Connection: digital out from D790-1/K2:5 to H428
005291
Function: 9.6.8 Revolving beacon
Signal value:

No output signal. It can also be a fault in the circuit as
errors can only be detected when the output signal is
active.
10 Output signal active, short circuit or open circuit.
Output signal active, circuit OK.
PRESENT INPUT SIGNAL, BRAKE LGT SWITCH

Description: Signal from make-contact (closing switch) brake lights.
DIAG LIGHTS 7(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit lighting group 9.6_5
BRAKE LGT SWITCH X
REVERSE LGT SIGNAL X Connection: from S216/2 to digital in D797-1/K1:20
005292
Function: 4.3.8 Make-contact (closing switch) brake lights
Signal value:

0 No signal.
PRESENT INPUT SIGNAL, REVERSE LGT SIGNAL

Description: Signal from Control unit, transmission (D793) when
DIAG LIGHTS 7(X) reverse gear is activated.
PRESENT INPUT SIGNAL
BRAKE LGT SWITCH X Circuit diagram: Circuit Lighting group 9.6
REVERSE LGT SIGNAL X
005292
Contact: -
Function: 9.6.5 Back-up lights
Signal value:
1 Input signal active. Output signal "reverse gear active" from

Control unit, transmission (D793).
0 No signal.

PRESENT OUTPUT SIGNAL, BRAKE LGT

Description: Voltage feed to brake lights.
DIAG LIGHTS 8(X)
BRAKE LGT LE XY RI XY
REV. LGT LE XY RI XY Contact:
005293
REVERSE ALARM XY • LE: digital out from D797-1/K1:7 to H411L
• RI: digital out from D797-1/K1:9 to H411R
Function: 9.6.4 Brake lights
Signal value:

signal is missing.
PRESENT OUTPUT SIGNAL, REV. LGT

Description: Voltage feed to back-up lights.
DIAG LIGHTS 8(X)
REV. LGT LE XY RI XY Contact:
005293
REVERSE ALARM XY • LE: digital out from D790-1/K2:6 to E405L

• RI: digital out from D790-1/K2:7 to E405R
Function: 9.6.5 Back-up lights
Signal value:

signal is missing.

PRESENT OUTPUT SIGNAL, REVERSE ALARM

Description: Voltage feed to reverse alarm.
DIAG LIGHTS 8(X)
PRESENT OUTPUT SIGNAL Circuit diagram: Circuit back-up alarm group 9.7_2
Connection: digital out from D797-1/K1:10 to H965
REV. LGT LE XY RI XY
005293
REVERSE ALARM XY Function: 9.7.5 Reverse alarm
Signal value:

signal is missing.

CAB LIGHT, MANUAL SWITCH
Description: Signal from switch, lighting cab.
DIAG LIGHTS 9(X)
CAB LIGHT Circuit diagram: Circuit interior lighting group 9.6_8
MANUAL SWITCH X
Connection: signal from D790-2/K8:11 to digital in D790-1/K11:2
DOOR SWITCH X
005294
OUTPUT XXX Function: 9.6 Lighting system
Signal value:

0 No signal.
CAB LIGHT, DOOR SWITCH

Description: Signal from break contact (opening switch) door.
DIAG LIGHTS 9(X)
MANUAL SWITCH X
Connection: signal from S266-LE or S266-RI (connected in parallel)
DOOR SWITCH X
to digital in D790-1/K11:3
005294
OUTPUT XXX
Function: 9.10.2 Doors
Signal value:

0 No signal.
CAB LIGHT, OUTPUT

Description: Voltage feed to interior lighting cab.
DIAG LIGHTS 9(X)
MANUAL SWITCH X
Connection: digital out from D790-1/K11:6 to E434-1
DOOR SWITCH X
005294
OUTPUT XXX Function: 9.6.11 Interior lighting
Signal value: XXX = 0-255 = 0-24 V (255 means 24 V which

corresponds to battery voltage).


WORKING LIGHT MAST, SWITCH
Description: Signal from switch for working light, mast.
DIAG LIGHTS 10(X)
WORKING LIGHT MAST Circuit diagram: Circuit working light mast group 9.6_3
SWITCH X
Connection: signal from S105-3/1 to digital in D790-1/K6:3
OUTPUT LE/RI XY
005295
Signal value:

0 No signal.
WORKING LIGHT MAST, OUTPUT

Description: Voltage feed to working light, mast.
DIAG LIGHTS 10(X)
WORKING LIGHT MAST Circuit diagram: Circuit working light mast group 9.6_3
SWITCH X
Connection: digital out from D797-1/K1:1 to E404L-1 and E404R-1
OUTPUT LE/RI XY
005295
Function: 9.6.9 Working light, mast
Signal value:

signal is missing.

WORKING LIGHT EXTRA OUTPUT, D797-1 C1 P42
DIAG LIGHTS 11(X)

WORKING LIGHT EXTRA Description: Voltage feed to auxiliary working light.
OUTPUT
D797-1 C1 P42 XY Circuit diagram: Circuit working light option group 9.6_9
005296
D797-2 C1 P42 XY Connection: digital out from D797-1/K1:42 to E404L-4 and E404R-4
Function: 9.1.4 Switch for working light, front wing, 9.1.5 Switch for
working light, attachment, 9.1.6 Switch for working light, mast
Signal value:

signal is missing.

WORKING LIGHT EXTRA OUTPUT, D797-2 C1 P42

DIAG LIGHTS 11(X)
WORKING LIGHT EXTRA
OUTPUT
D797-1 C1 P42 XY
005296
D797-2 C1 P42 XY
WORKING LIGHT CAB, SWITCH

Description: Signal from switch, working lights cab roof
DIAG LIGHTS 12(X)
WORKING LIGHT CAB Circuit diagram: Circuit working lights 20-40 group 9.6_1
SWITCH X
005297
OUTPUT 20' XY 40' XY Function: 9.6 Lighting system
Signal value:

0 No signal.
WORKING LIGHT CAB, OUTPUT

Description: Control of relays for power supply to working lights cab
DIAG LIGHTS 12(X) roof.
WORKING LIGHT CAB
SWITCH X Circuit diagram: Circuit working lights 20-40 group 9.6_1
005297
OUTPUT 20' XY 40' XY Contact:

• 20': digital out from D790-1/K7:8 to K3017-2. K3017-2 voltage
feeds E406L-2 and E406R-2
• 40': digital out from D790-1/K10:8 to K3017-1. K3017-1 voltage
feeds E406L-1 and E406R-1
Function: 9.6.10 Work light cab
Signal value:

signal is missing.

WORKING LIGHT ATTACH, SWITCH

Description: Signal from switch, working lights attachment
DIAG LIGHTS 13(X)
WORKING LIGHT ATTACH Circuit diagram: Circuit working lights truck group 9.6_2
SWITCH X
OUTPUT LE XY RI XY Connection: signal from S105-2/1 to digital in D790-1/K6:2
008895
Signal value:

0 No signal.
WORKING LIGHT ATTACH, OUTPUT

Description: Voltage feed to working light, attachment.
DIAG LIGHTS 13(X)
WORKING LIGHT ATTACH Circuit diagram: Attachment DCF 90/100/100-45E group 9.6_1
SWITCH X
OUTPUT LE XY RI XY Contact:
008895
• LE: digital out from D791-1/K1:1 to E404UL (and E404L )

• RI: digital out from D791-1/K1:15 to E404UR (and E404R )
Function: 9.6.12 Work light attachment
Signal value:

signal is missing.

SWITCH LIGHTS, OUTPUT

Description: Voltage feed to background lighting in switches, panels
DIAG LIGHTS 14(X) and keys.
SWITCH LIGHTS
Circuit diagram: Circuit brake system group 4.0_1, circuit 20-40, 30-35
stop group 7.5_1, circuit twistlock group 7.9_1, circuit extra equipment
OUTPUT XXX
group 9.1_1, circuit seat heating group 9.3_1, circuit climate system
005300
group 9.4_1, circuit working lights 20-40 group 9.6_1, circuit working
lights truck group 9.6_2, circuit working light mast group 9.6_3, circuit
lighting group 9.6_4, circuit blinkers & hazard group 9.6_7
Contact:
output signal from D790-1/K6:1 to S117, S118, S139
output signal from D790-1/K6:2 to S105-2
output signal from D790-1/K6:4 to S110
Function: 9.6.11 Interior lighting
Signal value:
50 Means 4-5 V.
170 Means 15-16 V.
NOT USED
XXXXXXX X(X)
NOT USED
008793

8:36 8 Control system – CAB
8.4.3 CAB
CAB, description
This group covers functions in the cab.
DIAGNOSIS
CLIMATE HYD ENGINE
005301
OLS EXTRA
8.4.3.1 CAB, menu 1
WASHER, SWITCH
Description: Signal from gear and multi-function lever switch washer.
DIAG CAB 1(X)
WASHER Circuit diagram: Circuit wiper group 9.5_1
SWITCH X
OUTPUT FRONT XY Connection: signal from S162/53C to digital in D790-2/K3:4
005541
OUTPUT REAR ROOF XY Function: 9.5 Wiper/washer system
Signal value:

0 No signal.
WASHER, OUTPUT FRONT

Description: Voltage feed to windscreen washer motor.
DIAG CAB 1(X)
WASHER Circuit diagram: Circuit wiper group 9.5_1
SWITCH X
OUTPUT FRONT XY Connection: digital out from D790-1/K10:13 to M651-1 and M651-2
005541
OUTPUT REAR ROOF XY Function: 9.5.4 Washer motor and reservoir
Signal value:

active.

8 Control system – CAB 8:37
WASHER, OUTPUT REAR ROOF

Description: Grounding of motor washer roof and rear window. The
DIAG CAB 1(X) motor is supplied with voltage parallel with Motor windscreen washing,
WASHER activation is controlled by controlling grounding of the motor. The
SWITCH X motor is grounded at windscreen washing if the wiper motor roof or
OUTPUT FRONT XY rear window is activated.
005541
OUTPUT REAR ROOF XY
Circuit diagram: Circuit wiper group 9.5_1
Connection: PWM out D790-1/K5:4 to M651-2
Function: 9.5.4 Washer motor and reservoir
Signal value:

signal is missing.
8.4.3.2 CAB, menu 2
FRONT WIPER, SWITCH (1-3)

Description: Signal from multi-function lever, switch wiper function.
DIAG CAB 2(X)
FRONT WIPER Circuit diagram: Circuit wiper group 9.5_1
SWITCH (1-3) X
OUTPUT XY Contact:
005542
FEEDBACK X X = 1 Interval slow: signal from S162/J1 to digital in D790-2/K3:6

X = 2 Interval less slow: signal from S162/J2, digital in D790-2/K3:7
X = 3 Interval continuous: signal from S162/53, digital in
D790-2/K3:8
Function: 9.5 Wiper/washer system
Signal value:
1 Long interval.
2 Normal interval.
3 Continuous operation.

FRONT WIPER, OUTPUT

Description: Voltage feed to wiper front.
DIAG CAB 2(X)
FRONT WIPER Circuit diagram: Circuit wiper group 9.5_1
SWITCH (1-3) X
OUTPUT XY Connection: digital out from D790-1/K2:1 to M650-1/53
005542
FEEDBACK X Function: 9.5.5 Wiper motor front
Signal value:

active.
FRONT WIPER, FEEDBACK

Description: Signal from motor wiper front, indicates when the wiper
DIAG CAB 2(X) sweep is completed.
FRONT WIPER
SWITCH (1-3) X Circuit diagram: Circuit wiper group 9.5_1
OUTPUT XY
005542
FEEDBACK X Connection: signal from M650-1/31B to digital in D790-1/K4:13
Function: 9.5.5 Wiper motor front
Signal value:
1 Input signal active (wiper sweep).

0 No signal (home position).
8.4.3.3 CAB, menu 3
REAR WIPER, SWITCH

Description: Status of rear window wiper switch on Control unit KIT
DIAG CAB 3(X) (D790-2).
REAR WIPER
SWITCH X Circuit diagram: -
OUTPUT XY
005543
FEEDBACK X Contact: -
Function: 9.5 Wiper/washer system
Signal value:
1 Input signal active. Key for continuous/interval pressed

down.
0 No signal.

REAR WIPER, OUTPUT

Description: Voltage feed to direction windscreen wiper rear.
DIAG CAB 3(X)
REAR WIPER Circuit diagram: Circuit wiper group 9.5_1
SWITCH X
OUTPUT XY Connection: digital out from D790-1/K2:4 to M650-2/53
005543
FEEDBACK X Function: 9.5.7 Wiper motor rear
Signal value:

active.
REAR WIPER, FEEDBACK

Description: Signal from motor windscreen wiper rear, indicates when
DIAG CAB 3(X) the wiper sweep is completed.
REAR WIPER
SWITCH X Circuit diagram: Circuit wiper group 9.5_1
OUTPUT XY
005543
FEEDBACK X Connection: signal from M650-2/31b to digital in D790-1/K12:2
Function: 9.5.7 Wiper motor rear
Signal value:

8.4.3.4 CAB, menu 4
ROOF WIPER, SWITCH

Description: Signal from switch, wiper roof.
DIAG CAB 4(X)
ROOF WIPER Circuit diagram: -
SWITCH X
OUTPUT XY Contact: -
005544
FEEDBACK X Function: 9.5 Wiper/washer system
Signal value:
1 Input signal active. Key for continuous/interval pressed

down.
0 No signal.

ROOF WIPER, OUTPUT

Description: Voltage feed to wiper roof.
DIAG CAB 4(X)
ROOF WIPER Circuit diagram: Circuit wiper group 9.5_1
SWITCH X
OUTPUT XY Connection: digital out from D790-1/K10:14 to wiper motor M650-3/53
005544
FEEDBACK X Function: 9.5.6 Wiper motor roof
Signal value:

signal is missing.
ROOF WIPER, FEEDBACK

Description: Signal from motor wiper roof, indicates when the wiper
DIAG CAB 4(X) sweep is completed.
ROOF WIPER
SWITCH X Circuit diagram: Circuit wiper group 9.5_1
OUTPUT XY
005544
FEEDBACK X Connection: signal from M650-3/31B to digital in D790-1/K12:4
Function: 9.5.6 Wiper motor roof
Signal value:

8.4.3.5 CAB, menu 5
HORN, SWITCH
Description: Signal from switch, horn.
DIAG CAB 5(X)
HORN Circuit diagram: Circuit alarm, audible signals group 9.7_1
SWITCH X
SWITCH 2 X Connection: signal from S162/H to digital in D790-2/K3:2
005545
OUTPUT XY Function: 9.7 Signalling system
Signal value:

0 No signal.

HORN, SWITCH 2
DIAG CAB 5(X)

HORN Description: Signal from horn switch on hydraulic control panel.
SWITCH X
SWITCH 2 X Circuit diagram: Circuit horn servo panel group 9.7_4
005545
OUTPUT XY
Connection: signal from S149-3 to digital in D790-1/K9:10
Function: 9.7 Signalling system
Signal value:

0 No signal.
HORN, OUTPUT
Description: Voltage feed to horn.
DIAG CAB 5(X)
HORN Circuit diagram: Circuit alarm, audible signals group 9.7_1 and circuit
SWITCH X compressor horn group 9.7_3
SWITCH 2 X
005545
OUTPUT XY Connection: digital out D790-1/K11:11 to H850 ( for compressor

horn, signal to relay K3016/86)
Function: 9.7.1 Horn
Signal value:

1 No output signal. It can also be a fault in the circuit as errors
can only be detected when the output signal is active.
0
1 Output signal active, circuit OK.
8.4.3.6 CAB, menu 6
BUZZER
Description: Voltage feed to buzzer for alarm indication panel, feed.
DIAG CAB 6(X)
BUZZER XY Circuit diagram: Circuit alarm, audible signals group 9.7_1
SWITCH SEAT X
ALARM X Connection: digital out from D790-2/K8:4 to H853/1
005546
OP X Function: 9.3 Seats, 1 Engine, 8.2.1 Overload protection
Signal value:

circuit as this can only be detected when the output signal
is missing.

SWITCH SEAT
Description: Signal from Sensor, operator-in-seat.
DIAG CAB 6(X)
BUZZER XY Circuit diagram: Circuit alarm, audible signals group 9.7_1
SWITCH SEAT X
ALARM X Connection: signal from S230/1 to D790-1/K11:14
005546
OP X Function: 9.3.14 Sensor operator in seat
1 Input signal active. Operator in seat.

0 No signal. No operator in seat.
ALARM
Description: Status for alarm indication panel, warning from control
DIAG CAB 6(X) system.
BUZZER XY
SWITCH SEAT X Circuit diagram: -
ALARM X
005546
OP X Contact: -
Function: 8.1.2 Information display
1 Conditions for activation of buzzer from seat switch and

parking brake are fulfilled
0 Conditions for activation of buzzer are not fulfilled.
OP
DIAG CAB 6(X)
BUZZER XY
SWITCH SEAT X
ALARM X
005546
OP X
8.4.3.7 CAB, menu 7
FUEL, SENSOR VALUE

Description: Signal from sensor fuel level.
DIAG CAB 7(X)
FUEL Circuit diagram: Circuit drivetrain engine group 1.0_1
SENSOR VALUE XXXohm
PROC XXX Connection: analogue rheostat signal from B757 to D797-1/K2:15
009182
Function: 1.2.2 Sensor fuel level
Signal value: XXXohm = Current resistance value from sensor fuel

level in ohm.
FUEL, PROC
Description: The control system's interpretation of the signal from
DIAG CAB 7(X) sensor, fuel tank.
FUEL
SENSOR VALUE XXXohm Circuit diagram: -
PROC XXX
009182
Contact: -
Function: 1.2.2 Sensor fuel level
Signal value: XXX = 0-100 = 0-100% = Fuel volume in tank.

8.4.3.8 CAB, menu 8
SEAT HEATER, SWITCH
DIAG CAB 8(X)

SEAT HEATER Description: Signal from switch, seat heating.
SWITCH X
OUTPUT XY Circuit diagram: Circuit seat heating group 9.3_1
005548
Function: 9.3 Seat
Signal value:

0 No signal.
SEAT HEATER, OUTPUT

Description: Voltage feed to seat heating relay.
DIAG CAB 8(X)
SEAT HEATER Circuit diagram: Circuit seat heating group 9.3_1
SWITCH X
OUTPUT XY Connection: digital out from D790-1/K10:7 to K383/86
005548
Function: 9.3.3 Heating coil
Signal value:

signal is missing.

8:44 8 Control system – CLIMATE
8.4.4 CLIMATE
CLIMATE, description
This group covers the cab's air conditioning.
DIAGNOSIS
CLIMATE HYD ENGINE
005302
OLS EXTRA
8.4.4.1 CLIMATE, menu 1

PRESENT INPUT SIGNAL, REQUIRED TEMP
Description: Set value for desired temperature.
DIAG CLIMATE 1(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit climate system group 9.4_1
REQUIRED TEMP XXX
Connection: signal from S117/3 to analogue in D790-1/K5:8
PRESENT TEMP XXX
005549
WATER VALVE FEEDB. XXX Function: 9.4 Heating, ventilation and air conditioning
Signal value: XXX = 160-280 = 16-28 ºC = Preset temperature shown

in tenths of degrees and adjusted in increments of half degrees (200
= 20 ºC). Test by increasing or decreasing temperature with the
temperature switch on the panel.
PRESENT INPUT SIGNAL, PRESENT TEMP

Description: Signal from sensor cab temperature.
DIAG CLIMATE 1(X)
REQUIRED TEMP XXX
Connection: signal from B775-1/2 to input D790-1/K4:8
PRESENT TEMP XXX
005549
WATER VALVE FEEDB. XXX Function: 9.4.17 Sensor cab temperature
Signal value: XXX = Cab's interior temperature in tenths of degrees

(200 = 20 ºC).
PRESENT INPUT SIGNAL, WATER VALVE FEEDB.

Description: Water valve's position (opening in percent).
DIAG CLIMATE 1(X)
REQUIRED TEMP XXX
Connection: signal from Y673/9 to analogue in D790-1/K10:4
PRESENT TEMP XXX
005549
WATER VALVE FEEDB. XXX Function: 9.4.5 Water valve
Signal value: XXX = 0-100 = 0-100% = Water valve's opening in %. 0 =

Closed. 100 = Fully open.

TEMP COIL
Description: Temperature of the air out from the fan. The sensor is
DIAG CLIMATE 2(X) fitted in the air distributor.
TEMP COIL XXX
TEMP COOLANT XXX Circuit diagram: Circuit climate system group 9.4_1
TEMP AMBIENT XXX
Connection: signal from B775-2 to input D790-1/K4:10
005550
TEMP DE-ICE XXX

Function: 9.4.16 Sensor, temperature outlet fan
Signal value: XXX = Temperature of the air blown into the cab in tenths
of degrees (200 = 20 ºC).

8 Control system – CLIMATE 8:45
TEMP COOLANT
Description: Coolant temperature, temperature of the engine's coolant.
DIAG CLIMATE 2(X) Signal is retrieved from the engine via CAN bus drive-train.
TEMP COIL XXX
TEMP COOLANT XXX Circuit diagram: Circuit climate system group 9.4_1 and 9.4_2
TEMP AMBIENT XXX
005550
TEMP DE-ICE XXX Connection: from engine via CAN bus, see PRESENT INPUT SIGNAL,
COOLANT TEMP, page 8:58.
Function: 1.7 Cooling system
Signal value: XXX = Engine temperature in tenths of degrees (200 =

20 ºC).
TEMP AMBIENT
Description: Outdoor temperature. Heat radiation from engine and sun
DIAG CLIMATE 2(X) may affect the value since the sensor is fitted on the rear of the cab roof.
TEMP COIL XXX
TEMP COOLANT XXX Circuit diagram: Circuit climate system group 9.4_1
TEMP AMBIENT XXX
005550
TEMP DE-ICE XXX Connection: signal from B774/2 to input D790-1/K4:9
Function: 9.4.18 Sensor ambient temperature
Signal value: XXX = Outdoor temperature in tenths of degrees (200 =

20 ºC).
TEMP DE-ICE
Description: Temperature in refrigerant circuit.
DIAG CLIMATE 2(X)
TEMP COIL XXX Circuit diagram: Circuit climate system group 9.4_1
TEMP COOLANT XXX
TEMP AMBIENT XXX Connection: signal from B775-3/2 to input D790-1/K4:11
005550
TEMP DE-ICE XXX Function: 9.4.12 Sensor temperature refrigerant
Signal value: XXX = Refrigerant temperature in tenths of degrees

(200 = 20 ºC).
PRESENT INPUT SIGNAL, PRESSURE SWITCH

Description: Signal from refrigerant pressure switch.
DIAG CLIMATE 3(X)
PRESSURE SWITCH X
005551
Function: 9.4.10 Pressure switch
Signal value:
1 Input signal active. Press OK.

0 No signal, too high or too low pressure.


PRESENT INPUT SIGNAL, WATER VALVE
Description: Signal from water valve, the voltage is a measure of the
DIAG CLIMATE 4(X) position.
WATER VALVE XX.XXV Circuit diagram: Circuit climate system group 9.4_2
DRAUGHT VALVE XX.XXV
005552
Function: 9.4.5 Water valve
Signal value: XX.XXV = 0.50 - 4.50 V
PRESENT INPUT SIGNAL, DRAUGHT VALVE

Description: Signal from the engine to the air distributor. The voltage is
DIAG CLIMATE 4(X) a measure of the damper's position.
WATER VALVE XX.XXV Circuit diagram: Circuit climate system group 9.4_2
005552
Function: 9.4.14 Air distributor
Signal value: XX.XXV = 0.50 - 4.50 V

PRESENT INPUT SIGNAL, REQUIRED TEMP
Description: Signal from switch, temperature. Voltage when the switch
DIAG CLIMATE 5(X) is pressed in the voltage level indicates increase or decrease of the
PRESENT INPUT SIGNAL temperature.
REQUIRED TEMP XX.XXV
REQ. DRAUGHT XX.XXV Circuit diagram: Circuit climate system group 9.4_1
005553
REQ. FAN SPEED XX.XXV

Function: 9.4 Heating, ventilation and air conditioning
Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Increase / - / decrease
PRESENT INPUT SIGNAL, REQ. DRAUGHT

Description: Signal from switch, air distribution, voltage when switch is
DIAG CLIMATE 5(X) pressed in. The voltage level indicates change of air control against
PRESENT INPUT SIGNAL windscreen (up) or floor (down). The damper's position changes in
REQUIRED TEMP XX.XXV steps between windscreen - floor.
REQ. DRAUGHT XX.XXV
005553
REQ. FAN SPEED XX.XXV Circuit diagram: Circuit climate system group 9.4_1
Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Up / - / down.
PRESENT INPUT SIGNAL, REQ. FAN SPEED

Description: Signal from switch, fan speed, switch controls increase
DIAG CLIMATE 5(X) or decrease of fan speed. Speed is adjustable steplessly. The voltage
PRESENT INPUT SIGNAL level indicates if the speed should be increased or decreased.
REQUIRED TEMP XX.XXV
REQ. DRAUGHT XX.XXV Circuit diagram: Circuit climate system group 9.4_1
005553
REQ. FAN SPEED XX.XXV

Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Increase / - / decrease.

PRESENT OUTPUT SIGNAL, FAN SPEED

Description: Current control of fan motor, speed is controlled with
DIAG CLIMATE 6(X) PWM-control of grounding (of fan motor).
PRESENT OUTPUT SIGNAL
FAN SPEED XXX Circuit diagram: Circuit climate system group 9.4_2
RECIRKULATION XY
005554
COMPRESSOR XY Connection: analogue out from D790-1/K2:2 to M657/31
Function: 9.4.3 cab fan.
Signal value: XXX = 0-255 = Fan speed (255 = max. fan speed).
PRESENT OUTPUT SIGNAL, RECIRCULATION

Description: Voltage feed to motor for fresh air and recirculation
DIAG CLIMATE 6(X) damper.
FAN SPEED XXX Circuit diagram: Circuit climate system group 9.4_2
RECIRKULATION XY
005554
COMPRESSOR XY Connection: digital out from D790-1/K2:3 to M612
Function: 9.4.2 Fresh air and recirculation damper
Signal value:

active.
PRESENT OUTPUT SIGNAL, COMPRESSOR

Description: Voltage feed of AC compressor's electromagnetic clutch.
DIAG CLIMATE 6(X) Controls cut-in and cut-out of the compressor. Two outputs are
PRESENT OUTPUT SIGNAL connected in parallel to handle the current intensity.
FAN SPEED XXX
RECIRKULATION XY Circuit diagram: Circuit climate system group 9.4_2
005554
COMPRESSOR XY
Connection: digital out from D797-1/K1:25 and D797-1/K1:29 to M645
Function: 9.4.7 Compressor
Signal value:

No output signal, circuit OK. It can also be a short
circuit as this is only detected when the output signal
is active.
signal is missing.

OUTPUT WATER VALVE, CLOCKWISE

Description: Voltage feed to water valve, for opening. The valve is
DIAG CLIMATE 7(X) connected to an H-bridge. The signal can only be diagnosed when the
OUTPUT WATER VALVE valve's position changes. The valve's opening and closing is controlled
CLOCKWISE XY XY by the air conditioning's software depending on desired temperature,
ANTI-CLOCKWISE XY XY outside temp. cab temperature and coolant temperature, so it may be
difficult to determine whether the valve is working as it should.
Circuit diagram: Circuit climate system group 9.4_2

24V
Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from
D790-1/K4:2 via R4 to Y673/6
M Signal value: motor runs clockwise row 1: 11 11 row 2: 00 11

005555

0V
H-bridge 10 Output signal active, short circuit.
signal is missing.
OUTPUT WATER VALVE, ANTI-CLOCKWISE

Description: Voltage feed to water valve, for closing. The valve is
DIAG CLIMATE 7(X) connected to an H-bridge. The signal can only be diagnosed when the
OUTPUT WATER VALVE valve's position changes. The valve's opening and closing is controlled
CLOCKWISE XY XY by the air conditioning's software depending on desired temperature,
ANTI-CLOCKWISE XY XY outside temp. cab temperature and coolant temperature, so it may be
difficult to determine whether the valve is working as it should.
Circuit diagram: Circuit climate system group 9.4_2

24V
D790-1/K4:2 via R4 to Y673/6
M Signal value: motor runs anticlockwise row 1: 00 11, row 2: 11 11

005555

0V
H-bridge 10 Output signal active, short circuit.
signal is missing.

OUTPUT DRAUGHT VALVE, CLOCKWISE

Description: Voltage feed to the motor for the air distributor, rotation
DIAG CLIMATE 8(X) clockwise. Is connected in accordance with an H-bridge. The signal
OUTPUT DRAUGHT VALVE can only be diagnosed when the air distributor's position changes.
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY Circuit diagram: Circuit climate system group 9.4_2

D790-1/K4:4 via R6 to Y672/6
24V
Signal value: motor runs clockwise row 1: 11 11, row 2: 00 11

M 01 Normal mode function off.
005556

0V
H-bridge circuit as this can only be detected when the output
signal is missing.
OUTPUT DRAUGHT VALVE, ANTI-CLOCKWISE

Description: Voltage feed to the motor for the air distributor, rotation
DIAG CLIMATE 8(X) anticlockwise. The motor is connected to an H-bridge. The signal can
OUTPUT DRAUGHT VALVE only be diagnosed when the air distributor's position changes.
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY Circuit diagram: Circuit 9.4_2

D790-1/K4:4 via R6 to Y672/6
24V
Signal value: motor runs anticlockwise row 1: 00 11, row 2: 11 11

M 01 Normal mode function off.
005556

0V
H-bridge circuit as this can only be detected when the output
signal is missing.

8:50 8 Control system – HYD
8.4.5 HYD
HYD, description
This group covers the hydraulic functions.
DIAGNOSIS
CLIMATE HYD ENGINE
005303
OLS EXTRA
8.4.5.1 HYD, menu 1

HYDRAULIC OIL, TEMP
Description: Signal from sensor hydraulic oil temperature.
DIAG HYDRAULIC 1(X)
HYDRAULIC OIL Circuit diagram: Circuit cooling hydraulic oil group 10.6_1
TEMP XXX Connection: signal from B776/1 to temperature in D797-1/K2:13
FAN XY
010070
SET OUTPUT + - X Function: 10.6.4 Sensor hydraulic oil temperature

Signal value: XXX = Temperature in tenths of degrees (200 = 20 ºC).
HYDRAULIC OIL, FAN

Description: Voltage feed cooling fan hydraulic oil.
DIAG HYDRAULIC 1(X)
TEMP XXX Connection: digital out from D797-1/K1:14 to M668/1
FAN XY
010070
SET OUTPUT + - X Function: 10.6.3 Cooling fan

Signal value:
active.
HYDRAULIC OIL, SET OUTPUT +/-

Description: Functionality test of hydraulic oil cooling fan.
DIAG HYDRAULIC 1(X)
TEMP XXX Connection: digital out from D797-1/K1:14 to M668/1 is activated or
FAN XY deactivated with +/-
010070
SET OUTPUT + - X
Function: 10.6.3 Cooling fan
Signal value:
8.4.5.2 HYD, menu 2

NOT USED
XXXXXXX X(X)
NOT USED
008793

8 Control system – HYD 8:51
8.4.5.3 HYD, menu 3
NOT USED
XXXXXXX X(X)
NOT USED
008793
8.4.5.4 HYD, menu 4
PRESSURE SWITCHES, BRAKE PRESSURE

Description: Signal from break contact (opening switch) brake pressure.
DIAG HYDRAULIC 4(X)
PRESSURE SWITCHES Circuit diagram: Circuit brake system group 4.0_1
BRAKE PRESSURE X
BRAKE LIGHT PRESS. X Connection: signal from S204/2 to analogue in D797-1/K1:13
007240
DECLUTCH PRESSURE X Function: 4.3.7 Normally open (NO) switch, brake pressure
Signal value:

0 No signal.
PRESSURE SWITCHES, BRAKE LIGHT PRESSURE

Description: Signal from make-contact (closing switch) brake lights.
DIAG HYDRAULIC 4(X)
PRESSURE SWITCHES Circuit diagram: Circuit lighting group 9.6_5
BRAKE PRESSURE X
BRAKE LIGHT PRESS. X Connection: signal from S216/2 to digital in D797-1/K1:20
007240
DECLUTCH PRESSURE X Function: 4.3.8 Make-contact (closing switch) brake lights
Signal value:

0 No signal.
PRESSURE SWITCHES, DECLUTCH PRESSURE

Description: Signal from break contact (opening switch) declutch.
DIAG HYDRAULIC 4(X)
PRESSURE SWITCHES Circuit diagram: Circuit drivetrain gearbox group 2.0_1
BRAKE PRESSURE X
BRAKE LIGHT PRESS. X Connection: signal from S220-2/2 to analogue in D797-1/K1:27
007240
DECLUTCH PRESSURE X Function: 2.8.2 Normally closed (NC) switch, disengagement
Signal value:

0 No signal.

8:52 8 Control system – HYD
8.4.5.5 HYD, menu 5

P-BRAKE, SWITCH
Description: Signals from switch parking brake. Two signals, one for
DIAG HYDRAULIC 5(X) released parking brake and one for applied parking brake. Both signals
P-BRAKE must be valid to enable release of parking brake.
SWITCH X/Y
FEEDBACK SWITCH X Circuit diagram: Circuit brake system group 4.0_1
007241
VALVE XY Connection: signal from S107/1 to digital in D790-1/K8:13 and from
S107/7 to digital in D790-1/K8:5
Function: 4.5 Parking brake system
Signal value:
1/0 Open, parking brake released.
0/1 On, parking brake applied.
P-BRAKE, FEEDBACK SWITCH

Description: Signal from break contact (opening switch) parking brake.
DIAG HYDRAULIC 5(X)
P-BRAKE Circuit diagram: Circuit brake system group 4.0_1
SWITCH X/Y Connection: signal from S200/2 to analogue in D797-1/K1:41
FEEDBACK SWITCH X
007241
VALVE XY Function: 4.5.5 Normally open (NO) switch, parking brake

Signal value:
0 No signal.
P-BRAKE, VALVE
Description: Voltage feed to Solenoid valve parking brake.
DIAG HYDRAULIC 5(X)
P-BRAKE Circuit diagram: Circuit brake system group 4.0_1
SWITCH X/Y Connection: digital out from D797-1/K1:34 to solenoid valve Y642/1
FEEDBACK SWITCH X
007241
VALVE XY Function: 4.5.3 Solenoid valve parking brake

Signal value:
signal is missing.
8.4.5.6 HYD, menu 6

NOT USED
XXXXXXX X(X)
NOT USED
008793

8 Control system – HYD 8:53
8.4.5.7 HYD, menu 7
NOT USED
XXXXXXX X(X)
NOT USED
008793
8.4.5.8 HYD, menu 8
PRESENT OUTPUT SIGNAL, PRESSURE TO

ATTACHM. VALVE
Description: Voltage feed to solenoid valve for main pump relief
DIAG HYDRAULIC 8(X) (pressurised attachment).
PRESSURE TO ATTACHM. Circuit diagram: circuit disengage. hydr pump group 10.4_1
VALVE XY
010074
SET OUTPUT + - X Connection: digital out from circuit disengage hydraulic pump group
D797-1/K1:35 to solenoid valve Y6062-2
Function: 10.4.2 Axial piston pump with variable displacement
Signal value:
1 Output signal active.

0 No output signal.
PRESENT OUTPUT SIGNAL, PRESSURE TO

ATTACHM, SET OUTPUT +/-
Description: Begin sending or cut off hydraulic pressure to the
DIAG HYDRAULIC 8(X) attachment.
PRESSURE TO ATTACHM. Circuit diagram: circuit disengage. hydr pump group 10.4_1
VALVE XY
010074
SET OUTPUT + - X Connection: digital out from D797-1/K1:35 to solenoid valve Y6062-2 is
activated or deactivated with +/-
Function: 10.4.2 Axial piston pump with variable displacement
Signal value:

0 No output signal.

8:54 8 Control system – ENGINE
8.4.6 ENGINE
ENGINE, description
This group covers the engine functions.
DIAGNOSIS
CLIMATE HYD ENGINE
005306
OLS EXTRA
8.4.6.1 ENGINE, menu 1
PRESENT INPUT SIGNAL, ACCELERATOR

Description: Signal from accelerator pedal.
DIAG ENGINE 1(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit drivetrain engine group 1.0_1
ACCELERATOR X.XXV
REQUIRED SPD PROC XXX Connection: signal from B690-1/2 to analogue in D790-1/K6:11
006866
REQUIRED SPD RPM XXXX Function: 1 Engine
Signal value: X.XXV = 0.50-4.50 V
PRESENT INPUT SIGNAL, REQUIRED SPD PROC

Description: Required engine speed (in percent) which is sent from
DIAG ENGINE 1(X) Control unit, cab (D790-1) to Control unit, engine (D794) via CAN bus
PRESENT INPUT SIGNAL drive-train.
ACCELERATOR X.XXV
REQUIRED SPD PROC XXX Circuit diagram: -
006866
REQUIRED SPD RPM XXXX

Contact: -
Function: 1.9 Control system, engine
Signal value: XXXX = 0-100%
PRESENT INPUT SIGNAL, REQUIRED SPD RPM

Description: Required engine speed (in percent) which is sent from
DIAG ENGINE 1(X) Control unit, cab (D790-1) to Control unit, engine (D794) via CAN bus
PRESENT INPUT SIGNAL drive-train.
ACCELERATOR X.XXV
REQUIRED SPD PROC XXX Circuit diagram: -
006866
REQUIRED SPD RPM XXXX

Contact: -
Signal value: XXXX = 0-2010 rpm
PRESENT INPUT SIGNAL, ENGINE SPEED EDC

Description: Engine speed from Control unit, engine (D794) to Control
DIAG ENGINE 2(X) unit, cab (D790-1) via CAN bus drive-train. Actual value for engine
PRESENT INPUT SIGNAL speed.
ENGINE SPEED EDC XXXX
ENGINE SPEED TCU XXXX Circuit diagram: -
005308
Contact: -
Function: 1.9.2 Sensor engine rpm
Signal value: XXXX = Active speed in rpm.

8 Control system – ENGINE 8:55
PRESENT INPUT SIGNAL, ENGINE SPEED TCU
DIAG ENGINE 2(X)

PRESENT INPUT SIGNAL Description: Engine speed from Control unit, transmission (D793) to
ENGINE SPEED EDC XXXX Control unit, cab (D790-1) via CAN bus drive-train. Actual value for
ENGINE SPEED TCU XXXX rotation speed, engine.
005308
Circuit diagram: -
Contact: -
Function: 2.2.5 Sensor engine speed and oil temperature transmission
Signal value: XXXX = active speed in rpm.

PRESENT INPUT SIGNAL, PRESENT TORQUE
Description: Actual torque from Control unit, engine (D794).
DIAG ENGINE 3(X) Percentage torque use of engine's capacity.
PRESENT TORQUE XXX Circuit diagram: -
REQUIRED TORQUE XXX Contact: -
005309
PRES TORQUE @ RPM XXX

Signal value: XXX = 0-100%
PRESENT INPUT SIGNAL, REQUIRED TORQUE
DIAG ENGINE 3(X)

PRESENT INPUT SIGNAL Description: Requested torque from cab control unit (D790-1) to engine
PRESENT TORQUE XXX control unit (D794).
REQUIRED TORQUE XXX Circuit diagram: -
005309
PRES TORQUE @ RPM XXX

Contact: -
PRESENT INPUT SIGNAL, PRES TORQUE @ PPM

Description: Available torque at current engine speed.
DIAG ENGINE 3(X)
PRESENT INPUT SIGNAL Circuit diagram: -
PRESENT TORQUE XXX Contact: -
REQUIRED TORQUE XXX
005309
PRES TORQUE @ RPM XXX Function: 1.9 Control system, engine


PRESENT INPUT SIGNAL, PREHEAT SWITCH
Description: Signal from ignition key lock, preheating position. Only
DIAG ENGINE 4(X) used on a machine with a Volvo engine.
PREHEAT SWITCH X Circuit diagram: Circuit 11.5-3, 1.0-1
CRANK ENGINE SWITCH X Connection: signal from S150/19 to digital in D790-2/K2:2
005310
D+ X
Function: 1 Engine, 1.10.1 Preheating
Signal value:
0 No signal.

PRESENT INPUT SIGNAL, CRANK ENGINE SWITCH

Description: Signal from ignition key lock, start position.
DIAG ENGINE 4(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit power group 11.5_3, Circuit drivetrain engine
PREHEAT SWITCH X group 1.0_1
CRANK ENGINE SWITCH X
009282
D+ X Connection: signal from S150/50 to digital in D790-2/K2:1
Function: 1 Engine, 1.11 Start and stop
Signal value:

0 No signal.
PRESENT INPUT SIGNAL, D+

Description: Signal from alternator, indicates if alternator supplies
DIAG ENGINE 4(X) current.
PREHEAT SWITCH X Circuit diagram: Circuit engine QSB6.7 group 1.0_2E1 and circuit
CRANK ENGINE SWITCH X drive-train engine group 1.0_1
009282
D+ X
Connection: from G660/D+ to digital in D797-1/K2:16
Function: 11.4.1 Alternator
Signal value:

0 No signal.
PRESENT OUTPUT SIGNAL, PREHEAT

Description: Status for preheating of induction air.
DIAG ENGINE 5(X)
PRESENT OUTPUT SIGNAL Circuit diagram: -
PREHEAT X
CRANK ENGINE X Contact:
015098
CRANK ENGINE WIRE XY Function: 1.10.1 Preheating
Signal value:

0 No output signal.
PRESENT OUTPUT SIGNAL, CRANK ENGINE

Description: Voltage feed starter motor.
DIAG ENGINE 5(X)
PRESENT OUTPUT SIGNAL Applies to Volvo TAD760VE
PREHEAT X
CRANK ENGINE X Circuit diagram: -
015098
CRANK ENGINE WIRE XY Connection: software signals on CAN-bus drivetrain.
Function: 1.11 Start and stop
Signal value:

0 No output signal.

8 Control system – ENGINE 8:57
PRESENT OUTPUT SIGNAL, CRANK ENGINE WIRE

Description: Status for voltage feed to the Starter relay (K360). Applies
DIAG ENGINE 5(X) to Cummins QSB6.7.
PREHEAT X Circuit diagram: Circuit drive-train engine group 1.0_1, Circuit engine
CRANK ENGINE X QSB6.7 group 1.0_2E1
015098
CRANK ENGINE WIRE XY
Connection: digital out D797-1/K1:32 to K360/86
Function: 1.11 Start and stop
Signal value:

PRESENT INPUT SIGNAL, OIL PRESSURE

Description: Engine oil pressure. CAN bus message from Control unit,
DIAG ENGINE 6(X) engine (D794) to Control unit, cab (D790-1).
OIL PRESSURE XX.X Circuit diagram: see supplier documentation, engine
BOOST PRESSURE XX.X
008899
OIL LEVEL XXX Contact:

Volvo TAD760VE: signal from "2 oil pressure sensor" to engine
control unit (D794) "Connector B" sleeve 11
Function: 1.8.3 Sensor oil pressure engine
Signal value= XX.X = pressure in bar.
PRESENT INPUT SIGNAL, BOOST PRESSURE

Description: Boost pressure. CAN bus message from Control unit,
DIAG ENGINE 6(X) engine (D794) to Control unit, cab (D790-1).
OIL PRESSURE XX.X Circuit diagram: see supplier documentation, engine
BOOST PRESSURE XX.X
008899
OIL LEVEL XXX Contact:

Volvo TAD760VE: signal from "33 charge air pressure sensor" to
engine control unit (D794) "Connector A" sleeve 22
Function: 1.6.5 Sensor boost pressure
Signal value= XX.X = pressure in bar.
PRESENT INPUT SIGNAL, OIL LEVEL

Not used.

PRESENT INPUT SIGNAL, OIL TEMP

Description: Engine oil temperature. CAN bus message from Control
DIAG ENGINE 7(X) unit, engine (D794) to Control unit, cab (D790-1).
OIL TEMP XXX Circuit diagram: see supplier documentation, engine.
COOLANT TEMP XXX
009284
INTAKE MAIN.TEMP XXX Contact:
Volvo TAD760VE: signal from "1 Sensor oil temperature and oil
level" to Control unit engine (D794) "connector A" sleeve 31
Cummins QSB6.7 : signal from "Oil pressure/temperature
sensor" sleeve 4 to Control unit, engine (D794) "Sensor connector"
sleeve 42
Function: 1 Engine
Signal value: XXX = 200 corresponds to 20 ºC.
PRESENT INPUT SIGNAL, COOLANT TEMP

Description: Coolant temperature. CAN bus message from Control
OIL TEMP XXX Circuit diagram: see supplier documentation, engine
COOLANT TEMP XXX
009284

Volvo TAD760VE: signal from "4 coolant temperature sensor" to
engine control unit (D794) "Connector B" sleeve 27
Function: 1.7.9 Sensor coolant temperature
PRESENT INPUT SIGNAL, INTAKE MAIN.TEMP

Description: Charge air temperature. CAN bus message from Control
OIL TEMP XXX Circuit diagram: see supplier documentation, engine
COOLANT TEMP XXX
009284

Volvo TAD760VE: signal from "34 charge air pressure/temperature
sensor" to engine control unit (D794) "connector A" sleeve 47
Function: 1.6.6 Sensor charge-air temperature
PRESENT EDC ERROR, NO. OF ACT ERROR

Description: Number of active error codes from Control unit, engine
DIAG ENGINE 8(X) (D794).
PRESENT EDC ERROR
NR OF ACT ERROR XX Circuit diagram: -
SPN XXXX
009279
FMI XX Contact: -
Function: 1.9 Control system
Signal value: XX = number of active error codes.

8 Control system – TRANSM 8:59
PRESENT EDC ERROR, SPN

Description: SPN number for the first error code from Control unit,
DIAG ENGINE 8(X) engine (D794). SPN indicates the malfunction area, i.e. what
PRESENT EDC ERROR component or signal is defective. Error codes are shown with SPN/FMI
NR OF ACT ERROR XX in the error code menus.
SPN XXXX
009279
FMI XX Circuit diagram: -
Contact: -
Function: 8.3 Error codes
Signal value: XXXX = error code number. Use the error code list; see
section D Error codes.
PRESENT EDC ERROR, FMI

Description: FMI number for the first error code from the Control unit,
DIAG ENGINE 8(X) engine (D794). FMI indicates error type, e.g. short circuit or low value.
PRESENT EDC ERROR Error codes are shown with SPN/FMI in the error code menus.
NR OF ACT ERROR XX
SPN XXXX Circuit diagram: -
009279
FMI XX
Contact: -
Function: 8.3 Error codes
Signal value: XX = fault type number. Use the error code list; see
section D Error codes.

FUEL CONSUMPTION, MOMENTARILY l/h
Description: Current fuel consumption in litres/hour.
DIAG ENGINE 9(X)
FUEL CONSUMTION Circuit diagram: -
MOMENTARILY l/h XXX
Contact: -
009280
Function: 1.2 Fuel system
Signal value: XXX = fuel consumption in l/h.
8.4.7 TRANSM
TRANSM, description
This group covers transmission functions.
DIAGNOSIS
CLIMATE HYD ENGINE
005324
OLS EXTRA
8.4.7.1 TRANSM, menu 1

PRESENT INPUT SIGNAL, BRAKE PEDAL
DIAG TRANSM. 1(X)
BRAKE PEDAL X.XXV
DECLUTCH SWITCH X
005325
DECLUTCH PRESS SW. X

8:60 8 Control system – TRANSM
PRESENT INPUT SIGNAL, DECLUTCH SWITCH

Description: Signal from declutch pedal.
DIAG TRANSM. 1(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit drivetrain gearbox group 2.0_1
BRAKE PEDAL X.XXV
DECLUTCH SWITCH X Connection: signal from S220-1/2 to digital in D790-1/K6:14
005325
DECLUTCH PRESS SW. X Function: 2 Transmission
Signal value:
1 Input signal active. Declutch pedal depressed.

0 No signal.
PRESENT INPUT SIGNAL, DECLUTCH PRESS SW.

Description: Signal from break contact (opening switch) declutch
DIAG TRANSM. 1(X) (pressure switch).
BRAKE PEDAL X.XXV Circuit diagram: Circuit drivetrain gearbox group 2.0_1
DECLUTCH SWITCH X
005325
DECLUTCH PRESS SW. X Connection: signal from S220-2/2 to digital in D797-1/K1:27
Function: 2.8.2 Normally closed (NC) switch, disengagement
Signal value:

0 No signal.
SWITCHES, FORWARD
Description: Signal from gear and multi-function lever (forward).
DIAG TRANSM. 2(X)
SWITCHES Circuit diagram: Circuit drivetrain gearbox group 2.0_1
FORWARD X
REVERSE X Connection: signal from S162/F to digital in D790-2/K3:11
005326
SHIFT MODE X Function: 2 Transmission
Signal value:
1 Input signal active. Travel direction forward selected.

0 No signal.
SWITCHES, REVERSE
Description: Signal from gear and multi-function lever (reverse).
DIAG TRANSM. 2(X)
SWITCHES Circuit diagram: Circuit drivetrain gearbox group 2.0_1
FORWARD X
REVERSE X Connection: signal from S162/R to digital in D790-2/K3:12
005326
SHIFT MODE X Function: 2 Transmission
Signal value:
1 Input signal active. Travel direction reverse selected.

0 No signal.

SWITCHES, SHIFT MODE

Description: Signal from switch, shifting program. Status on CAN bus
DIAG TRANSM. 2(X) from Control unit KIT (D790-2). The switches are integrated in Control
SWITCHES unit KIT (D790-2).
FORWARD X
REVERSE X Circuit diagram: -
005326
SHIFT MODE X
Contact: -
Function: 2 Transmission
Signal value:
1 Shifting program 1 selected.

2 Shifting program 2 selected.
4 Automatic shifting selected.
PRESENT VALUE, FORWARD

Description: Status for forward direction of travel from Control unit,
DIAG TRANSM. 3(X) transmission (D793). Indicates if forward drive is activated in the
PRESENT VALUE transmission.
FORWARD X
005327
GEAR X
Contact: -
Signal value:
1 Output signal for travel direction forward active.

0 No output signal.

PRESENT VALUE, REVERSE

Description: Status for rearward direction of travel from Control unit,
DIAG TRANSM. 3(X) transmission (D793). Indicates if rearward drive is activated in the
PRESENT VALUE transmission.
FORWARD X
005327
GEAR X
Contact: -
Signal value:
1 Output signal for travel direction reverse active.

0 No output signal.
PRESENT VALUE, GEAR

Description: Current gear, status from Control unit, transmission
DIAG TRANSM. 3(X) (D793). Shows which gear is activated in the transmission.
PRESENT VALUE
FORWARD X Circuit diagram: -
REVERSE X
005327
GEAR X Function: 2.8 Control system, transmission
Contact: -
Signal value: X = current gear.
OPERATING STATE, AUT/MAN MODE

Description: Shows which shifting program is selected automatic or
DIAG TRANSM. 4(X) manual.
OPERATING STATE
AUT/MAN MODE X Circuit diagram: -
WARNING X
005328
OPERATING MODE X Contact: -
Signal value:
1 Automatic.
0 Manual.
OPERATING STATE, WARNING

Description: Warning for serious malfunction in transmission from
DIAG TRANSM. 4(X) Control unit, transmission (D793).
OPERATING STATE
WARNING X
005328
Signal value:
1 Active error.
0 No errors.

OPERATING STATE, OPERATING MODE

Description: Operating mode status for Control unit, transmission
DIAG TRANSM. 4(X) (D793), also shown in control unit display.
OPERATING STATE
WARNING X
005328
Signal value:
0 Not used.
1 Manual or automatic shifting, standard mode shown during
operation.
2 Not used.
3 Not used.
4 Limp home, reduced capacity due to malfunction in
transmission.
5 Shut down, serious transmission malfunction control unit
shuts down, likely that malfunction cannot be shown as
CAN-bus.
6 Calibration of transmission in progress.
OPERATING STATE, SHIFT IN PROGRESS

Description: Status for transmission function during operation, shifting
DIAG TRANSM. 5(X) in progress. Active during shifting.
OPERATING STATE
SHIFT IN PROGRESS X Circuit diagram: -
FAULT X
005329
OLD FAULT X Contact: -
Signal value:
1 Shifting in progress.
0 No activity.
OPERATING STATE, FAULT

Description: Status for transmission's function during operation, active
DIAG TRANSM. 5(X) error codes present.
OPERATING STATE
FAULT X
005329
Signal value:
1 Active error code.

0 No error codes.

OPERATING STATE, OLD FAULT

Description: Status for transmission's function during operation, there
DIAG TRANSM. 5(X) are inactive error codes that have not been acknowledged.
OPERATING STATE
FAULT X
005329
Signal value:
1 There are inactive error codes that have not been

acknowledged.
0 No unacknowledged error codes.
ENGINE SPEED
Description: Speed signal from speed sensor, engine speed.
DIAG TRANSM. 6(15)
ENGINE SPEED XXXXrpm Circuit diagram: Circuit Dana TE 17 FF group 2.0
TURBINE SPEED XXXXrpm
DRUM SPEED XXXXrpm Connection: signal from B7530 to D7937F3 and D793/K3
015549
OUTPUT SPEED XXXXrpm Function: 2 Transmission
Signal value: XXXXrpm = rpm.
TURBINE SPEED
Description: Signal from sensor rpm turbine transmission.
DIAG TRANSM. 6(15)
DRUM SPEED XXXXrpm Connection: signal from B7510 to D793/G3 and D793/K3
015549
DRUM SPEED
Description: Signal from sensor rpm drum,
DIAG TRANSM. 6(15)
DRUM SPEED XXXXrpm Connection: signal from B7520 till D793/B3 and D793/C3
015549
OUTPUT SPEED
Description: Signal from sensor rpm output shaft (propeller shaft).
DIAG TRANSM. 6(15)
DRUM SPEED XXXXrpm Connection: signal from B7580 till D793/ D3 and D793/ E3
015549

FWD SELECTION
Description: Status of supply to the Solenoid valve drive forward
DIAG TRANSM. 7(15) (Y6300).
FWD SELECTION X
REV SELECTION X Circuit diagram: Circuit Dana TE 17 FF group 2.0
2/4 SELECTION X
013178
1/3 SELECTION X Connection: signal from D793/K1 and D793/S3 to Y6300
1 Activated
0 No signal.
REV SELECTION
Description: Status of supply to the Solenoid valve drive reverse
DIAG TRANSM. 7(15) (Y6310)
FWD SELECTION X
2/4 SELECTION X
013178
1/3 SELECTION X Connection: signal from D793/E2 and D793/S3 to Y6310
1 Activated
0 No signal.
2/4 SELECTION
DIAG TRANSM. 7(15)
FWD SELECTION X
REV SELECTION X
2/4 SELECTION X
013178
1/3 SELECTION X
1/3 SELECTION
Description: Status of supply to the Solenoid valve gear selection 1/3
FWD SELECTION X
2/4 SELECTION X
013178
1/3 SELECTION X Connection: signal from D793/EF2 and D793/S3 to Y6075
1 Activated
0 No signal.


FWD/REV SUPPLY
Description: Status of control current to Servo valve forward/reverse
SUPPLY
FWD/REV SUPPLY X Circuit diagram: Circuit Dana TE 17 FF group 2.0
2/4 SUPPLY X Connection: signal from D793/B1 and D793/C1 to Y6096
013252
1/3 SUPPLY X
Signal value:
1 Activated.
0 No signal.
2/4 SUPPLY
Description: Status of control current to Servo valve gear 2 (Y6069)
DIAG TRANSM. 8(15)
SUPPLY Circuit diagram: Circuit Dana TE 17 FF group 2.0
FWD/REV SUPPLY X Connection: signal from D793/F1 and D793/G1 to Y6069
2/4 SUPPLY X
013252
1/3 SUPPLY X Function: 2.8 Control system, transmission

Signal value:
1 Activated.
0 No signal.
1/3 SUPPLY
Description: Status of control current to Servo valve gear 1/3.
DIAG TRANSM. 8(15)
SUPPLY Circuit diagram: Circuit Dana TE 17 FF group 2.0
FWD/REV SUPPLY X Connection: digital out from D793/ D1 and D793/ E1 to Y6067
2/4 SUPPLY X
013252
1/3 SUPPLY X Function: 2.8 Control system, transmission

Signal value:
1 Activated.
0 No signal.

ANALOG OUTPUTS, FWD/REV FEEDBACK
Description: Present control current to Servo valve forward/reverse
DIAG TRANSM. 9(X) (Y6096).
ANALOG OUTPUTS
FWD/REV F.B XXXXmA Circuit diagram: Circuit Dana TE 17 FF group 2.0
2/4 FEEDBACK XXXXmA Connection: signal from D793/B1 and D793/C1 to Y6096
013408
1/3 FEEDBACK XXXXmA

Signal value: XXXX = Measured value in mA.
ANALOG OUTPUTS, 2/4 FEEDBACK

Description: Present control current to Servo valve gear 2 (Y6069)
DIAG TRANSM. 9(X)
ANALOG OUTPUTS Circuit diagram: Circuit Dana TE 17 FF group 2.0
FWD/REV F.B XXXXmA Connection: signal from D793/F1 and D793/G1 to Y6069
2/4 FEEDBACK XXXXmA
013408
1/3 FEEDBACK XXXXmA Function: 2.8 Control system, transmission


ANALOG OUTPUTS, 1/3 FEEDBACK

Description: Present control current to Servo valve gear 1/3 (Y6067).
DIAG TRANSM. 9(X)
ANALOG OUTPUTS Circuit diagram: Circuit Dana TE 17 FF group 2.0
FWD/REV F.B XXXXmA
2/4 FEEDBACK XXXXmA Connection: digital out from D793/ D1 and D793/ E1 to Y6067
013408
1/3 FEEDBACK XXXXmA Function: 2.8 Control system, transmission
2/4 PRESSx10
Description: Signal from Pressure sensor gear 2 (B7652).
DIAG TRANSM. 10(X)
2/4 PRESSx10 XXXXBar Circuit diagram: Circuit Dana TE 17 FF group 2.0
1/3 PRESSx10 XXXXBar
TRANSM.TEMP XXXXmV Connection: signal from B7652/C to D793/S1
013410
CONV OUT TEMP XXXXmV Function: 2.8 Control system, transmission
Signal value:
0 bar Short-circuiting to ground.

1 – 30 bar Oil pressure is correct.
When gear 2 is activated, the pressure
must be above 23 bar.
When gear 1 or 3 is activated, the
pressure must be below 1 bar.
Over 30 bar Open circuit.
1/3 PRESSx10
Description: Signal from Pressure sensor gear 1/3 (B7651).
DIAG TRANSM. 10(X)
TRANSM.TEMP XXXXmV Connection: signal from B7651/C to D793/A2
013410
Signal value:
0 bar Short-circuiting to ground.

1 – 30 bar Oil pressure is correct.
When gear 1 or 3 is activated, the
pressure must be above 23 bar.
When gear 2 is activated, the pressure
must be below 1 bar.
Over 30 bar Open circuit.
TRANSM. TEMP
Description: Signal from Sensor for oil temperature (B7660).
DIAG TRANSM. 10(X)
TRANSM.TEMP XXXXmV Connection: signal from B7660 to D793/H3
013410
Signal value: 2000 - 4800 mV = Oil temperature -50 - 150 °C.

CONV OUT TEMP

Description: Signal from Temperate monitor torque converter (S2210)
DIAG TRANSM. 10(X) on transmission. The transmission uses a temperature sensitive
2/4 PRESSx10 XXXXBar make-contact (closing switch) and two resistors in the wiring to create
1/3 PRESSx10 XXXXBar different voltage levels.
TRANSM.TEMP XXXXmV
013410
CONV OUT TEMP XXXXmV Circuit diagram: Circuit Dana TE 17 FF group 2.0
Connection: signal from S2210 to D793/J3
Signal value:
2500 mV Transmission oil has an operating
temperature (below 110 °C).
0 mV Transmission oil temperature is high
(above under 120 °C).

PRESENT VALUE, AXLE RATIOx1024
Description: Drive axle's gear ratio.
DIAG TRANSM. 11(X)
PRESENT VALUE Circuit diagram: -
AXLE RATIO XXXXX Contact: -
RADIUS XXXX
005335

Signal value: XXXXX = drive axle's total gear ratio x 1000.
PRESENT VALUE, RADIUS

Description: Drive wheel's radius
DIAG TRANSM. 11(X)
PRESENT VALUE Circuit diagram: -
AXLE RATIO XXXXX Contact: -
RADIUS XXXX
005335

Signal value: XXXX = Drive wheels' radius in mm.

NOT USED
XXXXXXX X(X)
NOT USED
008793

ACT ERROR AREA
Description: Indicates malfunction area active error, first part of the
DIAG TRANSM. 13(X) error code. In the event of several error codes, the most serious error
ACT ERROR AREA XXX code is shown.
TYPE XXX
NUMBER OF OCCU. XXXXX Circuit diagram: -
005337
TIME AGO XXXXX Contact: -

Signal value: XXX = First part of error code; see section D Error codes

TYPE
Description: Indicates type of active error.
DIAG TRANSM. 13(X)
ACT ERROR AREA XXX Circuit diagram: -
TYPE XXX
NUMBER OF OCCU. XXXXX Contact: -
005337
TIME AGO XXXXX Function: 2.8 Control system, transmission
Signal value: XXX = Second part of error code.
NUMBER OF OCCU.
Description: Number of times active errors have occurred.
DIAG TRANSM. 13(X)
TYPE XXX
005337
Signal value: XXXXX = Number of times active errors have occurred.
TIME AGO
Description: When latest active error occurred.
DIAG TRANSM. 13(X)
TYPE XXX
005337
Signal value: XXXXX = Operating time in hours since latest error
MANUAL GEAR SHIFT, GEAR

Description: Manual control of the transmission with the plus and minus
DIAG TRANSM. 14(X) keys. The menu can be used to rule out mechanical malfunctions in
MANUAL GEAR SHIFT the transmission's gear control.
GEAR X Circuit diagram: -

014102
(+/-)
Contact: -
Signal value: X = Selected gear.

8:70 8 Control system – ELSERV
8.4.8 ELSERV
ELSERV, description
DIAGNOSIS
CAN/POWER LIGHTS CAB This group covers electric servo functions.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH Confirm selections with function key for Enter.
005400
OLS EXTRA
8.4.8.1 ELSERV, menu 1
PRESENT INPUT SIGNALS, P1

Description: Signal from control lever P1.
DIAG ELSERVO 1(X)
PRESENT INPUT SIGNALS Circuit diagram: Circuit electric servo levers group 7.0_1, circuit electric
P1 XX.XXV servo joystick group 7.0_2
P2 XX.XXV
005401
P3 XX.XXV Connection: signal from R8071/3 (S815/8) to analogue in D790-1/K7:3
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

DIAG ELSERVO 1(X)
P2 XX.XXV
005401

DIAG ELSERVO 1(X)
P2 XX.XXV
005401
NOT USED
XXXXXXX X(X)
NOT USED
008793

8 Control system – ELSERV 8:71
OUTPUT LIFT, REFERENCE

Description: Status for control current to control valve (solenoid valve,
DIAG ELSERVO 3(X) lift mast).
OUTPUT LIFT
REFERENCE XY Circuit diagram: Circuit lift/lower electric servo group 7.2_1
REQUIRED VALUE XXXmA
005403
FEEDBACK XXXmA Contact: digital output from D797-1/K1:4 to Y6005/1
Function: 7.2.5 Control valve, lift and tilt
Signal value:
00 No output signal, PWM off.

NOTE
Depending on different types of PWM connections, the following is
also possible: XY = 01 No output signal, PWM off.
OUTPUT LIFT, REQUIRED VALUE

Description: Reference value for control current to control valve
DIAG ELSERVO 3(X) (solenoid valve, lift mast).
OUTPUT LIFT
005403
FEEDBACK XXXmA Connection: output signal reference value out from D797-1/K1:16 to
Y6005/2
Signal value: XXX = Current value in mA for controlling solenoid valve.
OUTPUT LIFT, FEEDBACK

Description: Current value for control current to control valve (solenoid
DIAG ELSERVO 3(X) valve, lift mast).
OUTPUT LIFT
005403
FEEDBACK XXXmA Connection: output signal, actual value out from D797-1/K1:16 to
Y6005/2
Signal value: XXX = Measured current value in mA.

OUTPUT LOWER, REFERENCE

DIAG ELSERVO 4(X) lower mast).
OUTPUT LOWER
005404
FEEDBACK XXXmA Contact: digital output from D797-1/K1:4 to Y6004/1
Signal value:

NOTE
OUTPUT LOWER, REQUIRED VALUE

DIAG ELSERVO 4(X) (solenoid valve, lower mast).
OUTPUT LOWER
005404
Y6004/2
OUTPUT LOWER, FEEDBACK

DIAG ELSERVO 4(X) valve, lower mast).
OUTPUT LOWER
005404
Y6004/2

OUTPUT TILT IN, REFERENCE

DIAG ELSERVO 5(X) tilt in).
OUTPUT TILT IN
REFERENCE XY Circuit diagram: Circuit tilt electric servo group 7.7_1
005405
FEEDBACK XXXmA Connection: digital out from D797-1/K1:5 to Y6011/1
Signal value:

NOTE
OUTPUT TILT IN, REQUIRED VALUE

DIAG ELSERVO 5(X) (solenoid valve, tilt in).
OUTPUT TILT IN
005405
Y6011/2
OUTPUT TILT IN, FEEDBACK

DIAG ELSERVO 5(X) valve, tilt in).
OUTPUT TILT IN
005405
Y6011/2

OUTPUT TILT OUT, REFERENCE

DIAG ELSERVO 6(X) tilt out).
OUTPUT TILT OUT
005406
FEEDBACK XXXmA Connection: digital out from D797-1/K1:5 to Y6010/1
Signal value:

NOTE
OUTPUT TILT OUT, REQUIRED VALUE

DIAG ELSERVO 6(X) (solenoid valve, tilt out).
OUTPUT TILT OUT
005406
FEEDBACK XXXmA Connection: output signal, reference value out from D797-1/K1:19,
to solenoid valve Y6010/1
OUTPUT TILT OUT, FEEDBACK

DIAG ELSERVO 6(X) valve, tilt out).
OUTPUT TILT OUT
005406
solenoid valve Y6010/2
NOT USED
XXXXXXX X(X)
NOT USED
008793

NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793


PRESENT INPUT SIGNALS, SPREADER
Description: Signal from switch for spreading the attachment.
DIAG ELSERVO 13(X)
PRESENT INPUT SIGNALS Circuit diagram: Circuit electric servo joystick group 7.0_2
SPREADER IN X OUT X Contact:
PISTOL X
IN: Signal from S815/14 to digital in D790-1/K7:14 (spreading in)
007128
UNLOCK TW X
OUT: Signal from S815/16 to digital in D790-1/K7:13 (spreading
out)
Function: 7.1.1 Control lever
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, PISTOL

DIAG ELSERVO 13(X)
PRESENT INPUT SIGNALS
SPREADER IN X OUT X
PISTOL X
007128
UNLOCK TW X
PRESENT INPUT SIGNALS, UNLOCK TW

Description: Signal from control lever to unlock twistlock.
DIAG ELSERVO 13(X)
PRESENT INPUT SIGNALS Circuit diagram: Circuit electric servo joystick group 7.0_2
SPREADER IN X OUT X Contact: Signal from S815/20 to digital in D790-1/K7:15
PISTOL X
007128
UNLOCK TW X Function: 7.1.1 Control lever

Signal value:
0 No signal.

NOT USED
XXXXXXX X(X)
NOT USED
008793

NOT USED
XXXXXXX X(X)
NOT USED
008793

8 Control system – ATTACH 8:77
8.4.9 ATTACH
ATTACH, description
This group covers attachment functions.
DIAGNOSIS
CLIMATE HYD ENGINE
005339
OLS EXTRA
8.4.9.1 ATTACH, menu 1

DIAG ATTACHMENT 1(X)
P4 XX.XXV
005416

P3 XX.XXV
P4 XX.XXV
005416
P7 XX.XXV

P3 XX.XXV
P4 XX.XXV
005416
P7 XX.XXV

P5 XX.XXV
005417

8:78 8 Control system – ATTACH

PRESENT INPUT SIGNALS, SPREADER
Description: Signals from switch for spreading the attachment.
PRESENT INPUT SIGNALS Circuit diagram: Circuit 20-40, 30-35 stop group 7.5-1, circuit electric
SPREADER IN X OUT X servo joystick group 7.0_2
AUTO 20/40 X
Contact:
005418
30/35 STOP X
IN: Signal from S1012/1 (S815/14) to digital in D790-1/K7:14
(spreading in)
OUT: Signal from S1012/7 (S815/16) to digital in D790-1/K7:13
(spreading out)
Function: 7.1.3 Switch, spreading 20'-40', 7.1.1 Control lever
Signal value:

0 No signal.
PRESENT INPUT SIGNALS, AUTO 20/40

PRESENT INPUT SIGNALS Description: Signal from switch automatic spreading 20/40.
SPREADER IN X OUT X
Circuit diagram: Circuit 20-40 opt. group 7.5_3
AUTO 20/40 X
005418
30/35 STOP X Connection: from S1012-2/1 to digital in D790-1/K8:11
Function: 7.5 Spreading
Signal value:

0 No signal.
PRESENT INPUT SIGNALS, 30/35 STOP

PRESENT INPUT SIGNALS Description: Signal from switch for stop at 30'/35'.
SPREADER IN X OUT X
Circuit diagram: Circuit 20-40, 30-35 stop group 7.5-1
AUTO 20/40 X
005418
30/35 STOP X Connection: from S1004/1 to digital in D790-1/K8:10
Signal value:

0 No signal.

PRESENT INPUT SIGNALS, PISTOL
PISTOL X
007130

PRESENT INPUT SIGNALS, LOCK CONT

Description: Signal from switch, lock twistlocks.
PRESENT INPUT SIGNALS Circuit diagram: Circuit Twistlock group 7.9_1
LOCK CONT X
Contact: Signal from S1003 to digital in D790-1/K8:12
UNLOCK CONT X
010079
Function: 7.9.1 Twistlocks
Signal value:

0 No signal.
PRESENT INPUT SIGNALS, UNLOCK CONT

Description: Signal from control lever to open twistlocks.
PRESENT INPUT SIGNALS Circuit diagram: Circuit Twistlock group 7.9_1
LOCK CONT X
Contact: Signal from S1002 to digital in D790-1/K7:15
UNLOCK CONT X
010079
Signal value:

0 No signal.
PRESENT INPUT SIGNALS, LOW SPEED 20/40

Description: Signal from spreading position sensor for end position
DIAG ATTACHMENT 6(X) damping 20'/40' right or left.
LE RI Circuit diagram: Attachment DCF90/100-45E group 7.5_3
LOW SPEED 20/40 X X
010080
30/35 STOP X X Connection: from inductive sensor B769L to digital in D791/K1:12 or

from inductive sensor B769R to digital in D791/K1:40
Function: 7.5.6 Position sensor spreading
Signal value:

0 No signal.
PRESENT INPUT SIGNALS, 30/35 STOP

Description: Signal from position sensor for end position 30' right or left.
PRESENT INPUT SIGNALS Circuit diagram: Attachment DCF90/100-45E group 7.5_3
LE RI
LOW SPEED 20/40 X X Connection: from inductive sensor B777L to digital in D791/K1:20 or
010080
30/35 STOP X X from inductive sensor B777R to digital in D791/K1:37
Function: 7.5.6 Position sensor spreading
Signal value:

0 No signal.

PRESENT INPUT SIGNALS, ALIGNMENT LE RI

Description: Signals from right and left alignment sensors.
PRESENT INPUT SIGNALS Circuit diagram: Attachment DCF90/100-45E group 7.9_5A, 7.9_4
ALIGNMENT LE RI
X X Contact:
010093
LE: signal from B7203L to digital in D791/K1:27
RI: signal from B7203R to digital in D791/K1:26
Function: 7.9.1.7 Alignment sensor
Signal value:

0 No signal.
PRESENT INPUT SIGNAL LE RI, LOCKED CONT

Description: Signals from sensors locked twistlock right and left.
LE RI
LOCKED CONT X X Contact:
010082
UNLOCKED CONT X X LE: Signal from B7205LL to analogue in (used as digital)

D791/K1:23
RI: Signal from B7205RL to analogue in (used as digital)
D791/K1:24
Function: 7.9.1.8 Twistlocks sensor
Signal value:

0 No signal.
PRESENT OUTPUT SIGNAL LE RI, UNLOCKED CONT

Description: Signals from sensors open twistlock right and left.
LE RI
LOCKED CONT X X Contact:
010082
UNLOCKED CONT X X LE: Signal from B7204L to analogue in (used as digital)

D791-1/K1:22
RI: Signal from B7204R to analogue in (used as digital)
D791-1/K1:41
Function: 7.9.1.8 Twistlocks sensor
Signal value:

0 No signal.

PRESENT OUTPUT SIGNAL, LOCK CONT

Description: Voltage feed to control valve attachment, locked twistlock.
PRESENT OUTPUT SIGNAL Circuit diagram: Circuit Twistlock group 7.9_1
LOCK CONT XY
UNLOCK CONT XY Connection: digital out from D791/K1:7 to Y6040/1
010083
Function: 7.9.1.2 Attachment control valve
Signal value:

signal is missing.
PRESENT OUTPUT SIGNAL, UNLOCK CONT

Description: Voltage feed to control valve attachment, open twistlock.
PRESENT OUTPUT SIGNAL Circuit diagram: Circuit Twistlock group 7.9_1
LOCK CONT XY
UNLOCK CONT XY Connection: digital out from D791/K1:9 to Y6039/1
010083
Function: 7.9.1.2 Attachment control valve
Signal value:

signal is missing.

PRESENT OUTPUT SIGNAL, IND. LOCKED CONT

Description: Voltage feed, indicator light for locked twistlocks - located
DIAG ATTACHMENT 10(X) on carriage.
IND. LOCKED CONT XY Circuit diagram: Circuit attachment DCF90/100-45E group 11.5_2,
IND. UNLOCKED CONT XY 7.9_3A
010084
IND. ALIGNMENT XY
Connection: digital out from D791/K1:29 to H563/1
Signal value:

signal is missing.
PRESENT OUTPUT SIGNAL, IND. UNLOCKED CONT

Description: Voltage feed, indicator light for unlocked twistlocks -
DIAG ATTACHMENT 10(X) located on carriage.
010084
IND. ALIGNMENT XY
Signal value:

signal is missing.

PRESENT OUTPUT SIGNAL, IND. ALIGNMENT

Description: Voltage feed, alignment indicator light - located on
DIAG ATTACHMENT 10(X) carriage.
010084
IND. ALIGNMENT XY
Signal value:

signal is missing.
OUTPUT SIDE SHIFT LE, REFERENCE

Description: Status for control current to attachment control valve for
DIAG ATTACHMENT 11(X) side shift left.
OUTPUT SIDESHIFT LE
REFERENCE XY Circuit diagram: Circuit attachment DCF90/100-45E group 7.4_1
REQUIRED VALUE XXX
010088
FEEDBACK XXX Connection: digital out from D791-1/K1:32 to Y6020/1
Function: 7.4.2 Control valve attachment
Signal value:

NOTE
OUTPUT SIDE SHIFT LE, REQUIRED VALUE

Description: Reference value for control current to attachment control
DIAG ATTACHMENT 11(X) valve for output signal, side shift left.
OUTPUT SIDESHIFT LE
REQUIRED VALUE XXX
010088
FEEDBACK XXX Connection: output signal reference value out from D791-1/K1:18 to
Y6020/2

OUTPUT SIDE SHIFT LE, FEEDBACK

Description: Current value for control current to attachment control
DIAG ATTACHMENT 11(X) valve for side shift left.
OUTPUT SIDESHIFT LE
REQUIRED VALUE XXX
010088
FEEDBACK XXX Connection: output signal actual value out from D791-1/K1:18 to
Y6020/2
OUTPUT SIDE SHIFT RI, REFERENCE

DIAG ATTACHMENT 12(X) side shift right.
OUTPUT SIDESHIFT RI
REQUIRED VALUE XXX
010089
FEEDBACK XXX Connection: digital out from D791/K1:33 to Y6021/1
Signal value:

NOTE
OUTPUT SIDE SHIFT RI, REQUIRED VALUE

DIAG ATTACHMENT 12(X) valve for output signal, side shift right.
OUTPUT SIDESHIFT RI
REQUIRED VALUE XXX
010089
FEEDBACK XXX Connection: output signal reference value out from D791-1/K1:18 to
Y6021/2
OUTPUT SIDE SHIFT RI, FEEDBACK

DIAG ATTACHMENT 12(X) valve for side shift right.
OUTPUT SIDESHIFT RI
REQUIRED VALUE XXX
010089
FEEDBACK XXX Connection: output signal, actual value out from D791-1/K1:18 to
Y6021/2

NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793

OUTPUT SPREAD LE OUT, REFERENCE

DIAG ATTACHMENT 17(X) spreading, left side out.
OUTPUT SPREAD LE OUT
REFERENCE XY Circuit diagram: Attachment DCF90/100-45E group 7.5_1
REQUIRED VALUE XXX
010087
FEEDBACK XXX Connection: digital out from D791/K1:3 to Y6018L/1
Signal value:

NOTE
OUTPUT SPREAD LE OUT, REQUIRED VALUE

DIAG ATTACHMENT 17(X) valve for output signal spreading left side out.
REQUIRED VALUE XXX
010087
FEEDBACK XXX Connection: output signal, reference value out from D791/K1:16 to
Y6018L/2
OUTPUT SPREAD LE OUT, FEEDBACK

DIAG ATTACHMENT 17(X) valve for spreading, left side out.
REQUIRED VALUE XXX
010087
FEEDBACK XXX Connection: output signal, actual value out from D791/K1:16 to
Y6018L/2

OUTPUT SPREADER LE IN, REFERENCE

DIAG ATTACHMENT 18(X) spreading, left side in.
OUTPUT SPREADER LE IN
REQUIRED VALUE XXX
010090
FEEDBACK XXX Connection: digital out from D791/K1:2 to Y6019L/1
Signal value:

NOTE
OUTPUT SPREADER LE IN, REQUIRED VALUE

DIAG ATTACHMENT 18(X) valve for output signal spreading left side in.
REQUIRED VALUE XXX
010090
FEEDBACK XXX Connection: output signal, reference value out from D791/K1:16 to
Y6019L/2
OUTPUT SPREADER LE IN, FEEDBACK

DIAG ATTACHMENT 18(X) valve for spreading, left side in.
REQUIRED VALUE XXX
010090
FEEDBACK XXX Connection: output signal, actual value out from D791/K1:16 to
Y6019L/2

OUTPUT SPREAD RI OUT, REFERENCE

DIAG ATTACHMENT 19(X) spreading, right side out.
OUTPUT SPREAD RI OUT
REQUIRED VALUE XXX
Connection: digital out from D791/K1:5 to Y6018R/1
010091
FEEDBACK XXX
Signal value:

NOTE
OUTPUT SPREAD RI OUT, REQUIRED VALUE

DIAG ATTACHMENT 19(X) valve for output signal spreading right side out.
REQUIRED VALUE XXX
Connection: output signal, reference value out from D791/K1:17 to
010091
FEEDBACK XXX
Y6018R/2
OUTPUT SPREAD RI OUT, FEEDBACK

DIAG ATTACHMENT 19(X) valve for spreading, right side out.
REQUIRED VALUE XXX
Connection: output signal, actual value out from D791/K1:17 to
010091
FEEDBACK XXX
Y6018R/2


OUTPUT SPREADER RI IN, REFERENCE
DIAG ATTACHMENT 20(X) spreading, right side in.
OUTPUT SPREADER RI IN
REQUIRED VALUE XXX Connection: digital out from D791/K1:4 to Y6019R/1
010092
FEEDBACK XXX
Signal value:

NOTE
OUTPUT SPREADER RI IN, REQUIRED VALUE

DIAG ATTACHMENT 20(X) valve for output signal spreading right side in.
REQUIRED VALUE XXX Connection: output signal, reference value out from D791/K1:17 to
010092
FEEDBACK XXX Y6019R/2

OUTPUT SPREADER RI IN, FEEDBACK

DIAG ATTACHMENT 20(X) valve for spreading, right side in.
REQUIRED VALUE XXX Connection: output signal, actual value out from D791/K1:17 to
010092
FEEDBACK XXX Y6019R/2


PRESENT OUTPUT SIGNAL, BUZZER AUTO 20-40

PRESENT OUTPUT SIGNAL Description: Voltage feed to buzzer, automatic spreading 20'-40'.
Circuit diagram: Attachment DCF90/100-45E group 7.5_2
BUZZER AUTO 20-40 XY
009181

Signal value:
01 No output signal. Error detection only possible when
output signal is active.

8:90 8 Control system – OLS
8.4.10 OLS
OLS, description
DIAGNOSIS
CLIMATE HYD ENGINE
005436
OLS EXTRA
8.4.11 EXTRA
EXTRA, description
DIAGNOSIS
CAN/POWER LIGHTS CAB This menu consists of optional functions:
CLIMATE HYD ENGINE • Reversible driver's seat, VBFS
005440
• Joystick control or mini-wheel, EL-STEERING

OLS EXTRA
• External attachment, EXT-ATTACH
• Freelift, FREELIFT
• Cab tipping, MOVE-CAB
• Auxiliary equipment, OPT
• Inputs and outputs, control units, I/O
• Remote machine interface, RMI
Confirm selections in the main menu with function key for Enter.
8.4.11.1 VBFS
VBFS, description
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
008904
8.4.11.2 EL-STEERING
EL-STEERING, description
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
008911

8 Control system – EXTRA 8:91
8.4.11.3 EXT-ATTACH
EXT-ATTACH, description
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
007625
8.4.11.4 FREELIFT
FREELIFT, description
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
008912
8.4.11.5 MOVE-CAB
MOVE-CAB, description
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
008913
8.4.11.6 OPT
OPT, description
This group covers a number of options.
DIAGNOSIS EXTRA
VBFS EL-STEERING Confirm selections with function key for Enter.
EXT-ATTACH FREELIFT
008914
OPT, menu 1
OPTION SWITCH, S199-1

Description: Signal from switch S199-1.
DIAG OPTION 1(X)
OPTION SWITCH Circuit diagram: Circuit extra equipment group 9.1_1
S199-1 X S199-4 X Connection: signal from S199-1/1 to digital in D790-1/K6:9
S199-2 X
005488
S199-3 X Function: -
Signal value:

0 No signal.

8:92 8 Control system – EXTRA

DIAG OPTION 1(X)
S199-1 X S199-4 X
S199-2 X
005488
Signal value:

0 No signal.

DIAG OPTION 1(X)
S199-1 X S199-4 X
S199-2 X
005488
Signal value:

0 No signal.

DIAG OPTION 1(X)
S199-1 X S199-4 X
S199-2 X
005488
Signal value:

0 No signal.

OPT, menu 2
PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION, FRAME
PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION,

FRAME
Description: Voltage feed to central lubrication of frame.
DIAG OPTION 2(X)
PRESENT OUTPUT SIGNAL Circuit diagram: Circuit std. opt. group 9.0_1 and circuit central
CENTRAL LUBRICATION lubrication group 9.14_1
FRAME XY Connection: digital out from D797-1/K1:42 to M693-1/1
005489
ATTACHMENT XY
Function: 9.14.1 Pump unit
Signal value:
signal is missing.
PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION, ATTACHMENT
PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION,

ATTACHMENT
Description: Voltage feed to central lubrication of attachment.
DIAG OPTION 2(X)
PRESENT OUTPUT SIGNAL Circuit diagram: Attachment DCF90/100-45E group 9.14_1
CENTRAL LUBRICATION Connection: digital out from D791-1/K1:14 to M693/1
FRAME XY
005489
ATTACHMENT XY Function: 9.14.1 Pump unit

Signal value:
OPT, menu 3
PRESENT OUTPUT SIGNAL, D797-1 C1 P42

Description: Voltage feed from D797-1/K1:42.
DIAG OPTION 3(X)
D797-1 C1 P42 XY Connection: digital out D797-1/K1:42
005490
Function: -
Signal value:
signal is missing.

8:94 8 Control system – EXTRA
OPT, menu 4
OPT, menu 5

DIAG OPTION 5(X)
D791-1 C1 P14 XY
Connection: digital out from D791-1/K1:14
D791-1 C1 P28 XY
005492
Function: -
Signal value:


DIAG OPTION 5(X)
D791-1 C1 P14 XY
Connection: digital out from D791-1/K1:28
D791-1 C1 P28 XY
005492
Function: -
Signal value:

signal is missing.
8.4.11.7 I/O
I/O, description
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
I/O RMI
MOVE-CAB OPT I/O
015099

8.4.11.8 RMI
RMI, description
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
007657

8:96 8 Control system – Setup
8.5 Setup
Setup, general
Settings are built-in functions to adapt the functions to the unique
machine individual. Settings are performed via menus in the display.
Settings are divided into initialization and calibration.
Initiation
Initiation, which involves setting start and stop currents for the steering
and hydraulic functions, is performed before the machine is used in
work. This is carried out in order to compensate for mechanical and
electrical tolerances (variations between different machines).
Calibration
Calibration is performed after the machine has started to be used for
work, after replacement of control units, and in certain cases, service or
replacement of components. Calibration is performed so that certain
functions shall function properly and show correct values.
8.5.1 Initialization
Initiation, description
1 2
DANGER
INIT ELSERVO 1(X)
START CURRENT
LIFT The settings influence the functions. Adjustments
4 STORED VALUE XXXmA may impair the function.
3
008891
PRESENT VALUE XXXmA If uncertain, contact Cargotec Service.
Example of initiation menu, start current for lift

function.
1. Menu group
NOTE
2. Menu number. The number of menus depends Initiation does not need to be performed in one process but each
on the equipment fitted to the machine. For this step can be performed separately, independently of other steps.
reason, number of menus is indicated with (X)
in this manual. In order that hydraulic functions shall work satisfactorily and safely,
3. Signal value certain values must be set to operate the machine, this is known as
initiation.
4. Actual variable
Initiation consists of several menus grouped according to functions.
Each individual menu sets a specific variable. The menus are similar in
structure and use a common terminology explained here:
PRESENT
Displays the stored value when the menu is opened. Adjust the value
with the plus and minus keys. Store the set value with the Enter key.
Go to the next menu with the arrow keys. Go back with the R-key.

8 Control system – Initialization 8:97
STORED
STORED
States the stored value for the current variable.
I [mA] START CURRENT

Specifies the start current to the solenoid valve for the selected function.
1
The start current is the lowest current that can be actuated. In practice,
2 it controls how slowly a function can be operated. On functions with
analogue control/activation (controllable), e.g. lift, this is the current
3
006299
that is triggered when the lever leaves the zero position. On certain
t [s] functions with digital activation (off/on) which are soft-started, this is the
1. Max. current (END CURRENT) current which is triggered immediately the function is activated.
2. Damping (PROC DAMPING) END CURRENT

3. Start current (START CURRENT) Specifies the max. current to the solenoid valve for the selected
function. The max. 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 position. On
certain functions with digital activation (off/on) which are soft-started,
this is the current which is triggered after the ramp time when the
function is activated. The interval between START CURRENT and
END CURRENT is the active range for controlling the solenoid valve.
PROC DAMPING
Specifies how much the control current shall be reduced during
damping. The interval is specified as 0-100% of the active range
between START CURRENT and END CURRENT.
Function Menu
1 Engine, speed limitation INIT DRIVE-TRAIN, menu 9, page
8:112
1 Engine, automatic engine shut-down on idle INIT DRIVE-TRAIN, menu 11, page
8:112
1 Engine, automatic engine speed increase for lifting INIT DRIVE-TRAIN, menu 13, page
8:113
2 Transmission, starting gear INIT DRIVE-TRAIN, menu 1, page
8:110
2 Transmission, speed limitation (gear lock-out) INIT DRIVE-TRAIN, menu 10, page
8:112
2 Transmission, automatic engine speed reduction for shift forward - reverse INIT DRIVE-TRAIN, menu 12, page
8:113
7.2 Lifting/lowering, lift mast INIT ELSERVO, menu 1, page 8:99
INIT ELSERVO, menu 2, page 8:99
7.2 Lifting/lowering, lower mast INIT ELSERVO, menu 3, page 8:100
Comment: The current value is for unladen machines. When loaded, the current INIT ELSERVO, menu 4, page 8:100
value is controlled by the limited lowering speed.
7.4 Side shift INIT ATTACH, menu 5, page 8:106
INIT ATTACH, menu 6, page 8:106
7.5 Spreading out INIT ATTACH, menu 9, page 8:107

8:98 8 Control system – Initialization
Function Menu
7.5 Spreading in INIT ATTACH, menu 12, page 8:108
7.7 Tilt INIT ELSERVO, menu 5, page 8:100
INIT ELSERVO, menu 6, page 8:101
Initiate hydraulic function, work instruction

To select a hydraulic function to initiate, proceed as follows:
All hydraulic functions are initiated in the same way.

1 Navigate to the service menu.
2 Press Enter.
000056
3 Enter the code for initiation.

1 23
4 5 NOTE
000060

4 Select group by scrolling with the arrow keys (1 and 2) and confirm
INITIATION with Enter.
ELSERVO ATTACHMENT
Each initiation consists of a sequence of a number of menus. The
STEERING DRIVE-TRAIN first menu for the selected initiation opens in the display. Select
SLIDING-CAB the desired menu with the arrow keys (1 and 2).
007169
RETURN
5 Change the current value with the plus and minus keys.
INIT ELSERVO 1(X)
START CURRENT NOTE
LIFT
STORED VALUE XXXmA Current values can only be adjusted within specific limits.
005494
PRESENT VALUE XXXmA

6 Use the function key for Enter to store the desired current value
setting, "STORED".

8.5.1.1 ELECTRIC SERVO
INIT ELSERVO
The menu group for this function covers initiation of the electric servo
INITIATION functions for load handling.
ELSERVO ATTACHMENT
STEERING DRIVE-TRAIN The settings for lift, lower, tilt in, tilt out are made here. For other load
SLIDING-CAB handling functions, see INIT ATTACH, page 8:105.
007169
RETURN
DANGER
The settings influence the functions. Adjustments
may impair the function.
If uncertain, contact Cargotec Service.
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
INIT ELSERVO, menu 1

START CURRENT, LIFT
START CURRENT, LIFT

INIT ELSERVO 1(X)
START CURRENT Description: Start current for activation of solenoid valve, lift mast
LIFT (Y6005).
STORED VALUE XXXmA
005494
PRESENT VALUE XXXmA PRESENT VALUE: indicates the current value for the start current.
Adjust the value with the plus and minus keys. Store the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Component: Solenoid valve, lift mast (Y6005)
Signal value: XXXmA = 0 - 999 mA.

END CURRENT, LIFT
END CURRENT, LIFT

INIT ELSERVO 2(X)
END CURRENT Description: Control current on full lever actuation for the activation of
LIFT the solenoid valve for mast lift (Y6005).
STORED VALUE XXXmA
005495
PRESENT VALUE XXXmA PRESENT VALUE: indicates the current value for max. current. Adjust
the value with the plus and minus keys. Store the set value with the
Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for max. current.
Component: Solenoid valve, lift mast (Y6005)


START CURRENT, LOWER
START CURRENT, LOWER

INIT ELSERVO 3(X)
START CURRENT Description: Start current for activation of solenoid valve, lower mast
LOWER (Y6004).
STORED VALUE XXXmA
005496
with the R-key.
Component: Solenoid valve, lower mast (Y6004)

END CURRENT, LOWER
END CURRENT, LOWER

INIT ELSERVO 4(X)
LOWER the solenoid valve for mast lower (Y6004).
STORED VALUE XXXmA
005497
with the R-key.
Component: Solenoid valve, mast (Y6004)

START CURRENT, TILT IN
START CURRENT, TILT IN

INIT ELSERVO 5(X)
START CURRENT Description: Start current for the activation of the solenoid valve for
TILT IN tilt in (Y6011).
STORED VALUE XXXmA
007139
with the R-key.
Component: Solenoid valve, tilt in (Y6011)


END CURRENT, TILT IN
END CURRENT, TILT IN

INIT ELSERVO 6(X)
TILT IN the solenoid valve for tilt in (Y6011).
STORED VALUE XXXmA
007140
with the R-key.
Component: Solenoid valve, tilt in (Y6011)

START CURRENT, TILT OUT
START CURRENT, TILT OUT

INIT ELSERVO 7(X)
START CURRENT Description: Start current for the activation of the solenoid valve for
TILT OUT tilt out (Y6010).
STORED VALUE XXXmA
007141
with the R-key.
Component: Solenoid valve, tilt out (Y6010)

END CURRENT, TILT OUT
END CURRENT, TILT OUT

INIT ELSERVO 8(X)
TILT OUT the solenoid valve for tilt out (Y6010).
STORED VALUE XXXmA
007142
with the R-key.
Component: Solenoid valve, tilt out (Y6010)


START CURRENT, SIDE SHIFT LE/RI
START CURRENT, SIDE SHIFT LE/RI

INIT ELSERVO 9(X)
START CURRENT Description: Start current of activation of solenoid valve for side shift
SIDESHIFT LE/RI left (Y6020) and solenoid valve for side shift right (Y6021).
STORED VALUE XXXmA
007143
with the R-key.
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021)

END CURRENT, SIDE SHIFT LE/RI
END CURRENT, SIDE SHIFT LE/RI

INIT ELSERVO 10(X)
END CURRENT Description: Control current at full lever actuation for activation of
SIDESHIFT LE/RI solenoid valve for side shift left (Y6020) and solenoid valve for side
STORED VALUE XXXmA shift right (Y6021).
007144
PRESENT VALUE XXXmA

PRESENT VALUE: indicates the current value for max. current. Adjust
with the R-key.
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021)

START CURRENT, SPREADING IN/OUT
START CURRENT, SPREADING IN/OUT

INIT ELSERVO 11(X)
START CURRENT Description: Start current for activation of solenoid valve for spreading
SPREADING IN/OUT in (Y6019) and solenoid valve for spreading out (Y6018).
STORED VALUE XXXmA
007145
with the R-key.
Component: Solenoid valve for spreading in (Y6019) and solenoid

valve for spreading out (Y6018)


END CURRENT, SPREADING IN/OUT
END CURRENT, SPREADING IN/OUT

INIT ELSERVO 12(X)
END CURRENT Description: Control current at full lever actuation for activation
SPREADING IN/OUT of solenoid valve for spreading in (Y6019) and solenoid valve for
STORED VALUE XXXmA spreading out (Y6018).
007146
PRESENT VALUE XXXmA
PRESENT VALUE: indicates the current value for max. current. Adjust
with the R-key.
Component: Solenoid valve for spreading in (Y6019) and solenoid

valve for spreading out (Y6018)

START CURRENT, LIFT 2
START CURRENT, LIFT 2

INIT ELSERVO 13(X)
START CURRENT Description: Start current for activation of solenoid valve, lift trolley
LIFT 2 (Y6022).
STORED VALUE XXXmA
007147
with the R-key.
Component: Solenoid valve trolley (Y6022)

END CURRENT, LIFT 2
END CURRENT, LIFT 2

INIT ELSERVO 14(X)
LIFT 2 the solenoid valve for lift trolley (Y6022).
STORED VALUE XXXmA
007148
with the R-key.
Component: Solenoid valve trolley (Y6022)


START CURRENT, LOWER 2
START CURRENT, LOWER 2

INIT ELSERVO 15(X)
START CURRENT Description: Start current for activation of solenoid valve, lower trolley
LOWER 2 (Y6023).
STORED VALUE XXXmA
007149
with the R-key.
Component: Solenoid valve, lower trolley (Y6023)

END CURRENT, LOWER 2
END CURRENT, LOWER 2

INIT ELSERVO 16(X)
LOWER 2 the solenoid valve for lower trolley (Y6023).
STORED VALUE XXXmA
007150
with the R-key.
Component: Solenoid valve, lower trolley (Y6023)

DAMP (PROC), LIFT
DAMP (PROC), LIFT

INIT ELSERVO 17(X)
DAMP (PROC) Description: Percentage damping of control current to solenoid valve
LIFT for mast lift (Y6005) when the mast reaches max height.
STORED VALUE XX
PRESENT VALUE XX PRESENT VALUE: indicates the current value for damping. Adjust
I [mA] Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
1
STORED VALUE: indicates stored value in percent.
2
3 Function: 7.2.5 Control valve, lift and tilt
007151
t [s] Component: Solenoid valve, lift mast (Y6005)

1. Max. current (END CURRENT) Signal value: XXX = 0 - 100%. 100% means no damping i.e. max.
2. Damping (PROC DAMPING) current. 0% means full damping i.e. start current.
3. Start current (START CURRENT)

8.5.1.2 ATTACHMENT
INIT ATTACH
This function handles initialization of the attachment functions side
INITIATION shift and spreading.
ELSERVO ATTACHMENT
STEERING DRIVE-TRAIN
SLIDING-CAB
DANGER
007170
RETURN

NOTE
INIT ATTACH, menu 1

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793
INIT ATTACH, menu 2

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793
INIT ATTACH, menu 3

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793

INIT ATTACH, menu 4

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793 INIT ATTACH, menu 5

START CURRENT, SIDE SHIFT
START CURRENT, SIDE SHIFT

Description: Start current of activation of solenoid valve for side shift
INIT ATTACH 5(X) left (Y6020) and solenoid valve for side shift right (Y6021).
START CURRENT
SIDESHIFT PRESENT VALUE: indicates the current value for the start current.
STORED VALUE XXXmA Adjust the value with the plus and minus keys. Store the set value with
005513
PRESENT VALUE XXXmA the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.

Component: Solenoid valve for side shift left (Y6020), Solenoid valve
for side shift right (Y6021)
Signal value: XXXmA = 0 - 999 mA
INIT ATTACH, menu 6

END CURRENT, SIDE SHIFT
END CURRENT, SIDE SHIFT

Description: Control current at full lever actuation for activation of
INIT ATTACH 6(X) solenoid valve for side shift left (Y6020) and solenoid valve for side
END CURRENT shift right (Y6021).
SIDESHIFT
STORED VALUE XXXmA PRESENT VALUE: indicates the current value for max. current. Adjust
005514
PRESENT VALUE XXXmA the value with the plus and minus keys. Store the set value with the
with the R-key.
Component: Solenoid valve for side shift left (Y6020), Solenoid valve
for side shift right (Y6021)
INIT ATTACH, menu 7

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793

INIT ATTACH, menu 8

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793
INIT ATTACH, menu 9
START CURRENT, SPREADER OUT, 20'-40'
START CURRENT, SPREADER OUT, 20'-40'

Description: Start current for activation of solenoid valve for spreading
INIT ATTACH 9(X) out left (Y6018L) and solenoid valve for spreading out right (Y6018R).
START CURRENT
SPREADER OUT, 20'-40' PRESENT VALUE: indicates the current value for the start current.
with the R-key.
I [mA]
1
2
Component: Solenoid valve, spreading out 20'-40' (Y6018)
3
005517
t [s] Signal value: XXXmA = 0 - 999 mA

1. Max. current (END CURRENT)
2. Damping (PROC DAMPING)
INIT ATTACH, menu 10

END CURRENT, SPREADER OUT, 20'-40'
END CURRENT, SPREADER OUT, 20'-40'

INIT ATTACH 10(X) solenoid valve for spreading out left (Y6018L) and solenoid valve for
END CURRENT spreading out right (Y6018R).
SPREADER OUT, 20'-40'
I [mA] with the R-key.
1 STORED VALUE: indicates stored value for max. current.
2 Function: 7.5.2 Control valve attachment
3
005518
Component: Solenoid valve for spreading out left (Y6018L) and

t [s] solenoid valve for spreading out right (Y6018R).


DAMP (PROC), SPREADER OUT, 20'-40'
DAMP (PROC), SPREADER OUT, 20'-40'

Description: Percentage damping of control current to solenoid valve
INIT ATTACH 11(X) for spreading out left (Y6018L) and solenoid valve for spreading out
DAMP PROC right (Y6018R) when spreading out approaches 40'.
SPREADER OUT, 20’-40’
STORED VALUE XX PRESENT VALUE: indicates the current value for damping. Adjust
PRESENT VALUE XX the value with the plus and minus keys. Store the set value with the
1 STORED VALUE: indicates stored value in percent.
3
014600
Component: Solenoid valve for spreading out left (Y6018L) and

t [s] solenoid valve for spreading out right (Y6018R).
Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max.
2. Damping (PROC DAMPING) current. 0% means full damping, i.e. start current

START CURRENT, SPREADER IN, 40'-20'
START CURRENT, SPREADER IN, 40'-20'

Description: Start current for activation of solenoid valve for spreading
INIT ATTACH 12(X) in left (Y6019L) and solenoid valve for spreading in right (Y6019R).
START CURRENT
SPREADER IN, 40'-20' PRESENT VALUE: indicates the current value for the start current.
with the R-key.
I [mA]
1
2
Component: Solenoid valve for spreading in left (Y6019L) and solenoid
3
005520
valve for spreading in right (Y6019R).

t [s]


END CURRENT, SPREADER IN, 40'-20'
END CURRENT, SPREADER IN, 40'-20'

INIT ATTACH 13(X) solenoid valve for spreading in left (Y6019L) and solenoid valve for
END CURRENT spreading in right (Y6019R).
SPREADER IN, 40'-20'
1 STORED VALUE: indicates stored value for max. current.
3 005521
t [s] valve for spreading in right (Y6019R).
1. Max. current (END CURRENT) Signal value: XXXmA = 0 - 999 mA

DAMP (PROC), SPREADER IN, 40'-20'
DAMP (PROC), SPREADER IN, 40'-20'

Description: Percentage damping of control current to solenoid valve
INIT ATTACH 14(X) for spreading in left (Y6019L) and solenoid valve for spreading in right
DAMP PROC (Y6019R) when spreading in approaches 20'.
SPREADER IN, 40’-20’
STORED VALUE XX PRESENT VALUE: indicates the current value for damping. Adjust
PRESENT VALUE XX the value with the plus and minus keys. Store the set value with the
1 STORED VALUE: indicates stored value in percent.
3
014704

t [s] valve for spreading in right (Y6019R).
Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max.
2. Damping (PROC DAMPING) current. 0% means full damping, i.e. start current
8.5.1.3 STEERING
INIT STEERING
INITIATION
ELSERVO ATTACHMENT
SLIDING-CAB
007171
RETURN

8.5.1.4 DRIVE-TRAIN
INIT DRIVE-TRAIN
This function covers engine and transmission initiation.
INITIATION
ELSERVO ATTACHMENT
SLIDING-CAB DANGER
007172
RETURN
NOTE
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.
INIT DRIVE-TRAIN, menu 1

START IN 1:ST
START IN 1:ST
INIT DRIVE-TRN 1(X)
START IN 1:ST Description: Setting to get transmission to always start in 1st gear.
1=YES 0=NO
PRESENT VALUE: indicates the current setting. Change the value with
STORED VALUE XXX
the plus and minus keys. Save the set value with the Enter key. Go to
013915
PRESENT VALUE XXX

the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Component: -
Signal value: XXX = 1= yes, XXX = 0 = no

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793


NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793


NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793
OPTION SPEED LIMIT
OPTION SPEED LIMIT

INIT DRIVE-T 9(X)
OPTION SPEED LIMIT
(km/h) Description: Setting of speed limitation.
STORED VALUE XXX
005587
PRESENT VALUE XXX PRESENT VALUE: indicates the current setting. Change the value with
Component: -
Signal value: XXX = speed (km/h)

OPTION HIGHEST GEAR AT SPEED LIMIT
OPTION HIGHEST GEAR AT SPEED LIMIT

INIT DRIVE-T 10(X)
OPTION HIGHEST GEAR
AT SPEED LIMIT Description: Setting of highest permissible gear (speed limitation
STORED VALUE XXX through blocked gears).
005588
PRESENT VALUE XXX

Component: -
Signal value: XXX = gear

OPTION ENGINE SHUT DOWN
OPTION ENGINE SHUT DOWN

INIT DRIVE-T 11(X)
OPTION ENGINE SHUT
DOWN AT IDLE (sec) Description: Setting of idle time prior to automatic engine shutdown.
STORED VALUE XXX
005589
PRESENT VALUE XXX PRESENT VALUE: indicates the current setting. Change the value with
Function: 1 Engine
Component: -
Signal value: XXX = time in seconds before engine shutdown.


F-R WITHOUT ENGINE SPEED REDUCTION
F-R WITHOUT ENGINE SPEED REDUCTION

INIT DRIVE-T 12(X)
F-R WITHOUT ENGINE Description: Activation or deactivation of automatic engine speed
SPEED REDUCTION reduction when changing direction of travel forward - reverse. This
STORED VALUE X makes it possible to change direction of travel without releasing the
005590
PRESENT VALUE X accelerator pedal. Engine speed drops to that set in menu 3, see
INIT DRIVE-TRAIN, menu 3, page 8:111. If no value is set in menu 3,
engine speed is reduced to idle speed.
Component: -
Signal value:
X = 1, activated
X = 0, deactivated

AUTO ENGINE SPEED AT LIFT
AUTO ENGINE SPEED AT LIFT

INIT DRIVE-T 13(X)
AUTO ENGINE SPEED AT
LIFT
STORED VALUE X Description: Activation or deactivation of automatic engine speed
005591
PRESENT VALUE X increase during lift.
Function: 1 Engine
Component: -
Signal value:
X = 1, activated
X = 0, deactivated

8:114 8 Control system – Calibration
8.5.1.5 SLIDING-CAB
NOT USED
XXXXXXX X(X)
NOT USED
008793 8.5.2 Calibration

Calibration, description
Certain functions require calibration in order to operate correctly. The
control system has integrated calibrations for these functions.
SCALE
SCALE
CALIBRATION
SCALE STEERING
DRIVE-TRAIN RETURN
000062
STEERING
STEERING
CALIBRATION
SCALE STEERING
DRIVE-TRAIN RETURN
000074
DRIVE-TRAIN
DRIVE-TRAIN
This function handles calibration for engine and transmission. The
CALIBRATION menu loop contains two different calibrations are not linked to each
other, see:
SCALE STEERING
DRIVE-TRAIN RETURN Accelerator pedal, calibration, page 8:117
000078
NOTE

8 Control system – Calibration 8:115
Calibration menu, explanation
Calibration menu, explanation
1 2 The illustration shows an example of a menu, here for the calibration of

the centre position for lever joystick control. The table indicates what a
description contains (which follows in the next section):
5 CALIBR STEERING 1(X)
STEERING LEVER CENTER
POSITION
4 STORED VALUE X.XXV
3
008892
PRESENT VALUE X.XXV
1. Menu group
2. Sequence number. The number of menus
depends on the equipment fitted to the machine.
For this reason, number of menus is indicated
with (X) in this manual.
3. Signal value
4. STORED indicates stored value, PRESENT
indicates the current value of the signal to be
calibrated
5. Heading of menu figure
Designation: Example Description

Variable (position 5): STEERING Name of the input
LEVER CENTRE POSITION signal/control signal affected.
Description: Setting the centre A short description of what is
position for lever joystick control calibrated and the meaning
(R825). of the variables.
STORED VALUE: Gives the stored
signal value for lever steering
control (R825), centre position.
PRESENT VALUE: Gives the
present signal value for lever
steering control (R825), centre
position.
Function: 5.2 Power-assisted Name of current function.
steering system
Component: Lever joystick control Indicates the component
(R825) whose signal is the basis for
calibration.
Calibration, work instructions

Calibration consists of a number of menus, the number of menus
depends on the function. All menus are similar in structure and
therefore the descriptions are similar.
To select a function to calibrate, proceed as follows:

1 Navigate to the service menu.
2 Press Enter.
000056

3 Enter the code for calibration.

1 23
4 5 NOTE
000060
4 Select group by scrolling with the arrow keys (1 and 2) and confirm
CALIBRATION with Enter.
Each calibration consists of a sequence of a number of menus.
SCALE STEERING The first menu for the selected calibration opens in the display.
DRIVE-TRAIN RETURN Select the next menu with key 1 and 2 (arrow function).
000062

8 Control system – Calibration 8:117
8.5.2.3 Calibrate DRIVE-TRAIN
Accelerator pedal, calibration

1 Start key in operating position, engine switched off.
DRIVE-TRAIN, menu 1
2 Go into the calibration menus and select DRIVE-TRAIN, menu 1,
CALIBR DRIVE-TRN 1(X) see Calibration, work instructions, page 8:115.
ACCELERATOR, ACCELERATOR, RELEASE THE PEDAL
RELEASE THE PEDAL
STORED VALUE X.XXV Description: setting the accelerator's pedal zero position.
005532
PRESENT VALUE X.XXV STORED VALUE: Indicates current calibrated control value from
accelerator pedal (R690-1).
PRESENT VALUE: indicates the current signal value from
Accelerator pedal (B690-1).
Function: 1 Engine
Component: Accelerator pedal (B690-1).
3 Release the accelerator pedal.
4 Store the position with function key for Enter.
DRIVE-TRAIN, menu 2
5 ACCELERATOR, PRESS THE PEDAL TO FLOOR
CALIBR DRIVE-TRN 2(X) Description: Setting of full-throttle position for Accelerator pedal
ACCELERATOR, PRESS (B690-1).
THE PEDAL TO FLOOR STORED VALUE: Indicates current calibrated control value from
STORED VALUE X.XXV accelerator pedal (R690-1).
PRESENT VALUE X.XXV
PRESENT VALUE: indicates the current signal value from
00
Accelerator pedal (B690-1).

Function: 1 Engine
Component: Accelerator pedal (B690-1).
6 Press the accelerator pedal down fully and keep it down until the
position is stored.
7 Store the position with function key for Enter.

8:118

9:1
Contents 9 Frame, body, cab and accessories

9 Frame, body, cab and accessories .................................................................. 9:3
9.1.1 Gear selector and multi-function lever.........................................................9:8
9.1.22 Switch, direction indicators..........................................................................9:9
9.2 Safety and emergency equipment .................................................................9:10
9.2.1 Control breaker .........................................................................................9:10
9.2.2 Seat belt ....................................................................................................9:10
9.2.3 Fire extinguisher........................................................................................9:10
9.2.4 Seat buzzer ...............................................................................................9:10
9.3 Seat................................................................................................................ 9:11
9.3.1 Seat cushion .............................................................................................9:13
9.3.2 Back rest cushion ......................................................................................9:13
9.3.3 Heating coil ...............................................................................................9:14
9.3.4 Bumper......................................................................................................9:15
9.3.5 Air suspension...........................................................................................9:15
9.3.6 Compressor air-suspension seat...............................................................9:15
9.3.7 Mechanical seat adjustment......................................................................9:16
9.3.8 Passenger seat .........................................................................................9:16
9.3.9 Arm rest.....................................................................................................9:16
9.3.14 Sensor, operator-in-seat............................................................................9:17
9.4 Heating, ventilation and air conditioning ........................................................9:18
9.4.1 Fresh air filter ............................................................................................9:25
9.4.2 Fresh air filter or recirculation damper.......................................................9:26
9.4.3 Cab fan......................................................................................................9:29
9.4.4 Heat exchanger heat .................................................................................9:32
9.4.5 Water valve ...............................................................................................9:35
9.4.6 Sensor, engine temperature ......................................................................9:35
9.4.7 Compressor...............................................................................................9:36
9.4.8 Condenser.................................................................................................9:39
9.4.9 Moisture filter.............................................................................................9:41
9.4.10 Pressure switch .........................................................................................9:41
9.4.11 Expansion valve ........................................................................................9:42
9.4.12 Sensor, temperature refrigerant ................................................................9:43
9.4.13 Heat exchanger, cooling............................................................................9:45
9.4.14 Air distributor .............................................................................................9:46
9.4.15 Defroster nozzles ......................................................................................9:47
9.4.16 Sensor, temperature outlet fan ..................................................................9:48
9.4.17 Sensor cab temperature............................................................................9:49
9.4.18 Sensor, ambient temperature ....................................................................9:50
9.5 Wiper/washer system.....................................................................................9:51
9.5.1 Wiper front.................................................................................................9:51
9.5.2 Wiper roof..................................................................................................9:51
9.5.3 Wiper rear .................................................................................................9:51
9.5.4 Washer motor and reservoir......................................................................9:51
9.5.5 Wiper motor front ......................................................................................9:52
9.5.6 Wiper motor roof .......................................................................................9:53
9.5.7 Wiper motor rear .......................................................................................9:54
9.6 Lighting system ..............................................................................................9:55
9.6.1 Headlights .................................................................................................9:59
9.6.2 Running lights ...........................................................................................9:59
9.6.3 Tail lights ...................................................................................................9:59
9.6.4 Brake light .................................................................................................9:59
9.6.5 Back-up lights............................................................................................9:59
9.6.6 Direction indicators....................................................................................9:60
9.6.7 Flashing hazard lights ...............................................................................9:60

9.6.8 Revolving beacon......................................................................................9:60

9.6.9 Working lights, mast ..................................................................................9:60
9.6.10 Working lights, cab ....................................................................................9:61
9.6.11 Interior lighting...........................................................................................9:61
9.6.12 Working lights, attachment ........................................................................9:62
9.6.14 Work lights, front wing ...............................................................................9:62
9.7 Signalling system ...........................................................................................9:63
9.7.1 Horn ..........................................................................................................9:65
9.7.2 Flashing hazard lights ...............................................................................9:65
9.7.3 Revolving beacon......................................................................................9:66
9.7.4 Warning parking brake ..............................................................................9:66
9.7.5 Reverse alarm ...........................................................................................9:66
9.8 Entertainment and communication ................................................................9:67
9.9 Glass/windows/mirrors...................................................................................9:68
9.9.1 Windscreen ...............................................................................................9:69
9.9.2 Side window ..............................................................................................9:71
9.9.3 Roof window..............................................................................................9:73
9.9.4 Rear window .............................................................................................9:74
9.9.5 Rear view mirror ........................................................................................9:74
9.10 Cab structure and suspension .......................................................................9:75
9.10.1 Cab frame .................................................................................................9:75
9.10.2 Doors.........................................................................................................9:75
9.10.3 Cab substructure .......................................................................................9:76
9.11 Cab interior ....................................................................................................9:77
9.11.1 Instrument and control panels ...................................................................9:77
9.11.2 Interior fittings, plastic ...............................................................................9:78
9.11.3 Interior fittings, textile ................................................................................9:78
9.11.4 Floor covering ...........................................................................................9:78
9.11.5 Insulation ...................................................................................................9:78
9.11.7 Terminal console .......................................................................................9:79
9.11.8 Writing desk...............................................................................................9:79
9.11.9 Reading-lamp ............................................................................................9:79
9.12 Frame.............................................................................................................9:80
9.13 Body structure................................................................................................9:81
9.13.1 Wings ........................................................................................................9:81
9.13.2 Hood engine compartment ........................................................................9:81
9.13.3 Footsteps and hand rail.............................................................................9:81
9.13.4 Counterweights .........................................................................................9:82
9.14 Central lubrication ..........................................................................................9:83
9.14.1 Pump unit ..................................................................................................9:85
9.14.2 Distribution block .......................................................................................9:85
9.14.3 Lines..........................................................................................................9:86
9.15 Paint/coatings ................................................................................................9:87

9 Frame, body, cab and accessories – Frame, body, cab and accessories 9:3
9 Frame, body, cab and

accessories
Controls and instruments, overview
Overview
Overview
1 2 3 4 5
15
12 13 12 11 10 9 8 7 6
14
015102
1. Left dashboard panel
2. Gear selector and multi-function lever (S162)
3. Steering panel
4. Steering wheel
5. Switch direction indicators (S161)
6. Panel for hydraulic functions
7. Emergency stop switch for hydraulics (S250)
8. Switch for parking brake (S107)
9. Control lever (S815)
10. Driver's seat
11. Accelerator pedal (B690)
12. Brake pedals
13. Declutch pedal (S220-1)
14. Electronic box with fuses and relays
15. Hour meter (P708)

9:4 9 Frame, body, cab and accessories – Controls and instruments
Left-hand dashboard panel
Left-hand dashboard panel

16. Switch for fan (S118)
17. Switch for heating (S117)
18. Switch for air distribution (S139)
29 30 31 19. Switch for working lights cab roof (S105-1)
24..28
20. Switch, work lights on carriage and attachment (S105-2)
19..23 Auxiliary work lights, carriage and attachment
18 21. Switch for work lights on mast (S105-3)
17
010907
Auxiliary work lights, mast
16
22. Switch for revolving beacon (S110)
Left dashboard panel
23. Switch for flashing hazard lights (S109)
24. Switch for headlights (S100)
25. Spare
26. Spare
27. Spare
28. Spare
29. Spare
30. Spare
31. Socket 12 VDC

9 Frame, body, cab and accessories – Controls and instruments 9:5
Steering panel
Steering panel
32. Warning lamp, low battery charging
36
35 33. Warning lamp for low brake pressure
34
33 34. Indicator for active error codes
32
35. Warning lamp, by-pass of hydraulic functions
36. Not used
37. Warning lamp, high coolant temperature
37..41 38. Warning light, low oil pressure engine
49
39. Indicator light for preheating
42..46 40. Warning lamp for low coolant level engine
47 48 41. Warning lamp for high transmission oil temperature
42. Warning lamp, low fuel level
43. Warning lamp, high temperature hydraulic oil
44. Indicator light, high beams
50 51 52 53
45. Indicator light, travel direction indication
46. Indicator light, parking brake
47. Indicator light, locked twistlock (secured load)
48. Indicator light, alignment (attachment / load)
49. Indicator light, unlocked twistlock (load released)
50. Panel, warning and indicator lights
51. Control system display
64 52. Control system indicator
54
63 53. Ignition
55
62 54. Switch for defroster
56
55. Switch, windscreen wiper roof, interval
008132
61 60 59 58 57
56. Switch, windscreen wiper roof, continuous
Steering panel 57. Switch, interior lighting
58. Switch, windscreen wiper rear, interval
59. Switch, windscreen wiper rear, continuous
60. Control system function keys
61. Travel direction indicator, Forward Neutral Reverse
62. Shifting program A, automatic shifting
63. Shifting program 1, locked to 1st gear
64. Shifting program 2, locked to 2nd gear

9:6 9 Frame, body, cab and accessories – Controls and instruments
Panel for hydraulic functions
Panel for hydraulic functions

65. Lift/lower (R8071)
68 66. Tilt (R8072)
67. Side shift (R8073)
70
68. Opening the twistlocks (S1002)
72
69. Switch, horn (S149)
70. Switch for twistlock, automatic/manual locking (S1003)
74
71. Switch, spreading 20'-40' (attachment) (S1012)
72. Switch for stopping spreading at 30' (attachment) (S1004)
74
73. Switch, automatic spreading 20'-40' (S1012-2)
73
74. Switch for bypassing of hydraulic functions (S1005)
Key for bypassing hydraulic functions
014179
8 7 69
Panel for hydraulic functions and control lever
65
66
68 67
7
69
70
71
72
73
014178
8 74 74
Panel for hydraulic functions and linear control levers

9 Frame, body, cab and accessories – Controls and instruments 9:7
Operating menus, overview
1 2 3 4
9 8 7 6
10
014668
11 12 13 14
1. Engine and transmission operating menu 8. Service operating menu
2. Engine operating menu 9. Operating menu heating and air conditioning
3. Operating menu for oil temperature 10. Operating menu, code lock
4. Operating menu electrical system 11. Operating menu statistics, operating hours
5. Operating menu, container counter 12. Operating menu statistics, fuel consumption
6. Operating menu service interval 13. Operating menu statistics, driving distance
7. Operating menu statistics 14. Operating menu statistics, lift statistics
Event menus overview
Event menus overview

Side lift attachment with twistlocks
1 2 3 4
014669
1. Event menu, twistlock alignment

2. Event menu twistlocks
3. Event menu open door
4. Event menu automatic spreading

9:8 9 Frame, body, cab and accessories – Gear selector and multi-function lever
9.1.1 Gear selector and multi-function lever

Gear selector and multi-function lever, description
Movement
The following functions are handled by the gear and multi-function

2 lever (position 2).
3 1
0 Move-
ment Function
Forward/ Travel direction (for selecting shifting program and
Reverse travel direction, see section 2 Transmission).
000338
Inward, Washing of windscreen, roof window and rear
handle window.
The signal can be checked via the diagnostic menu.
see section 8 Control system, group 8.4.3.1 CAB,
menu 1.
Rotation Windscreen wiper, front.
0 – No wiping of front window. If wiper rear or roof
are active then these run at slow interval wiping.
1 – Slow interval wiping front window, controls slow
interval wiping for roof window and rear window.
2 – Fast interval wiping front window, controls fast
interval wiping for roof window and rear window.
3 - Continuous wiping of front window. If wiper rear or
roof are active then these run at fast interval wiping.
The signal can be checked via the diagnostic menu.
See section 8 Control system, group 8.4.3.2 CAB,
menu 2.
Upward Light signal

Down- High beam (on/off)
ward With headlights on: The gear selector multi-function
lever are used for switching between high and low
beam.
With headlights off: The gear selector and
000339
A multi-function lever are used to flash with the

headlights.
The signal can be checked via the diagnostic
menu. See section 8 Control system, group 8.4.2.3
LIGHTS, menu 3.
Inward, Horn (position A).
button The signal can be checked via the diagnostic menu.
See section 8 Control system, group 8.4.3.5 CAB,
menu 5.

9 Frame, body, cab and accessories – Switch, direction indicators 9:9
Gear selector and multi-function lever, replacement

1 Separate the steering wheel panel.
6 attaching bolts and 2 bolts to the steering wheel shaft.
Remove the steering wheel, see Steering wheel panel,
2 Undo the attaching bolts (2 x hexagonal socket bolts).
3 Unplug the connector from Control unit KIT (D790-2).
4 Fit a new lever and refit the steering wheel panel.
9.1.22 Switch, direction indicators

Switch, direction indicators, replacement
2 Remove the steering wheel and separate the steering wheel panel.
3 Detach the cable harness from the direction indicator.

4 Press together the clips on the direction indicator and detach it
from the steering wheel panel.
5 Replace the direction indicator, fitting it in the reverse order.

9:10 9 Frame, body, cab and accessories – Safety and emergency equipment
9.2 Safety and emergency equipment

9.2.1 Control breaker
Control breaker, description
See section 11 Common electrics, group 11.5.1.4 Control breaker
voltage.
9.2.2 Seat belt

Seat belt, description
The seat belt is a two or a three-point belt, depending on the type of
seat fitted in the machine. The seat belt is mounted on the seat.
9.2.3 Fire extinguisher

Fire extinguisher, description
The fire extinguisher is located by the instep on the left-hand

frame member or inside the cab. Usage instructions are on the fire
extinguisher.
9.2.4 Seat buzzer

Seat buzzer, description
See 9.3.14 Sensor, operator-in-seat, page 9:17.

9 Frame, body, cab and accessories – Seat 9:11
9.3 Seat
Seat, general
There are three versions of the driver's seat:
• Seat, description (product alternative BE-GE 9200), page 9:11
• Seat, description (product alternative BE-GE 9200 air
suspension), page 9:12
As an option, the machine can be equipped with a fold-down passenger

seat to the left of the operator.
Seat, description (product alternative BE-GE

9200)
The seat's function is to provide the operator with a good sitting position
1 2 and contribute to a good work environment. The cab's seat has several
adjustment options and fulfils high comfort standards.
3 The seat has the following equipment:

• mechanical height adjustment
• arm rest right
4 • two-point seat belt
• seat heating
• head rest
• armrest left
5 The seat is equipped with a sensor that senses the spring deflection of
the seat. This is used to activate the buzzer if the operator leaves the
seat without applying the parking brake as well as without putting the
8 6
006825
transmission in neutral position if leaving the seat.

7
Controls
1. Adjusting lumbar support
2. Adjusting arm rest, right
3. Adjusting arm rest, left
4. Back rest rake adjustment
5. Adjusting suspension position
6. Seat cushion angle adjustment
7. Seat height adjustment
8. Front/rear adjustment

9:12 9 Frame, body, cab and accessories – Seat
Seat, description (product alternative BE-GE 9200

air suspension)
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
1 2
has several adjustment options and fulfils high comfort standards.
The air suspension automatically adjusts seat height and suspension
3 to the operator's weight. The air suspension is supplied by a special
compressor installed on the underside of the cab.
The seat has the following equipment:
4 • air suspension (with external compressor)
• arm rest right
• three-point seat belt
• seat heating
5 • armrest left
• head rest
8 6 The seat is equipped with a sensor that senses the spring deflection of
006826
7 the seat. This is used to activate the buzzer if the operator leaves the
Controls BE-GE 9200 seat without applying the parking brake as well as without putting the
transmission in neutral position if leaving the seat.
1. Adjusting lumbar support
2. Adjusting arm rest, right
3. Adjusting arm rest, left
4. Back rest rake adjustment
5. Adjusting suspension position
6. Seat cushion angle adjustment
7. Seat height adjustment
8. Front/rear adjustment
Seat, replacement (product alternative BE-GE

9200)
2 Slide back the seat to its rear position, remove the front attaching
bolts.
3 Slide the seat to its front position, remove the rear attaching bolts.
4 Disconnect the seat's connectors from the machine's cabling.
5 Remove the seat.

9 Frame, body, cab and accessories – Seat cushion 9:13
9.3.1 Seat cushion

Seat cushion, description
The function of the seat cushion is to provide good comfort to the
operator. Under the seat cushion is the driver's seat frame and a circuit
breaker for the buzzer. There may be a heating coil fitted ( ).
For location, see Seat, general, page 9:11.
Seat cushion, replacement (product alternative

BE-GE)
2 Loosen the rubber bellows by removing the plastic clips.
3 Unhook the upholstery's rails from the seat frame and remove
the upholstery.
2 5 4 Remove the padding.

If the seat is equipped with seat heater.
4 Unplug the connector for the heating coil before the padding is
removed.
NOTE
The seat's heating coil is glued to the padding. Exercise caution if
the padding is to be replaced but the heating coil is to be re-used,
or if only the coil is to be replaced.
3 5 Assemble in reverse order.
1
006276
1. Plastic clip, rubber bellows

2. Upholstery
3. Seat frame
4. Padding
5. Heating coil
9.3.2 Back rest cushion

Back rest cushion, description
The function of the back rest cushion is to provide good comfort to the
operator. Under the back rest cushion is the driver's seat frame. There
may be a heating coil fitted ( ).
For location, see Seat, general, page 9:11.

9:14 9 Frame, body, cab and accessories – Heating coil
Back rest cushion, replacement (product alternative

BE-GE)
2 Detach the rubber bellows on the rear of the seat by removing
the plastic clips and folding down the rubber bellows. See Seat
cushion, replacement (product alternative BE-GE), page 9:13.
3 Remove the back rest by first removing the attaching bolts on the
right and left-hand side of the seat and then remove the attaching
3 bolts for the seat belt on the right and left-hand side of the seat.
4 If the seat is equipped with 3-point seat belt.
4 Remove the belt guide by removing the cover and the attaching
bolt.
5 If the seat is equipped with arm rests.
Remove the arm rest by removing the attaching bolts.
6 Position the back rest on the seat and fit the attaching bolts, do not
tighten them. Then fit the attaching bolts for the seat belt.
Tighten the attaching bolts for the seat belt to a torque of 42 Nm,
5 then tighten the attaching bolts to a torque of 33 Nm..
7 If the seat is equipped with 3-point seat belt or arm rest.
Cut holes in the upholstery for seat belt and arm rest on the new
back rest before arm rest or seat belt is installed.
6 8 Fit in the reverse order.

006278
1 2
1. Attaching bolt back rest
2. Attaching bolt, seat belt
3. Cover, belt guide
4. Attaching bolt, belt guide
5. Arm rest
6. Attaching bolt, arm rest
9.3.3 Heating coil

Heating coil, description (product alternative BE-GE)
The function of the heating coil is to warm the back rest and seat
cushions in the driver's seat. The heating coil is fitted under the
upholstery on the seat.
The heating coil (E803) is supplied with voltage upon warm-up by

the Cab control unit, (D790-1) via the seat heating relay (K383). The
signal can be checked via the diagnostic menu. See section 8 Control
system, group 8.4.3.8 CAB, menu 8.
Heating coil, replacement (product alternative BE-GE)
See Seat cushion, replacement (product alternative BE-GE), page 9:13.

9 Frame, body, cab and accessories – Bumper 9:15
9.3.4 Bumper
Bumper, description
The bumpers are integrated in the suspension unit in the seat's
frame and are self-adjusting, that is, they adjust automatically to the
operator's weight.
Bumper, replacement (product alternative BE-GE)

2 Remove the driver's seat from the frame and lift it out of the
2 machine. See Seat, replacement (product alternative BE-GE
9200), page 9:12.
3 Remove the seat cushion, see Seat cushion, replacement (product
alternative BE-GE), page 9:13.
4 Remove the back rest cushion, see Back rest cushion, replacement
1 (product alternative BE-GE), page 9:14.
5 Remove the shock absorber's attaching bolts.
6 Replace the shock absorber.
7 Assemble in reverse order.
006277
1. Bumper
2. Attaching bolt
3. Attaching bolt
9.3.5 Air suspension

Air suspension, description (product alternative
BE-GE 9200 air suspension)
The air-suspension driver's seat consists of a seat with rubber bellows

and compressor. The air suspension is self-adjusting, that is, it adjusts
automatically to the operator's weight. The compressor provides air for
the suspension unit.
001621
For location, see Seat, description (product alternative BE-GE 9200 air
suspension), page 9:12.
Compressor air-suspension seat
9.3.6 Compressor air-suspension seat

Compressor air-suspension seat, description (product
alternative BE-GE 9200 air suspension)
The compressor is part of the air-suspension driver's seat and is fitted

inside the seat's suspension unit.
001621
Compressor air-suspension seat

9:16 9 Frame, body, cab and accessories – Mechanical seat adjustment
9.3.7 Mechanical seat adjustment

Mechanical seat adjustment, description
Seat adjustment is all mechanical and is adapted by the operator with
different controls in order to obtain a good sitting position.
See:
• Seat, description (product alternative BE-GE 9200), page 9:11
• Seat, description (product alternative BE-GE 9200 air suspension),
page 9:12
•
9.3.8 Passenger seat

Passenger seat, description
The passenger seat is collapsible (vertically), provided with a seat belt

and is located on the left-hand side of the driver's seat.
001627
Passenger seat with bracket
9.3.9 Arm rest

Armrests, description
The armrest is affixed to the back rest and is individually adjustable
vertically (around the attachment point).
An option there are also arm rests available on the left-hand side.

9 Frame, body, cab and accessories – Sensor, operator-in-seat 9:17
9.3.14 Sensor, operator-in-seat

Sensor, operator-in-seat, description (product
alternative BE-GE)
1 Sensor, operator-in-seat (S230) is fitted under the seat cushion and

it detects whether the driver's seat suspension is depressed, which
indicates to the control system that the driver's seat is occupied.
This is used to allow the control system to indicate with Buzzer,
operator-in-seat (H853) if the operator leaves the driver's seat without
2 applying the parking brake.
The signal from Sensor, operator-in-seat (S230) is also used to set the
transmission in neutral position if the operator leaves the seat. In an
emergency situation the machine can be operated by bypassing the
safety system. Activate the by-pass switch, select travel direction and
drive the machine to the workshop. Speed is limited to 10 km/h.
008220
Seat, view from below DANGER

1. Sensor, operator-in-seat, (S230) (product
alternative BE-GE)
2. Buzzer (H853) Bypassing the safety systems results in a risk of
tipping. Use at your own risk.
damage!
Only use the bypass of safety systems in emergency
situations.
Sensor, operator-in-seat (S230) is supplied with voltage by and sends a

voltage signal to Control unit, cab (D790-1). The signal can be checked
via the diagnostic menu. See section 8 Control system, group 8.4.3.6
CAB, menu 6.

9:18 9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
9.4 Heating, ventilation and air

conditioning
Heating, ventilation and air conditioning,
description
Heating system (EHC)
The heating system controls heating and ventilation of the cab. The
cab can also be equipped with air conditioning ( ).
F
The temperature in the cab is thermostat-controlled by Control unit,
cab (D790-1). The cab temperature is regulated to the set temperature.
2 The temperature can be set between 16 and 28 °C. The unit is operated
with controls on the dashboard panel.
4
D Heating system (EHC)
C
The heating system (EHC) handles heating and ventilation. (The
E E heating system cannot provide cooling.)
3 The heating system uses heat from the engine's cooling system via a
heating coil to heat the ambient air. The fan forces the ambient air
through the heating coil on through ducts in the cab interior. It is then
directed to the windscreen (defroster) or the feet.
Air conditioning (ECC)
6 A B
The climate control system (ECC) is responsible for heating, ventilation,

cooling and dehumidifying. The air is heated in the same way as for
the heating system (EHC).
During cooling, ambient air is forced through the evaporator, which

cools the air. The air can then be directed in the same way as for the
5 1
G heating system.
000762
The function of the air conditioning is to:

Outline view, air conditioning • heat the air when it is cold
1. Fluid reservoir/filter dryer with integrated • dehumidify the air when it is damp
pressure switch
• clean the air of impurities
2. Heating coil and evaporator
• cool the air when it is hot
3. Fan
• defrost (defroster function)
4. Expansion valve
5. Condenser
6. Compressor IMPORTANT
A. High-pressure gas
B. High-pressure fluid On machines with ECC or AC, it is vital that the engine
cooling system is refilled with coolant with the correct
C. Low-pressure fluid
concentration of antifreeze. Otherwise there is a risk
D. Low-pressure gas that the air conditioning system will freeze during
E. Outdoor air for cab ventilation usage.
F. Heated or cooled air to the cab
G. Outdoor air for eliminating heat

9 Frame, body, cab and accessories – Heating, ventilation and air conditioning 9:19
Heating, ventilation and air conditioning, function

description
2 1 3 26
D D 25
D
4 °C D
D
°C
6
7 D790-1 D790-2 D795
D D D797-1
16
D D794
15 D
12
M D D
14 22 23
5 °C Pa °C
M D
D 19 21
13 20 C 24
M 18
17
D
D 9
M
°C
8 11
10
007690

1 Switch, temperature (S117) sends Raise: U = 2.0–2.5 V Controls and instruments, overview, page
a voltage signal to Control unit, cab Unaffected: U = 0-0.5 V 9:3
Lower: U = 4.5-5.0 V
system, group 8.4.4.5, CLIMATE menu 5
2 Switch, fan (S118) sends a voltage Raise: U = 2.0–2.5 V Controls and instruments, overview, page
signal to Control unit, cab (D790-1). Unaffected: U = 0-0.5 V 9:3
Lower: U = 4.5-5.0 V D2: Diagnostic menu, see section 8 Control
3 Switch, air distribution (S139) sends Scroll up: U = 2.0–2.5 V Controls and instruments, overview, page
a voltage signal to Control unit, cab Unaffected: U = 0 V 9:3
Scroll down: U = 4.5-5.0 V
4 Sensor, cab temperature (B775-1) R = 10 kΩ at 25 °C Sensor, cab temperature, description, page
sends a voltage signal proportional to 9:49
the temperature to Control unit, cab D4: Diagnostic menu, see section 8 Control
(D790-1). system, group 8.4.4.1, CLIMATE menu 1


5 The outlet fan temperature sensor R = 10 kΩ at 25 °C Sensor, temperature outlet fan, description,
(B775-2) sends the cab control unit page 9:48
(D790-1) a voltage signal proportional D5: Diagnostic menu, see section 8 Control
to temperature. system, group 8.4.4.2, CLIMATE menu 2
6 Sensor, ambient temperature (B774) R = 10 kΩ at 25 °C Sensor, ambient temperature, description,
sends a voltage signal proportional to page 9:50
(D790-1). system, group 8.4.4.2, CLIMATE menu 2
7 Control unit, cab (D790-1) regulates Checked by control Section 11 Common electrics, group
temperature and air distribution with system, error shown with 11.5.3.1 Control unit, cab
signals from sensors and controls. error code.
8 The engine produces heat while running. - -
It is cooled with the cooling system. The
heat from the cooling system is used to
heat the cab air.
9 Control unit, cab (D790-1) controls U = 0.5-4.5 V Water valve, description, page 9:35
Water valve (Y673), which routes hot D9: Diagnostic menu, see section 8 Control
water for heat exchanger heat. system, group 8.4.4.7 CLIMATE, menu 7
The water valve's opening (%) is fed and 8.4.4.4 CLIMATE, menu 4
back to the Control unit, cab (D790-1).
This gives information for controlling the
water valve's position.
10 Sensor, engine temperature, sends a Checked by control Section 1 Engine
voltage signal proportional to the engine system, error shown with D10: Diagnostic menu, see section 8 Control
temperature to Control unit, engine error code. system, group 8.4.4.2, CLIMATE menu 2
(D794).
11 Heat exchanger heat supplies heat to - Heat exchanger heat, description, page 9:32
the cab air. The heat is transferred from
the engine's cooling system to the cab
air.
12 Control unit, engine (D794) transmits Checked by control Section 11 Common electrics, group
engine temperature in the cooling system, error shown with 11.5.3.10 Control unit, engine
system on the CAN bus. error code.
13 Control unit, cab (D790-1) controls Checked by control Fresh air filter or recirculation damper,
Actuator motor, recirculation (M612) system, error shown with description, page 9:26
which sets the fresh air or recirculation error code. D13: Diagnostic menu, see section 8 Control
damper in the required position. system, group 8.4.4.6, CLIMATE menu 6
14 Control unit, cab (D790-1) controls Fan Checked by control D14: Diagnostic menu, see section 8 Control
motor (M657), which increases the system, error shown with system, group 8.4.4.6, CLIMATE menu 6
airflow in the cab. error code.
15 Control unit, cab (D790-1) controls U = 0.5-4.5 V Air distributor, description, page 9:46
Damper motor (Y672), which sets the air D15: Diagnostic menu, see section 8
distributor to the required position. Control system, group 8.4.4.8 CLIMATE,
The air distributor's position is fed back menu 8 and 8.4.4.4 CLIMATE, menu 4
to Control unit, cab (D790-1). This
gives information for controlling the air
distributor's position.
16 The frame control unit (D797-1) controls Checked by control Section 11 Common electrics, group
AC compressor connection. system, error shown with 11.5.3.3 Frame control unit
error code.


17 The frame control unit (D797-1) supplies U = 24 V Compressor, description ), page 9:36
voltage to the compressor's solenoid
valve (645).
18 The compressor draws gaseous - Compressor, description ), page 9:36
refrigerant from the evaporator,
compresses it, and forces it on to the
condenser.
19 The condenser cools the refrigerant. - Condenser, description, page 9:39
The gaseous refrigerant condenses to
liquid form and is pumped on in the
circuit.
20 The moisture filter absorbs any moisture - Moisture filter, description, page 9:41
from the cooling circuit. The fluid
reservoir stores the refrigerant.
21 The pressure switch (S246) sends a U = 24 V Pressure switch, description, page 9:41
signal to the frame control unit (D797-1) D21: Diagnostic menu, see section 8 Control
if the pressure in the system becomes system, group 8.4.4.3, CLIMATE menu 3
abnormally high or low.
22 The expansion valve adjusts the - Expansion valve, description, page 9:42
amount of refrigerant that is let in to the
evaporator. If the temperature in the
evaporator's outlet pipe increases, the
expansion valve increases the flow of
refrigerant so that heat dissipation in the
evaporator increases.
23 Sensor, refrigerant circuit temperature, R = 10 kΩ at 25 °C Sensor, temperature refrigerant, description,
sends a voltage signal proportional to page 9:43
(D790-1). system, group 8.4.4.2, CLIMATE menu 2.
24 Heat exchanger, cooling, dissipates heat - Heat exchanger, cooling, description, page
from the cab air. The heat is transferred 9:45
from the air to the refrigerant and
transforms the refrigerant to a gaseous
state.
25 The defroster switch on Control unit KIT Checked by control Section 11 Common electrics, group
(D790-2) activates the defroster program system, error shown with 11.5.3.11 Control unit, KIT
for the air conditioning for six minutes. error code.
26 Control unit KID (D795) shows the Checked by control Section 11 Common electrics, group
heating and ventilation settings in the system, error shown with 11.5.3.12 Control unit, KID
display. error code.

Heating, ventilation and air conditioning,

checking
2 Navigate to the service menu and press Enter.
000056
3 Enter the code for diagnostics. Code is obtained from Cargotec
Support.
1 23 NOTE
4 5
000060

4 Select CLIMATE.
DIAGNOSIS
CLIMATE HYD ENGINE
004998
OLS EXTRA
Menu 1
5 Checking the desired temperature, inside temperature sensor and
DIAG CLIMATE 1(8) water valve.
PRESENT INPUT SIGNAL REQUIRED TEMP: should be 160 (16.0 ºC) for max. cooling and
REQUIRED TEMP XXX 280 (28.0 ºC) for max. heating. The setting is changed with the
PRESENT TEMP XXX temperature switch.
000132
WATER VALVE FEEDB. XXX

PRESENT TEMP: shows the temperature inside the cab. This is
measured by Sensor, cab temperature (located down to the left on
the instrument panel, behind the rubber lead-through). Blowing
through the hole should increase the value.
WATER VALVE FEEDB. should show 0 (closed) when the
requested temperature is 160, and 100 (open) when the requested
temperature is 280. The water valve is located under the cab.
Menu 2
6 Check of Sensor, temperature outlet fan (B775-2), engine
DIAG CLIMATE 2(8) temperature, Sensor, outdoor temperature (B774), and check of
TEMP COIL XXX Sensor, temperature refrigerant (B775-1).
TEMP COOLANT XXX TEMP COIL: temperature that the air has in the air distributor is
TEMP AMBIENT XXX measured by Sensor, temperature outlet fan (B775-2).
000133
TEMP DE-ICE XXX

TEMP COOLANT: engine temperature that is sent on the CAN bus.
TEMP AMBIENT: outdoor temperature that is measured by Sensor,
outdoor temperature (B774).
TEMP DE-ICE: cooling circuit's temperature that is measured by
Sensor, temperature refrigerant (B775-1). If the compressor is
activated then the value will be low. However, if heat has been
selected and the compressor is deactivated, the value will almost
be equal to TEMP COIL.

Menu 3
7 (Only machines with ECC)
DIAG CLIMATE 3(X)
Checks that the refrigerant circuit is filled.
PRESSURE SWITCH X PRESSURE SWITCH: 0 = not filled, 1 = filled.
OPT DOOR SWITCH X The sensor is located on the receiver drier which is fitted right
006865
rear in the frame.
Menu 4
8 Checks Water valve (Y673) and Air distributor (Y642).
DIAG CLIMATE 4(8) WATER VALVE: should work between 1.0-1.24 V and 2.95-3.2 V.
PRESENT INPUT SIGNAL This is checked by turning the temperature control and changing
WATER VALVE XX.XXV the temperature setting from min. to max.
000135
DRAUGHT VALVE: should work in the range 1.0-4.0 V. The

difference between min. and max. should be approx. 1 V. This is
checked by changing the air distribution from floor to front window.
At the same time, feel with your hand so that air blows through
different vents.
NOTE
Air to the round panel vents is not controlled by the air
conditioning.
Menu 5
9 Checks the switches for temperature, air distribution and fan
DIAG CLIMATE 5(8) speed.
PRESENT INPUT SIGNAL REQUIRED TEMP: home position U = 0 V; raise U = 2-2.5 V;
REQUIRED TEMP XX.XXV lower U = 4.5-5 V.
REQ. DRAUGHT XX.XXV
000136
REQ. FAN SPEED XX.XXV REQ. DRAUGHT: home position U = 0 V; against window U =
2-2.5 V; against floor U = 4.5-5 V.
REQ. FAN SPEED: home position U = 0 V; raise U = 2-2.5 V;
lower U = 4.5-5 V.
Menu 6
10 Checks Cab fan (M657), Fresh air and recirculation damper
DIAG CLIMATE 6(8) (M612) and Electromagnetic clutch, compressor (M645) .
PRESENT OUTPUT SIGNAL FAN SPEED: increase and decrease fan speed, value should
FAN SPEED XXX increase from 0 to 255 in steps.
RECIRKULATION XY
000137
COMPRESSOR XY RECIRCULATION: press in the Switch, bypass (S1005) (on the

panel for load handling functions). When checking, the display
should show "11". Check that the damper actually moves as it
should by removing the fresh air filter at the front of the climate
control system casing and feeling with your hand.
(Only machines with ECC)
COMPRESSOR: lower the temperature setting to max. cooling,
after approx. 45 seconds the compressor will be activated and
the display should show "11".
NOTE
Compressor activation can only be tested when the engine is
running and the system is filled.

Menu 7
11 Checks the direction selector for Water valve (Y673).
DIAG CLIMATE 7(8) CLOCKWISE: when the temperature is increased and the water
OUTPUT WATER VALVE valve opens shows "CLOCKWISE 11 11" and "ANTI-CLOCKWISE
CLOCKWISE XY XY 00 11".
ANTI-CLOCKWISE XY XY
ANTI-CLOCKWISE: when the temperature is decreased and
the water valve closes shows "CLOCKWISE 00 11" and
"ANTI-CLOCKWISE 11 11".
24V
NOTE
The "ones" are only shown for a moment when the water valve
changes position, "zeros" are shown when the valve does not
change position. The water valve does not open if the engine
temperature is low, or if the outdoor temperature is high.
M
000138
0V
Menu 8
12 Checks the direction selector for the air distributor.
DIAG CLIMATE 8(8)
CLOCKWISE: when the air is directed against the windscreen and
OUTPUT DRAUGHT VALVE the air distributor changes position shows "CLOCKWISE 00 11"
CLOCKWISE XY XY and "ANTI-CLOCKWISE 11 11".
ANTI-CLOCKWISE XY XY
ANTI-CLOCKWISE: when the air is directed against the feet and
the air distributor changes position shows "CLOCKWISE 11 11"
and "ANTI-CLOCKWISE 00 11".
24V
NOTE
The "ones" are only shown for a moment when the air distributor
changes position, "zeros" are shown when the air distributor does
not change position.
M
000139
0V

9 Frame, body, cab and accessories – Fresh air filter 9:25
9.4.1 Fresh air filter

Fresh air filter, description
The fresh air filter is located under a cover in the external unit for fresh
air intake into the cab, in front of the cab fan.
004999
1
Fresh air intake, cab
1. Fresh air filter 2. Fresh air and recirculation damper

9:26 9 Frame, body, cab and accessories – Fresh air filter or recirculation damper
9.4.2 Fresh air filter or recirculation damper

Fresh air filter or recirculation damper, description
The damper is controlled electrically and controls the air between fully
open for fresh air to recirculation of air. The damper is located in the
external unit for fresh air intake into the cab.
The signal can be checked via the diagnostic menu, section 8 Control
system, group 8.4.4.6 CLIMATE, menu 6.
2
004999
1
1. Fresh air filter 2. Fresh air and recirculation damper

9 Frame, body, cab and accessories – Fresh air filter or recirculation damper 9:27
Motor, fresh air filter or recirculation damper,

replacement
2 Remove the wiper arms.
3 Remove the nuts which hold the wiper motor in the protective plate.
4 Remove the protective plate.
5 Remove the fresh air filter.

9:28 9 Frame, body, cab and accessories – Fresh air filter or recirculation damper
6 Remove the bolts which secure the arm and motor in the plate.
7 Detach the connector from the motor.
8 Replace the motor.
9 Fit in the reverse order. Tighten the wiper arm to torque 16-20 Nm.

9 Frame, body, cab and accessories – Cab fan 9:29
9.4.3 Cab fan

Cab fan, description
The cab fan is located in the external unit for fresh air intake into the
cab. The fan consists of two single fans that are driven by a motor.
1
003209

1. Cab fan
Cab fan, replacement


9:30 9 Frame, body, cab and accessories – Cab fan
3 Remove the bolts which hold the wiper motor in the protective
plate.
5 Detach the washer hose from the protective plate.

9 Frame, body, cab and accessories – Cab fan 9:31
7 Remove the bolts which secure the plate and cab fan.
8 Detach the connector from the cab fan.

9 Remove the cab fan.
10 Replace the cab fan.

9:32 9 Frame, body, cab and accessories – Heat exchanger heat
9.4.4 Heat exchanger heat

Heat exchanger heat, description
The heat from the engine's coolant is transferred to the cab via the
heat exchanger. The heat exchanger is located behind the fan in the
external unit for fresh air intake into the cab.
1, 2
3
003210

1. Heat exchanger heat
2. Heat exchanger, cooling
3. Expansion valve and sensor for refrigerant
temperature
Heat exchanger, cooling/heating, replacement
WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.

2 Drain the AC system of R134a refrigerant.

9 Frame, body, cab and accessories – Heat exchanger heat 9:33
IMPORTANT
Working on the air conditioning requires special
authorisation.
3 Detach the AC system hoses and the coolant hoses.

5 Remove the nuts which hold the wiper motor in the protective plate.

9:34 9 Frame, body, cab and accessories – Heat exchanger heat
9 Remove the plate frame.
10 Remove the cab fan.
11 Remove the heat exchanger cover plate.
12 Detach all fluid inlets and outlets from the heat exchanger.
13 Lift out the heat exchanger carefully.
14 Replace the heat exchanger.
15 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.
16 Check for leaks and refill the AC-system with refrigerant R134a,
using the intended equipment.
For volume, see section F Technical data.
IMPORTANT
authorisation.
Connection points for cooling hoses.

9 Frame, body, cab and accessories – Water valve 9:35
9.4.5 Water valve

Water valve, description
The water valve controls the climate control system's capacity for
heating from 0 (closed valve) to 100% (open valve). The water valve is
electrically controlled.
The signal can be checked from the diagnostic menu, section 8 Control
system, group 8.4.4.1 CLIMATE, menu 1, 8.4.4.4 CLIMATE, menu 4
and 8.4.4.7 CLIMATE, menu 7.
010021
Water valve position under cab floor (from below)
Water valve, replacement

2 Detach the connector from the water valve.
3 Stop the flow of fluid to and from the water valve using hose
pinch-off pliers.
4 Detach the coolant hoses from the water valve.
5 Remove the water valve from the cab floor.
6 Replace the water valve.
8 Check the coolant level.
9 Run the heating system at the highest setting (fully open valve) to
vent air from the system.
1. Water valve
2. Steering valve
9.4.6 Sensor, engine temperature

Sensor, engine temperature, description
Sensor, coolant temperature, is fitted on the engine and detects
engine's coolant temperature. See supplier documentation, engine.
For location, see section 1 Engine.

9:36 9 Frame, body, cab and accessories – Compressor
9.4.7 Compressor
Compressor, description )
The compressor drives the air conditioning by working as a pump. It

draws in cold, low-pressure gas from the evaporator, compresses the
gas which then becomes warm, and then forces out high-pressure
gas to the condenser.
The compressor is driven by V-belts directly by the machine's engine.

Activation and deactivation of the compressor is handled by an
electromagnetic clutch, which is controlled by a thermostat.
1 2 3
4
009116
5
The figure shows the compressor for Cummins QSB
6.7
1. Rigging screw (belt tensioner)
2. Compressor
3. Connections
4. Screw and nut
5. Drive belt

9 Frame, body, cab and accessories – Compressor 9:37
Compressor, replacement
WARNING
B Safety.

IMPORTANT
authorisation.
3 Detach the coolant hoses from the compressor.

4 Loosen the turnbuckle so that the compressor belt is released.
5 Undo the hose couplings and detach the hoses from the
compressor intake and outlet. Plug the connections immediately to
prevent contamination.
6 Remove the bolts which secure the compressor.
7 Drain the oil from the old compressor (through the intake and outlet
connections) and the hoses. Measure the oil quantity.
8 Drain the oil from the new compressor.
9 Fill the new compressor with the same quantity of oil as was
drained from the old compressor - minimum 0.1 litre.
NOTE
Fill new oil through the compressor's suction connection.
10 Fit the new compressor and other equipment in reverse order.

For volume, see the plate for the climate control system.
IMPORTANT
authorisation.

9:38 9 Frame, body, cab and accessories – Compressor
Pulley and magnetic clutch, replacement

There is no need to drain refrigerant from the system before
replacement.
2 Slacken the belt tensioner and remove the drive belt.
3 Remove the screw from the centre of the pulley.
006263
4 Remove the locking washer and the outer lock ring.

1
2
006264
1. Lock ring
2. Locking washer
5 Remove the groove.

1
006265
1. Groove
6 Remove the three screws securing the electromagnetic clutch.

006266

9 Frame, body, cab and accessories – Condenser 9:39
7 Remove the magnetic clutch.

1 9 Check the function.
006267
1. Magnetic clutch
9.4.8 Condenser
Condenser, description
The condenser is located on the radiator in the engine compartment.

The function of the condenser is to convert the hot, high-pressure
gas from the compressor to liquid form. Pipes and cooling fins in the
condenser battery absorb the heat, which is dissipated with a fan.
The temperature of the refrigerant in the condenser varies from approx.

50 ºC to 70 ºC and the pressure varies between 12 and 14 bar,
depending on ambient temperature and airflow through the condenser.
When the refrigerant has been condensed to liquid, it is directed on
to the fluid reservoir/filter dryer.
010023

9:40 9 Frame, body, cab and accessories – Condenser
Condenser, replacement
WARNING
B Safety.
NOTE
For tightening torque of refrigerant hoses and pressure switch,
see section F Technical data.

IMPORTANT
authorisation.
3 Detach the inlet and outlet hoses from the condenser.

4 Remove the bolts which secure the condenser at the top edge and
lift the condenser out in a suitable way.
5 Replace the condenser, fitting it in the reverse order.
IMPORTANT
authorisation.

9 Frame, body, cab and accessories – Moisture filter 9:41
9.4.9 Moisture filter

Moisture filter, description
NOTE
For tightening torque of refrigerant hoses and pressure switch, see
section F Technical data.
The moisture filter collects the liquid refrigerant, binds moisture, and
filters out impurities. The reservoir functions as an expansion tank in
the cooling circuit.
When the refrigerant has passed through the dryer in the bottom of the
fluid reservoir, it rises through a standpipe. Through a sight glass, it is
possible to check that there is flow without bubbles and that the system
is adequately filled with refrigerant.
1. Moisture filter
2. Pressure switch
3. Sight glass
9.4.10 Pressure switch

Pressure switch, description
NOTE
For tightening torque of refrigerant hoses and pressure switch, see
The pressure switch cuts off the current to the compressor's

electromagnetic clutch if the pressure in the cooling circuit becomes
abnormally high or low.
1. Moisture filter
2. Pressure switch
3. Sight glass

9:42 9 Frame, body, cab and accessories – Expansion valve
Pressure switch, replacement
WARNING
B Safety.

2 Drain the machine of refrigerant, R134a.
IMPORTANT
authorisation.
3 Detach the connector from the pressure switch.

4 Unscrew the pressure switch from its mounting.
5 Replace the pressure switch.
1. Moisture filter 6 Check for leaks and refill the AC-system with refrigerant R134a,
2. Pressure switch using the intended equipment.
3. Sight glass For volume, see section F Technical data.
IMPORTANT
authorisation.
9.4.11 Expansion valve

Expansion valve, description
The expansion valve is the part in the circuit that separates the
high-pressure side from the low-pressure side. The refrigerant arrives
at the expansion valve under high pressure and leaves it under low
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 evaporator varies

depending on the heat load. The valve works from fully open to fully
closed and searches between these for an optimal evaporation point.

9 Frame, body, cab and accessories – Sensor, temperature refrigerant 9:43
Expansion valve, replacement
WARNING
B Safety.

2 Drain the AC system of refrigerant.
IMPORTANT
authorisation.
3 Detach the AC system hoses.

4 Detach the coolant hoses.
5 Remove the heat exchanger for cooling/heating to access
the expansion valve, see Heat exchanger, cooling/heating,
6 Replace the expansion valve.
IMPORTANT
authorisation.
9.4.12 Sensor, temperature refrigerant

Sensor, temperature refrigerant, description
Sensor, temperature refrigerant, (position 2) detects the refrigerant

temperature in the heat exchanger, cooling. This is used to control
the air conditioning.
1 system, group 8.4.4.2 CLIMATE, menu 2.
3
005001
1. Sensor cab temperature

2. Sensor temperature refrigerant
3. Sensor, temperature outlet fan

9:44 9 Frame, body, cab and accessories – Sensor, temperature refrigerant
Sensor, temperature refrigerant, replacement
WARNING
B Safety.

2 Drain the AC system of refrigerant.
IMPORTANT
authorisation.
3 Detach the AC system hoses from the heat exchanger.

4 Detach the coolant hoses from the heat exchanger.
5 Detach the heat exchanger to access the refrigerant temperature
sensor, see Heat exchanger, cooling/heating, replacement, page
9:32.
6 Replace the temperature sensor.
IMPORTANT
authorisation.

9 Frame, body, cab and accessories – Heat exchanger, cooling 9:45
9.4.13 Heat exchanger, cooling

Heat exchanger, cooling, description
Heat exchanger, cooling, consists of pipes and cooling fins. The cab air
is cooled as it passes through the heat exchanger, cooling. The heat
exchanger is located behind the fan in the external unit for fresh air
intake into the cab.
1, 2
3
003210

1. Heat exchanger heat
2. Heat exchanger, cooling
3. Expansion valve and sensor for refrigerant
temperature
Heat exchanger, cooling, replacement

See Heat exchanger, cooling/heating, replacement, page 9:32.

9:46 9 Frame, body, cab and accessories – Air distributor
9.4.14 Air distributor

Air distributor, description
The air distributor controls the air between defroster and floor and is
located behind the panel inside the cab. The damper is controlled
electrically by the control system.
The signal can be checked from the diagnostic menu, section 8 Control
system, group 8.4.4.4 CLIMATE, menu 4 and 8.4.4.5 CLIMATE, menu
5 and 8.4.4.8 CLIMATE, menu 8.
002230
Air distributor, replacement

2 Remove the dashboard panel.
3 Remove the steering wheel shaft cover.
4 Detach the steering wheel shaft and angle it back against the
driver's seat.
5 Remove the lower cover in front of the pedal assembly.
6 Detach the air hoses from the air distributor and detach the
connector.
1. Dashboard panel
2. Steering column adjustment
3. Lower protective cover
7 Remove the air distributor from its mounting.

8 Replace the air distributor, fitting it in the reverse order.
Air distributor

9 Frame, body, cab and accessories – Defroster nozzles 9:47
9.4.15 Defroster nozzles

Defroster nozzles, description
There are a number of fixed defroster nozzles in the cab's interior:
at the front of the doors and the defroster for the windscreen. There
are also two adjustable air vents (flow and direction) in the instrument
panel's outside corners.
There is an air inlet towards the cab's lower part (floor).
001839
Defroster nozzles, replacement

2 Remove the air damper manually.
3 Remove the bolts which hold the other part of the defroster nozzle
in the dashboard.
4 Detach the air hose from the defroster nozzle.

5 Replace the defroster nozzle.

9:48 9 Frame, body, cab and accessories – Sensor, temperature outlet fan
9.4.16 Sensor, temperature outlet fan

Sensor, temperature outlet fan, description
Sensor, temperature outlet fan, detects the temperature of the air that
blows out in the defroster nozzles. The air conditioning is controlled by
signals from the following sensors:
1
3
005001
2
Sensor, temperature outlet fan, replacement

3 Remove the lower protective cover in front of the steering wheel
shaft.
4 Detach the steering wheel shaft and angle it back against the
driver's seat.
1. Dashboard panel
2. Steering column adjustment
3. Lower protective cover
5 Detach the temperature sensor from the air distributor.

Air distributor including temperature sensor.

9 Frame, body, cab and accessories – Sensor cab temperature 9:49
9.4.17 Sensor cab temperature

Sensor, cab temperature, description
Sensor, cab temperature, detects the temperature of the air in the cab.
1
3
005001
2

Sensor, cab temperature, replacement

3 Detach the hose from the temperature sensor.

4 Detach the connector from the temperature sensor.
5 Remove the temperature sensor.
007985

9:50 9 Frame, body, cab and accessories – Sensor, ambient temperature
9.4.18 Sensor, ambient temperature

Sensor, ambient temperature, description
Sensor, ambient temperature, detects the temperature of the air
outside the cab.
Sensor, ambient temperature
Sensor, ambient temperature, replacement

2 Detach the connector from the temperature sensor.
3 Remove the temperature sensor from its mounting in the cab.

9 Frame, body, cab and accessories – Wiper/washer system 9:51
9.5 Wiper/washer system

Wiper/washer system, description
The wipers automatically switch off 2 minutes after the operator has
left the driver's seat.
9.5.1 Wiper front

Wiper front, description
The front wiper is the parallel wiper type, i.e. the wiper blade is moved
in a constant vertical position over the front window.
9.5.2 Wiper roof

Wiper roof, description
The roof wiper is the sector wiper type. Wiping angle is approx. 180
degrees.
9.5.3 Wiper rear

Wiper rear, description
The rear wiper is the sector wiper type. Wiping angle is approx. 180
degrees.
9.5.4 Washer motor and reservoir

Washer motor and reservoir, description
Washer motors are located on the washer fluid reservoir. There are
non-return valves on the lines from the reservoir to the washer nozzles,
preventing the washer fluid from draining back in the line between
washings. This minimises the time between the activation of the switch
for washing and washer fluid spraying on the window.
The washer nozzles are mounted on the wiper arms.
Control system, group 8.4.3.1 CAB, menu 1.

9:52 9 Frame, body, cab and accessories – Wiper motor front
Washer motor and reservoir, replacement

2 Remove the protection over the washer fluid reservoir.
3 Drain the washer fluid from the fluid reservoir.
4 Remove the washer motors from the fluid reservoir.
5 Remove the bolts which secure the fluid reservoir in the cab wall.
6 Replace the washer fluid reservoir. Replace the washer motor, if
necessary.
003619
A B
Washer fluid reservoir without protective plate.
A. Washer fluid reservoir
B. Washer motors
9.5.5 Wiper motor front

Wiper motor front, description
The wiper motor drives the wiper for the front window. The wiper arm is
mounted on the motor. The motor produces the movement of the wiper.
Wiper motor front, replacement

3 Remove the nuts which hold the motor in the protective plate.
6 Remove the nuts which hold the motor in the cab.

7 Detach the connector from the wiper motor.
8 Replace the motor.
9 Fit in the reverse order. Tighten the wiper arms to torque 16-20
Nm.

9 Frame, body, cab and accessories – Wiper motor roof 9:53
9.5.6 Wiper motor roof

Wiper motor roof, description
The wiper motor drives the wiper for the roof window. The wiper arm is
Wiper motor roof, replacement

2 Remove the plastic cover.
3 Detach the washer hose and the connector to the wiper motor.
4 Undo the lock nut securing the wiper arm and disconnect the
washer fluid hose.
5 Remove and replace the wiper motor.

9:54 9 Frame, body, cab and accessories – Wiper motor rear
9.5.7 Wiper motor rear

Wiper motor rear, description
The wiper motor drives the wiper for the rear window. The wiper arm is
Wiper motor rear, replacement

2 Remove the panels behind the driver's seat.
3 Remove the screws holding the motor's plastic cover.
4 Detach the connector to the motor.

5 Raise the plastic cover and remove the nut securing the wiper arm.
Detach the washer fluid hose.
6 Remove the screws securing the motor and the lock nut on the
motor.
7 Replace the wiper motor.
8 Fit in the reverse order. Tighten the wiper arms to torque 16-20
Nm.

9 Frame, body, cab and accessories – Lighting system 9:55
9.6 Lighting system

Lighting system, function description
The working lights are shut off automatically after 5 minute's idle in
order to prevent discharge of the batteries. Extra working lights are
shut off after 2 minutes. The lights are activated automatically again
when the operator sits in the seat, a gear is selected or the accelerator
pedal is pressed.
NOTE
It is important that the right type of bulb is used for each area. See
1 2 3 5 4
D1 D2 D3 D5 D4 8
9
13 D13 10
6 D8
D6
17 14 14
D17 D10
15
16 M D15
D9
D16 D790-1 D790-2
19 7, 12 11 28
D797-1 D791-1
D18
D20 D21 D22 D23 D24
Pa 18
D25
D29 D30
D26
015047
D27
20 21 22 23 24 25 26 27 29 30
1 The switch for cab roof work lights (S105-1) Switch in ON position: U D1: Diagnostic menu, see section
sends a voltage signal to the cab control unit = 24 V 8 Control system, group 8.4.2.12
(D790-1). LIGHTS, menu 12
2 Switch, working lights attachment (S105-2) Switch in ON position: U D2: Diagnostic menu, see section
sends a voltage signal to Control unit, cab = 24 V 8 Control system group 8.4.2.13
(D790-1). LIGHTS, menu 13.
3 The switch for mast work lights (S105-3) Switch in ON position: U D3: Diagnostic menu, see section
sends a voltage signal to the cab control unit = 24 V 8 Control system group 8.4.2.10
(D790-1). LIGHTS, menu 10.
4 Switch, headlights (S100) sends a voltage Switch in ON position: U D4: Diagnostic menu, see section 8
signal to Control unit, cab (D790-1). = 24 V Control system, group 8.4.2.1 LIGHTS,
menu 1.
5 Switch, revolving beacon (S110) sends a Switch in ON position: U D5: Diagnostic menu, see section 8
voltage signal to Control unit, cab (D790-1). = 24 V Control system group 8.4.2.6 LIGHTS,
menu 6.

9:56 9 Frame, body, cab and accessories – Lighting system
6 The door NC switch (S266-LE & S266-RI) Door open: U = 24 V Interior lighting cab, description, page
sends a voltage signal to the cab control unit 9:61
(D790-1). D6: Diagnostic menu, see section 8
Control system group 8.4.2.9 LIGHTS,
menu 9.
7 Control unit, cab (D790-1) transmits "switch on Checked by control Section 11 Common electrics, group
lights" messages on the CAN bus. system, error shown with 11.5.3.1 Control unit, cab
error code.
8 Multi-function lever (S162) sends a voltage Lever in high beam Gear selector and multi-function lever,
signal to Control unit KIT (D790-2). position: US162/56a = 24 V description, page 9:8
menu 3
9 Lever, direction indicator (S161) sends a Left: US161/6 = 24 V D9: Diagnostic menu, see section 8
voltage signal to Control unit KIT (D790-2). Right: US161/1 = 24 V Control system group 8.4.2.4 LIGHTS,
menu 4
10 Switch, interior lighting on Control unit KIT Checked by control D10: Diagnostic menu, see section 8
(D790-2) sends a voltage signal to Control unit system, error shown with Control system group 8.4.2.9 LIGHTS,
KIT (D790-2). error code. menu 9
11 Control unit KIT (D790-2) sends a "switch on Checked by control Section 11 Common electrics, group
lights" message on the CAN bus. system, error shown with 11.5.3.11 Control unit, KIT
error code.
12 Control unit, cab (D790-1) supplies voltage to Checked by control Section 11 Common electrics, group
the lights in and around the cab. system, error shown with 11.5.3.1 Control unit, cab
error code.
13 The relay for cab roof work lights (K3017-1 UK3017/30 = 24 V Working lights, cab, description, page
and K3017-2) is activated when the cab roof UK3017/85 = 0 V 9:61
work lights are activated. It supplies voltage to
the cab roof work lights (E406L-1 E406R-1, Cab roof work lights on:
E406L-2 & E406R-2). UK3017/86 = 24 V
UK3017/87 = 24 V
Cab roof work lights off:
UK3017/86 = 0 V
UK3017/87 = 0 V
14 The cab roof work lights (E406L-1 E406R-1, Light on: U = 24 V Working lights, cab, description, page
E406L-2 & E406R-2) come on when the cab 9:61
roof work lights are activated. D14: Diagnostic menu, see section
8 Control system group 8.4.2.12
LIGHTS, menu 12
15 Back-up lights, white (E405L & E405R) are Light on: U = 24 V Back-up lights, description, page 9:59
switched on when reverse gear is selected. D15: Diagnostic menu, see section 8
menu 8
16 Revolving beacon (H428) is switched on when Light on: U = 24 V Revolving beacon, description, page
the revolving working light is activated. 9:60
menu 6
17 Interior lighting (E434-1) comes on when a Light on: U = 24 V Interior lighting cab, description, page
door is opened or if activated when the switch 9:61
on the KIT control unit (D790-2). D17: Diagnostic menu, see section 8
Control system, group 8.4.2.9 LIGHTS,
menu 9
18 The brake light NO switch (S216) sends Brake pressure over 0.2 Section 4 Brakes, group 4.3.8
a voltage signal to the frame control unit MPa: U = 24 V Make-contact (closing switch) brake
(D797-1). lights
menu 7

9 Frame, body, cab and accessories – Lighting system 9:57
19 The frame control unit (D797-1) supplies Checked by control Section 11 Common electrics, group
voltage to the machine lights. system, error shown with 11.5.3.2 Frame control unit
error code.
20 The direction indicators (H422, H423, H426 Light on: U = 24 V Direction indicators, description, page
& H427) come on when they or the warning 9:60
lights are activated. D20: Diagnostic menu, see section 8
menu 5
21 The running lights (H416-1, H416-2, H417-1 & Light on: U = 24 V Running lights, description, page 9:59
H417-2) come on together with the headlights. D21: Diagnostic menu, see section 8
menu 2
22 Headlights, low beam (E400L & E400R) are Light on: U = 24 V Headlights, description, page 9:59
switched on when the headlight is activated. D22: Diagnostic menu, see section 8
menu 3
23 Headlights high beam (E402L-1 & E402R-1) Light on: U = 24 V Headlights, description, page 9:59
are lit when high beam is activated. D23: Diagnostic menu, see section 8
menu 3
24 Tail lights, red (H412L & H412R) are switched Light on: U = 24 V Tail lights, description, page 9:59
on when the headlight is activated. D24: Diagnostic menu, see section 8
menu 2
25 Brake lights (H411L & H411R) are switched on Light on: U = 24 V Brake lights, description, page 9:59
when the brake is activated. D25: Diagnostic menu, see section 8
menu 8
26 The mast work lights (E404L-1 & E404R-1) Light on: U = 24 V Mast working lights, description, page
come on when activated. 9:60
D26: Diagnostic menu, see section
LIGHTS, menu 10
27 The auxiliary mast work lights (E404L-4 & Light on: U = 24 V Mast working lights, description, page
E404R-4) come on when the mast work lights 9:60
are activated. D27: Diagnostic menu, see section
LIGHTS, menu 11
28 Control unit, attachment (D791-1) supplies Checked by control Section 11 Common electrics, group
voltage to the attachment's lights. system, error shown with 11.5.3.5 Control unit, attachment
error code.
29 The twistlock attachment work lights (E404L-3 Light on: U = 24 V Working lights, attachment, description,
& E404R-3) come on when activated. page 9:62
D29: Diagnostic menu, see section
LIGHTS, menu 13
30 The twistlock attachment auxiliary work lights Light on: U = 24 V Working lights, attachment, description,
(E404L-5 and E404R-5) come on when page 9:62
activated. D30: Diagnostic menu, see section
LIGHTS, menu 11

9:58 9 Frame, body, cab and accessories – Lighting system
Lighting system, component location

The purpose of the lighting is to increase safety during operation and
load handling.
NOTE
The machine has the following lights:
1 4 5 6 6 7 9
3,8,10
12
24
23
22
018774
19, 20, 21 18 17 16 15 11, 13, 14
1. Mast work lights (E404L-1 & E404R-1) 14. Direction indicators, rear (H426 & H427)
2. Auxiliary mast work lights (E404L-4 & E404R-4) 15. Door NC (normally closed) switch (S266-LE &
3. Relay, cab roof work lights (K3017-1 & K3017-2) S266-RI)
4. Multi-function lever (S162) 16. Switch, see Controls and instruments, overview, page
9:3
5. Control unit KIT (D790-2)
17. Frame control unit (D797-1)
6. Interior lighting (E434-1)
18. Make-contact (closing switch) brake light (S216)
7. Cab roof work lights (E406L-1 & E406R-1)
19. Direction indicators, front (H422 & H423)
8. Auxiliary cab roof work lights (E406L-2 & E406R-2)
9. Revolving beacon (H428) 20. Running lights, front (H416-1 & H417-1)
10. Control unit, cab (D790-1) 21. Headlights, low beam (E400L & E400R)
11. Running lights, rear (H416-2 & H417-2) Headlights, high beam (E402L-1 & E402R-1)
12. Back-up lights, white (E405L & E405R) 22. Control unit, attachment (D791-1)
13. Tail lights, red (H412L & H412R) 23. Twistlock attachment work lights (E404L & E404R)
Brake lights (H411L & H411R) 24. Auxiliary carriage work lights (E404L-5 & E404R-5)

9 Frame, body, cab and accessories – Headlights 9:59
9.6.1 Headlights
Headlights, description
Headlights are located in the front of the machine to give the
operator enhanced vision when operating in darkness, and to provide
surrounding traffic and the environment an indication of the machine's
position. Headlights have the options of high beam and low beam (for
meeting other traffic).
Switch between high and low beam with the gear and multi-function
lever. The signal travels to Control unit, cab (D790-1).
High and low beam signals can be checked from the diagnostic menu,
section 8 Control system, group 8.4.2.3 LIGHTS, menu 3.
9.6.2 Running lights

Running lights, description
The running lights are fitted on the right and left-hand sides of the
machine to provide surrounding traffic and the environment an
indication of the machine's position and direction of travel.
The running lights are controlled by selecting with the headlight switch.
The signal travels to Control unit, cab (D790-1).
The lights and their signal can be checked from the diagnostic menu,
9.6.3 Tail lights

Tail lights, description
Tail lights are located in the rear of the machine to provide surrounding
traffic and the environment an indication of the machine's position, and
a limited enhancement of the view for the operator in darkness.
The tail lights are controlled by selecting with the headlight switch. The
signal travels to Control unit, cab (D790-1).
9.6.4 Brake light

Brake lights, description
The brake lights are fitted on the rear of the machine to provide
surrounding traffic and the environment an indication that the machine
is braking and consequently slowing down.
The brake lights are regulated by brake pedal position (via actuated
break contact (opening switch)). The signal travels to Control unit,
frame (D797-1), which supplies power to the brake lights.
see section 8 Control system, group 8.4.2.7 LIGHTS, menu 7 and
8.4.2.8 LIGHTS, menu 8.
9.6.5 Back-up lights

Back-up lights, description
The back-up lights are fitted on the rear of the machine to provide
surrounding traffic and the environment an indication that the machine
is travelling backwards. In addition, this provides the operator
enhanced view when operating in darkness.
The back-up lights are controlled by direction of travel. Signals are
sent via the CAN-bus).

9:60 9 Frame, body, cab and accessories – Direction indicators
9.6.6 Direction indicators

Direction indicators, description
The direction indicators are located on both the front and rear of
the machine to provide surrounding traffic and the environment an
indication that the machine is changing direction, i.e. turning.
The direction indicators are controlled by the choice made with the
direction indicators switch (lever). The signal goes to frame control
unit (D797-1).
9.6.7 Flashing hazard lights

Flashing hazard lights, description
Flashing hazard lights (Hazard) are used to warn the surroundings,
flashing hazard lights activate all direction indicators simultaneously.
The flashing hazard lights are controlled by selecting with the switch for
flashing hazard lights. The signal travels to Control unit, cab (D790-1).
Control system, group 8.4.2.4 LIGHTS, menu 4 and 8.4.2.5 LIGHTS,
menu 5.
9.6.8 Revolving beacon

Revolving beacon, description
The revolving beacon is located high on the machine's cab. This is
used to provide surrounding traffic and the environment an indication
that a working vehicle is moving and at work. An indication to
bystanders to exercise caution.
The revolving beacon is controlled by selecting with the revolving

beacon switch. The signal travels to Control unit, cab (D790-1).
9.6.9 Working lights, mast

Mast working lights, description
Work lights on the mast provide enhanced view when load handling
in darkness.
The working lights are controlled by selecting with the switch for
working lights, mast. The signal travels to Control unit, cab (D790-1).
The mast can be equipped with two auxiliary work lights ( ).

9 Frame, body, cab and accessories – Working lights, cab 9:61
Working lights, replacement (product alternative

Xenon lights)
DANGER
Xenon lights are activated with high voltage. Always
switch off the system voltage before working on
Xenon lights.
Handle the headlight with care since the light is under
gas pressure and may explode.
NOTE
The Xenon light is filled with different gases and metals. Replaced
Xenon headlights should be considered as hazardous waste and
should be deposited for recycling.
9.6.10 Working lights, cab

Working lights, cab, description
Working lights on the cab provide visibility when handling a load in

darkness.
The working lights are controlled by selecting with the switch for
working lights, cab roof. The signal travels to Control unit, cab
(D790-1), which in turn supplies power to the working lights.

Xenon lights)
See Working lights, replacement (product alternative Xenon lights),

page 9:61.
9.6.11 Interior lighting

Interior lighting cab, description
The interior lighting illuminates the cab when the doors are opened or
when activated with the interior lighting switch.
There is background lighting in all switches, function keys and rotary

controls. This is so that the operator will be able to read their functions
and settings in darkness. Brightness is controlled by the plus and
minus keys.

9:62 9 Frame, body, cab and accessories – Working lights, attachment
9.6.12 Working lights, attachment

Working lights, attachment, description
Working lights on the attachment provide increased visibility when
handling a load in darkness.
The working lights are controlled by selecting with the switch for working
lights, attachment. The signal travels to Control unit, cab (D790-1).
The attachment can be equipped with two extra working lights ( ).

Xenon lights)

page 9:61.
9.6.14 Work lights, front wing

Front wing work lights, lighting
Work lights on the front wing provide enhanced view when load
handling in darkness.
The working lights are controlled by selecting with the switch for working
lights, cab roof . The signal travels to Control unit, cab (D790-1).

Xenon lights)

page 9:61.

9 Frame, body, cab and accessories – Signalling system 9:63
9.7 Signalling system

Signalling system, function description
NOTE
1 2 3 4
D2 D3 D17 17 6
7
D1 D4
15
16
D6
D6
D15 D13 D18
13 18
14 M
8 19
D790-1 D790-2 D795
D14 5
9
D797-1 D791-1
D10 20
D11
10 11 D21
21
010027
12
D12
Pos Description Signal description Reference

1 Switch, revolving beacon (S110) Switch in ON position: U = D1: Diagnostic menu, see section 8 Control
sends a voltage signal to Control unit, 24 V system group 8.4.2.6 LIGHTS, menu 6
cab (D790-1).
2 Switch, flashing hazard lights Switch in ON position: U = D2: Diagnostic menu, see section 8 Control
(Hazard) (S109) sends a voltage 24 V system group 8.4.2.4 LIGHTS, menu 4
signal to Control unit, cab (D790-1).
3 Switch, parking brake (S107) sends Switch in ON position: U = D3: Diagnostic menu, see section 8 Control
a voltage signal to Control unit, cab 24 V system group 8.4.5.4 HYD, menu 4
(D790-1).
4 The horn switch (S149-3) sends a Switch in ON position: U = D4: Diagnostic menu, see section 8 Control
voltage signal to the cab control unit 24 V system, group 8.4.3.5 CAB, menu 5
(D790-1).
5 Control unit, cab (D790-1) sends Checked by control Section 11 Common electrics, group 11.5.3.1
messages about activation on the system, error shown Control unit, cab
6 Multi-function lever (S162) sends a Signal button pressed in: Gear selector and multi-function lever,
voltage signal to Control unit KIT US162/H = 24 V description, page 9:8
system group 8.4.3.5 CAB, menu 5
7 Lever, direction indicator (S161) Left: US161/6 = 24 V D7: Diagnostic menu, see section 8 Control
sends a voltage signal to Control unit Right: US161/1 = 24 V system group 8.4.2.4 LIGHTS, menu 4
KIT (D790-2).
8 Control unit KIT (D790-2) sends Checked by control Section 11 Common electrics, group 11.5.3.11
messages about activation on the system, error shown Control unit, KIT
9 The frame control unit (D797-1) Checked by control Section 11 Common electrics, group 11.5.3.2
supplies voltage to the machine lights system, error shown Frame control unit
and buzzers. with error code.

9:64 9 Frame, body, cab and accessories – Signalling system
Pos Description Signal description Reference

10 The direction indicators (H422, H423, Light on: U = 24 V Direction indicators, description, page 9:60
H426 and H427) come on when the D10: Diagnostic menu, see section 8 Control
warning lights are activated. system, group 8.4.2.5 LIGHTS, menu 5
11 The reversing lights (E405L and Light on: U = 24 V Back-up lights, description, page 9:59
E405R) come on when reverse gear D11: Diagnostic menu, see section 8 Control
is selected. system group 8.4.2.8 LIGHTS, menu 8
12 Back-up alarm (H965) is activated Reverse gear selected: U Reverse alarm, description, page 9:66
when reverse gear is selected. = 24 V D12: Diagnostic menu, see section 8 Control
system group 8.4.2.8 LIGHTS, menu 8
13 Horn (H850) sounds when the horn Horn active: U = 24 V Horn, description, page 9:65
is activated. D13: Diagnostic menu, see section 8 Control
system group 8.4.3.5 CAB, menu 5
14 Revolving beacon (H428) is switched Light on: U = 24 V Revolving beacon, description, page 9:60
on when the flashing hazard light is D14: Diagnostic menu, see section 8 Control
activated. system, group 8.4.2.6 LIGHTS, menu 6
15 Relay loud horn (K3016) is activated UK3016/30 = 24 V Horn, description, page 9:65
when horn is activated. UK3016/85 = 0 V D15: Diagnostic menu, see section 8 Control
Horn activated: system, group 8.4.2.6 LIGHTS, menu 6
UK3016/86 = 24 V
UK3016/87 = 24 V
16 Loud horn (H850-1) sounds when the Horn active: U = 24 V Horn, description, page 9:65
horn is activated.
17 Make-contact (closing switch) Operator in seat: U = 24 V 9.3.14 Sensor, operator-in-seat, page 9:17
operator-in-seat (S230) sends a D17: Diagnostic menu, see section 8 Control
voltage signal to Control unit, cab system group 8.4.3.6 CAB, menu 6
(D790-1) when there is a load on the
driver's seat.
18 In the event of warnings, Buzzer, Checked by control D18: Diagnostic menu, see section 8 Control
cab (H853) is supplied voltage by system, error shown system group 8.4.3.6 CAB, menu 6
Control unit KIT (D790-2) to draw the with error code.
operator's attention to the warning
message.
19 In the event of warnings, control unit A clicking sound is audible Section 11 Common electrics, group 11.5.3.12
KID (D795) activates the warning when then termination Control unit, KID
lamp to draw the operator's attention resistor is activated.
to the warning message.
20 The attachment control unit (D791-1) Checked by control Section 11 Common electrics, group 11.5.3.5
supplies voltage to the automatic system, error shown Control unit, attachment
spreading buzzer during automatic with error code.
spreading.
21 The automatic spreading buzzer Buzzer active: U = 24 V Section 7 Load handling, group 7.5.10 Buzzer,
(H9003) is activated when automatic automatic spreading 20'-40'
spreading 20'-40' is activated. D21: Diagnostic menu, see section 8 Control
NOTE
On machines with side lift attachment, an audible signal can also be given with the open twistlock button (S1002) on
the panel for hydraulic functions or the open twistlock button on the joystick, provided that the "open twistlocks upon
contact" function is not active.

9 Frame, body, cab and accessories – Horn 9:65
Signalling system, component location

The machine has the following signalling systems:
1 2 3 4 5 6
018775
19 18 17 16 15 14 13 12 10,1 1 9 8 7
1. Control unit, KID (D795) 11. Control unit, cab (D790-1)
2. Buzzer, cab (H853) 12. Make-contact (closing switch) operator-in-seat (S230)
3. Control unit KIT (D790-2) 13. Horn (H850)
4. Multi-function lever (S162) 14. Switch, see Controls and instruments, overview, page
5. Direction indicator lever (S161) 9:3
6. Revolving beacon (H428) 15. Loud horn (H850-1)
7. Reverse alarm (H965) 16. Frame control unit (D797-1)
8. Reversing lights (E405L & E405R) 17. Direction indicators, front (H422 & H423)
9. Direction indicators, rear (H426 & H427) 18. Control unit, attachment (D791-1)
10. Relay loud horn (K3016) 19. Buzzer automatic spreading (H9003)
9.7.1 Horn
Horn, description
The horn is electromagnetic. Compressed air horn can be selected
( ).
The horn is activated from the gear selector and multi-function lever or
from the horn switch ( ). The horn is located under the cab (the air
horn is located on the front of the cab).
001247
9.7.2 Flashing hazard lights

Flashing hazard lights, description
See Flashing hazard lights, description, page 9:60.

9:66 9 Frame, body, cab and accessories – Revolving beacon
9.7.3 Revolving beacon

Revolving beacon, description
See Revolving beacon, description, page 9:60.
9.7.4 Warning parking brake

Warning parking brake, description
If the operator leaves the machine without applying the parking brake, a
buzzer sounds to alert the operator, i.e. to ensure the operator applies
the parking brake.
A sensor in the driver's seat (see , Sensor, operator-in-seat, description

(product alternative BE-GE), page 9:17) indicates to the control system
if the operator leaves the seat.
The buzzer is located in the steering wheel panel.
9.7.5 Reverse alarm

Reverse alarm, description
When reverse is selected, a warning sound and the back-up lights

are activated. This is to give surrounding traffic an indication that the
machine is reversing. Indication to bystanders to take caution. An
indication to bystanders to exercise caution.
Control system, group 8.4.2.8 LIGHTS, menu 8.

9 Frame, body, cab and accessories – Entertainment and communication 9:67
9.8 Entertainment and

communication
Entertainment and communication, general
The machine is prepared with a connector for customer accessories,

see section 11 Common electrics, group 11.5.2.1 Electronic box, cab.
Entertainment and communication, repair
Repairs should be left to authorised personnel.

9:68 9 Frame, body, cab and accessories – Glass/windows/mirrors
9.9 Glass/windows/mirrors
Glass/windows/mirrors, component placement
The windows are designed to both enclose the cab and provide the
C operator with a good view. Toughened glass windows are standard on
all trucks. The roof window is a safety detail and is therefore always
D made of polycarbonate plastic.
The rear view mirrors are of the convex mirror type. There is an interior
rear view mirror on all machines.
The machine has tinted, toughened glass windows.
The following windows may have laminated glass:
• Side windows front, position E
001512 • Windshield (front window), position B
A E B
A. Side windows
B. Windscreen (front window)
C. Roof window
D. Rear window
E. Front side windows
Silicone adhesive, handling advice

The window panes are secured with decor strips adhesive and silicone
adhesive.
NOTE
The purpose of this instruction is to describe how silicone adhesive
923854.0001 should be handled in connection with replacement of
the windscreen and roof window on the Spirit Delta cab.
• Silicone adhesive 923854.0001 is a quick-hardening,
two-component silicone adhesive that can withstand
temperatures between -50 ºC and +200 ºC. The hardening
properties of the adhesive are extremely dependent on the
ambient temperature. An increase of 10 ºC cuts hardening
time in half.
Silicone adhesive 923854.0001 is mixed at a ratio of 1:10
in a static mixer. Change mixer after every interruption that
lasts more than 5 minutes. The short setting time means that
work has to be planned carefully in order to avoid undesired
hardening.
Fixing time:
10-20 minutes at 20 ºC
approx. 5 minutes at 60 ºC
Hardening time:
approx. 24 hours at 20 ºC
approx. 1 hour at 60 ºC
Full strength is obtained after 7 days.
• In warm climates, it is advantageous to cool the container to
increase hardening time. The silicone adhesive should not be
used at temperatures above +75 °C.
• In cold climates, the hardening time can be shortened by
covering the joints so that cooling is prevented. The window
pane can be warmed with defroster or cab heater.
• The recommended storage temperature is between -30 ºC
and +20 ºC. Storage in a refrigerator or a colder environment
is recommended.

9 Frame, body, cab and accessories – Windscreen 9:69
9.9.1 Windscreen
Windscreen, description
The windscreen consists of the front window and side windows. The
windscreen is attached to the cab with a decor strip and is glued to
the roof window with silicone adhesive. Front and side windows are
joined with silicone adhesive to give good all-round visibility from the
operator's station.
For location see, Glass/windows/mirrors, component placement, page

9:68.
Windscreen, replacement
NOTE
Read the handling advice for silicone adhesive before starting
work. See Silicone adhesive, handling advice, page 9:68.

2 Remove the decor strip.
3 Remove the broken window pane and check that no remains of
glass or other particles remain in the window pane's groove on the
strip. Cut apart silicone joints with a sharp tool.
NOTE
Make sure that no silicone adhesive remains between the window
pane and the strip by the window pane's lower front edge.
If the roof window is to be replaced, then all bolts must be
removed before the silicone adhesive is cut away.
CAUTION
Strong dissolvents, e.g. acetone, must not come
Removing the decor strip into contact with a window made of polycarbonate
plastic. Dissolvents have a chemical effect on the
polycarbonate plastic which reduces the strength of
the roof.
4 Clean all surfaces thoroughly. Remove old remains of silicone with

a razor blade or similar.
5 Fit masking tape on the inside and outside of the window panes by
the surfaces that are to be glued.

9:70 9 Frame, body, cab and accessories – Windscreen
1 2 3 6 When the windscreen or a side window is to be replaced, then the

window panes must be adjusted so that the upper edge on the side
window has the same height as the upper edge of the cab roof and
so that the distance between windscreen and side window.
Use spacers against the roof member to ensure that the distances
are maintained.
1,0
1
006268
Adjusting side window - cab roof
1. Side window
006269
2. Rubber strip 1,0
3. Cab frame/door opening
Adjusting side window - windscreen
1. Masking tape
7 Fit the decor strip around the whole window pane.
8 Apply silicone adhesive 923854.0100 around the window panes.
Make the new joint wider than the old one in order to create a good
seam.
The silicone should be applied from the outside of the joints, to
give a full and smooth joint.
NOTE
There must be silicone between the window panes, to avoid
contact between the window panes.
9 Remove excess silicone from the outer vertical corners, using a

tool made of cardboard. Smooth out the joints on the inside with a
finger soaked in water or soapy water.
10 Apply silicone adhesive 923854.0100 between the strip and
window pane at the bottom edge of the front corners, so-called
top sealing.
11 If the roof window is to be replaced, apply silicone adhesive
923854.0100 by the cab frame (where it was glued earlier).
12 Align the roof window into place and check that there is a uniform
distance of one or several millimetres along the window pane's
edges and by the protection over the frame's sides. Then tighten
the corner bolts for the window pane.
13 Apply silicone adhesive 923854.0100 by the edges and smooth
out the joints with a finger, wet with water or soapy water.
IMPORTANT
006272
Cardboard tool template for silicone joint scale 1:1 Mark the window panes with "New adhesive. Do not
touch".
14 Remove the masking tape immediately after applying adhesive to

avoid edge formation. Hardening time is dependent on ambient
temperature, plan the change so that downtime is minimised.

9 Frame, body, cab and accessories – Side window 9:71
9.9.2 Side window

Side window, description
The side windows are secured in the cab and doors with decor strips.
For further details, see Glass/windows/mirrors, component placement,

page 9:68.
Side window, replacement
NOTE
The method describes a general procedure.

2 Use special tools to detach the decor strip.
3 Remove the decor strip which runs around the whole window.
4 Carefully remove any remains of glass from the rubber strip.
5 Fit the new window, securing it at the bottom edge in the rubber
strip.

9:72 9 Frame, body, cab and accessories – Side window
6 Spray soap solution on the window and rubber strip to facilitate

fitting.
7 Thread the rubber strip around the whole window; use special
tools.
8 Secure the decor strip with a special tool. Use a soap solution on
the decor strip and rubber strip.
9 Pull the decor strip around the whole window. Avoid stretching
the decor strip.

9 Frame, body, cab and accessories – Roof window 9:73
10 Cut off the decor strip approx. 2 cm too long.

11 Fit the other end of the decor strip edge to edge.
12 Adjust the decor strip so that the correct fit is obtained. Push in
the remaining part of the decor strip in the rubber strip. Press the
decor strip toward its opposite end.
9.9.3 Roof window

Roof window, description
The roof window is made of polycarbonate plastic, which is a safety
feature for the operator, intended to protect the operator from falling
objects. The polycarbonate plastic plate is elastic.
Safety is maintained within a temperature interval of 120 ºC to -45 ºC

(becomes brittle at -110 ºC, glass conversion temperature 145 ºC). The
roof window has a patented surface layer that increases its resistance
to wear, UV light and chemicals.
The roof window is joined with the windscreen. Joints between the
window panes and between roof window and cab are sealed tightly with
silicone adhesive. Align a new seal of silicone adhesive when replacing.
For location, see Glass/windows/mirrors, component placement, page

9:68.
WARNING
The strength of the roof window may be significantly
reduced in case of exposure to substances containing
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the surface layer of the roof window and
clean only with washer fluid or mild detergent. Rinse
thoroughly with lukewarm water afterwards. Replace a
damaged roof window that shows cracks or scratches
immediately!
Roof window, replacement

See Windscreen, replacement, page 9:69, for the general procedure.
The roof window is joined with the windscreen. The joint is sealed with
silicone. Align a new seal of silicone when replacing.

9:74 9 Frame, body, cab and accessories – Rear window
9.9.4 Rear window

Rear window, description
The rear window is attached to the cab with a decor strip.
For further details, see Glass/windows/mirrors, component placement,

page 9:68.
Rear window, replacement

See Side window, replacement, page 9:71 for the general procedure.
9.9.5 Rear view mirror

Rear view mirror, description
The cab has a rear-view mirror located inside the cab as well as
exterior mirrors on the outside of the machine. The function of the rear
view mirror is to give the operator visibility around the machine.

9 Frame, body, cab and accessories – Cab structure and suspension 9:75
9.10 Cab structure and suspension

Cab structure and suspension, description
The cab is mounted in a cab substructure via strong rubber insulators
fitted on the underside of the cab. This minimises vibrations from the
frame to the cab. There is an insulator at four points, one at each
1 corner. Each insulator mounting has one rubber bushing and one bolt.
003206
4
Cab Spirit Delta
1. Cab frame
2. Door
3. Cab suspension
4. Cab substructure
9.10.1 Cab frame

Cab frame, description
The cab frame is made of high-strength steel sheet profiles. The cab is
dimensioned to handle impacts and, to some degree, dropped loads.
The frame must not be modified!
002210
Cab Spirit Delta
9.10.2 Doors
Doors, description
The cab has two doors, the left is the operator's door and the right is
the emergency exit. The door has:
• hand rail
• handle
• key lock
• openable window (emergency exit )
Switches in the doors' locks sense if the door is open. The switch is
used to light the interior lighting and warn of an open door.
Control system, group 8.4.2.9 LIGHTS, menu 9.

9:76 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 chassis mounting depends on whether the machine is
equipped with a hydraulic tiltable cab.

9 Frame, body, cab and accessories – Cab interior 9:77
9.11 Cab interior

9.11.1 Instrument and control panels
Steering wheel panel, description
The steering wheel panel is secured to the steering column and
contains warning and indicator lights, display (KID), function keys
(KIT) and switches.
Left-hand dashboard panel, description

The left-hand dashboard panel is located in the left-hand corner of the
cab. It contains rotary controls, switches, and ventilation.
Panel for load handling functions, description

The panel is mounted on the driver's seat. The panel includes switches
and controls for load handling functions and emergency stop switches
to interrupt ongoing load handling functions.
On machines equipped with a control lever, it is located next to the

panel .
Steering wheel panel, replacement

2 Remove the steering wheel centre cover.
3 Remove the nut and the steering wheel.
4 Remove the bolts on the underside of the steering wheel panel.

9:78 9 Frame, body, cab and accessories – Interior fittings, plastic
5 Remove the bolts on the top of the steering wheel panel.
6 Unplug the connector from the multi-function levers, ignition key

lock, Control unit KIT (D790-2) and Control unit KID (D795).
7 Transfer the components to the new steering wheel cover.
9.11.2 Interior fittings, plastic

Interior fittings, plastic, description
The interior of the cab consists of recyclable material.
9.11.3 Interior fittings, textile

Interior fittings, textile, description
The interior of the cab consists of recyclable material.
9.11.4 Floor covering

Floor covering, description
The floor covering is a wear-resistant and recyclable material.
9.11.5 Insulation
Insulation, description
The cab insulation consists of recyclable material.

9 Frame, body, cab and accessories – Terminal console 9:79
9.11.7 Terminal console

Terminal console, description
The function of terminal desk is to provide a work surface for a

computer/terminal. It is located to the right of the steering wheel, easily
accessible for the operator.
008227
9.11.8 Writing desk
Writing desk, description
The writing desk with a reading lamp is fitted on a jointed bracket

to the right in front of the door in the cab. Work orders, etc. can be
attached here.
008228
9.11.9 Reading-lamp
Reading lamp, description
The reading lamp is fitted on a jointed bracket to the right in front of

the door in the cab.

9:80 9 Frame, body, cab and accessories – Frame
9.12 Frame
Frame, description
The frame 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, gearbox, drive axle,
steering axle, fuel and hydraulic tanks, cab, mast and body parts.
The space in the rear section of the frame is used for counterweights,
the number of which is adapted to the machine in question. The
counterweights are designed to allow as good visibility rearwards as
possible.
The front wings are bolted into the frame (which has advantages when
delivering the machine).
1
2
018776
3 4 5 6
1. Frame's rear section with counterweights 4. Bracket for front wings
2. Engine compartment with mountings for engine and 5. Cab mounting (4 points)
transmission
6. Steering axle mounting
3. Frame's front section with drive axle mounting

9 Frame, body, cab and accessories – Body structure 9:81
9.13 Body structure

Body structure, description
The body structure's components comprise:
2 1
018777
3
1. Counterweight
2. Hood engine compartment
3. Wings
9.13.1 Wings
Wings, description
There are wings over the wheels to protect from dirt thrown up by
the wheels during operation. The design of the counterweight (see
Counterweights, description, page 9:82) acts as a mudguard for the
rear wheels.
The fenders can be equipped with extra mudguards when the

machine's work environment requires such ( ).
9.13.2 Hood engine compartment

Hood engine compartment, description
The machine's engine compartment is protected by a hood.
The machine compartment for the transmission and drivetrain/axle is

protected by floor plates. The floor plates are secured with fastening
bolts. The floor plates are designed for walking on and are ribbed to
provide sure footing.
9.13.3 Footsteps and hand rail

Footsteps and hand rail, description
The cab has footsteps for easy access. There is a hand rail by the cab.

9:82 9 Frame, body, cab and accessories – Counterweights
9.13.4 Counterweights
Counterweights, description
The machine has counterweights to balance the machine's lift capacity
and these may therefore vary in quantity and weight.
The counterweights are located at the very back of the frame for
maximal leverage.
The machine has counterweights in the following locations:

• Under the steering axle
• Furthest back on the machine there are vertical counterweights
secured in the rear edge of the frame; the outer has a towing eye.
Between the outer counterweight and frame, there are smaller
counterweights whose dimensions and quantity are adapted to
balance the machine's lifting capacity.
• Upper horizontal counterweight.
Under the horizontal counterweight, there are smaller
counterweights whose dimensions and quantity are adapted to
balance the machine's lifting capacity.
DANGER
The counterweights are factory fitted and are adapted
according to the machine's properties.
The machine's driving characteristics change if the
counterweights are removed or added!
Never change the quantity of counterweights.

9 Frame, body, cab and accessories – Central lubrication 9:83
9.14 Central lubrication

Central lubrication, checking
1 Check that no grease has been forced out through the safety
valve (position 2).
If grease has been forced out through the safety valve, this means
that there is a blockage in the system. Locate the line that is
blocked by feeling the connections on the distribution blocks. A
blocked hose remains pressurized and the connection will be rigid.
NOTE
If several distribution blocks are connected in series, a clogged
line will be pressurised all the way to the first distribution block.
2 Turn the start key to position I.

3 Operate the pump manually and check that the indicator pin moves
in and out on the distribution block.
To operate the pump, loosen the cover and press in the switch for
manual operation (position 5).
If the indicator pins do not move even when the pump is running,
troubleshoot the pump unit.
NOTE
The system can be lubricated manually through the grease nipple
on the distribution block.
4 Fill grease in the pump unit through the filler nipple, see section
F Technical data.
Overview central lubrication. Example illustration.

1. Grease nipple, filling point grease
2. Safety valve
3. Grease nipple, manual lubrication of system
4. Indicator pin
5. Switch, manual operation

9:84 9 Frame, body, cab and accessories – Central lubrication
Central lubrication, adjusting lubrication times

Test or extra greasing
The central lubrication's pause and run-time must be set after changing,
the setting is unique to each machine, depending on the machine's
equipment. When changing the new pump unit must be set in the
same way as the old one.
If the machine does not lubricate properly the running and pause times
can be adjusted. The running time is adjusted first, so that all the
lubrication points on the machine have time to be lubricated each time.
If large amounts of grease are forced out to all lubrication points the
pause time can be increased.
NOTE
Only adjust one step each time. Small adjustments make a large
difference.
Test or extra greasing

Central lubrication can be run manually by pressing and holding
the button for manual operation for 2 seconds. This starts an extra
lubrication cycle.
Pause time
Example illustration The pause time is the length of the interval between lubrications. The
interval is adjusted in full hours between 1 and 15 hours. The pause
1. Pause time setting (red) time is adjusted with the red dial.
2. Run-time setting (blue)
3. Manual pump operation
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Pause time [hours] 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Run-time
The run-time is the time that the pump is activated each time. The
run-time can be adjusted between 2 and 30 minutes. The pause time is
adjusted with the blue dial.
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Run-time [minutes] 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

9 Frame, body, cab and accessories – Pump unit 9:85
9.14.1 Pump unit

Pump unit, description
The pump unit consists of containers with stirrer, pump housing with
built-in motor, timer, pump element, filler nipple, and safety valve.
Central lubrication works with lubrication cycles (pause and run-time
and read time). There is a circuit board with a timer in the pump. This
can be used to set the run and pause time of the pump motor.
When the central lubrication works so that the lubrication points are
lubricated one by one in series. If there is a blockage in a lubrication
point, the pressure will rise and the safety valve will release grease, in
addition subsequent lubrication points will not be lubricated.
NOTE
The safety valve will force grease out if a lubrication point cannot
be lubricated. If a lubrication point is not lubricated, none of the
subsequent points will be lubricated. It is therefore very important
to check the safety valve.
Example illustration, components central lubrication

1. Pump unit
2. Safety valve
9.14.2 Distribution block

Distribution block, description
The distribution blocks distribute grease from pump unit to the

lubrication points or to other distribution blocks. The number of
distribution blocks can vary depending on how many (and which)
lubrication points are selected.
The distribution blocks consist of pistons that proportion grease into
each lubrication point. The pistons are powered by the lubricant and
have no springs and seals. It is the grease that powers the pistons
inside the distributor. The design of the pistons and channels in the
distribution block make the pistons move in a predetermined manner.
Each piston must have complete its movement before the next piston
can move. The pistons are interdependent. It is technically impossible
for a connected lubrication point to be missed. If a lubrication point
cannot be lubricated, the complete system is blocked and the grease is
pressed out through the safety valve.
There is an indicator pin on the system's first distribution block (i.e. the
block closest to the pump unit). If the pin moves back and forth (at
the same rate as the piston movement) this indicates that the grease
is being pumped through the system. If one distributor block cannot
deliver grease to one of its lubrication points, the pin stops and thus
Example illustration, components central lubrication
the whole system.
1. Pump unit
2. Safety valve If there is a blockage in the system, this line will be pressurised from
the pump to the stop through all distribution blocks on the circuit. This
3. Distribution block makes it easy to find a blockage in the system. The blockage can be
traced by feeling the distribution blocks' connectors and identifying
which connections are rigid. Note that several distribution blocks can
be connected in series.

9:86 9 Frame, body, cab and accessories – Lines
9.14.3 Lines
Lines, description
Central lubrication works under very high pressure, only use lines that
meet the following specifications.
Main hose
Diameter 8.4 mm
Explosion pressure min. 60.0 MPa

9 Frame, body, cab and accessories – Paint/coatings 9:87
9.15 Paint/coatings
Paint/coatings, description
The machine is painted with an alkyd-based mono-component paint
that is applied with a brush or a spray. For paint codes (RAL), see
machine card.
Check the machine frequently for stone chips, dents and paint
scratches, repair them at once to prevent corrosion on the metal
underneath. Only use touch-up paint for small stone chips and
scratches. More extensive paint damage should be repaired by a paint
workshop.
NOTE
Before touching up, the surfaces to be touched up must be
thoroughly cleaned.
Please contact Cargotec for information about other surface treatment

and material colours.

9:88

10:1
Contents 10 Common hydraulics

10 Common hydraulics ........................................................................................ 10:3
10.2 Safety valves..................................................................................................10:3
10.2.1 Accumulator drain valve ............................................................................10:3
10.2.3 Pressure relief valve..................................................................................10:4
10.2.4 Pipes and hoses........................................................................................10:4
10.3 Tanks and accumulators ................................................................................10:5
10.3.1 Hydraulic oil tank .......................................................................................10:5
10.3.2 Accumulator ..............................................................................................10:5
10.3.4 Pipes and hoses........................................................................................10:6
10.4 Pumps............................................................................................................10:7
10.4.1 Gear pump with fixed displacement ..........................................................10:7
10.4.3 Pipes and hoses......................................................................................10:13
10.5 Hoses, pipes and valves ..............................................................................10:14
10.5.1 Pipes and hoses......................................................................................10:14
10.5.4 Main valve ...............................................................................................10:15
10.6 Temperature control, cleaning and hydraulic oil...........................................10:19
10.6.2 Cooler hydraulic oil..................................................................................10:21
10.6.3 Cooling fan ..............................................................................................10:22
10.6.4 Sensor hydraulic oil temperature.............................................................10:22
10.6.5 Bypass valve, cooler ...............................................................................10:24
10.6.6 Breather filter hydraulic oil tank ...............................................................10:25
10.6.7 Hydraulic oil filter .....................................................................................10:25
10.6.8 Hydraulic oil.............................................................................................10:27
10.6.9 Pipes and hoses......................................................................................10:29
10.6.10 Fine filter hydraulic oil..............................................................................10:29
10.7 Other ............................................................................................................10:31
10.7.1 Hydraulic cylinders ..................................................................................10:31

10:2

10 Common hydraulics – Common hydraulics 10:3
10.2 Safety valves
10.2.1 Accumulator drain valve
Accumulator drain valve, description
The accumulator drain valve is located on the valve block brake system
and is used to drain the pressure in the brake system's accumulators to
the tank. See section 4 Brakes, group 4.3.12 Valve block brake system.
014619
Accumulator drain valve, the illustration shows the

closing of the valve.

The relief valve is located on the pressure supply from the lift, tilt and
attachment control valve included in the main valve to the attachment
control valve. The valve drains the pressure build-up between the lift,
1 tilt and attachment control valve and the attachment control valve to
tank. See section 7 Load handling, group 7.4.7 Relief valve attachment.
015019
Relief valve, attachment. The illustration depicts an

open valve.

10:4 10 Common hydraulics – Pressure relief valve
10.2.3 Pressure relief valve

Pressure limiting valve, description
The pressure limiting valve (position 3) is located on the valve block
1 2 3 brake system and protects the brake system against excessive
4 pressure. See section 4 Brakes, group 4.3.12 Valve block brake
system.
11
6
7
10
9 8
015018


Pipes and hoses, general
See Pipes and hoses, general, page 10:14.

10 Common hydraulics – Tanks and accumulators 10:5
10.3 Tanks and accumulators

10.3.1 Hydraulic oil tank
Tank, description
1 2 1 3 2 4 5 The hydraulic oil tank forms part of the side panel on the right-hand side
of the machine. The oil filters for the working hydraulics are fitted inside
the tank. These are accessible through hatches on top of the tank.
Hydraulic oil is filled directly into the tank through the filler caps on
the filter manhole covers. For oil capacity and grade, see section F
Technical data. The whole filter unit can be removed to facilitate access
for cleaning. There is a drain plug located at the bottom of the tank.
The tank is equipped with filtered breather that allows volume changes
in the tank, due to temperature variations and use.
The oil level is checked on the sight glass on the tank's side when all
hydraulic cylinders are in the bottom position.
018778
1. Hydraulic oil filter cover

2. Hydraulic oil filler plug
3. Sight glass hydraulic oil
4. Breather filter hydraulic oil tank
5. Hydraulic oil drain plugs
10.3.2 Accumulator
Accumulators, description
Brake system accumulators, see section 4 Brakes, group 4.3.4
1 2 Accumulator
Accumulator lift, see section 7 Load handling, group 7.2.14 Accumulator

lift
018779
Accumulators
1. Brake system accumulators
2. Accumulator lift

10:6 10 Common hydraulics – Pipes and hoses


10 Common hydraulics – Pumps 10:7
10.4 Pumps
10.4.1 Gear pump with fixed displacement
Gear pump with fixed displacement, description
The hydraulic system is fed by two gear pumps with fixed displacement
6 1 that are driven via the transmission's power take off. A pump feeds the
brakes, steering and cooling circuit, the second feeds load handling.
The gear pumps pump oil by the two gears rotating against each other.
One gear wheel is driven by the pump's input shaft and the other rotates
freely. The movement of the gears creates suction between gear and
housing. Each turn that the gears spin pumps a certain quantity of oil
5 2
(fixed displacement). The pump's flow varies with the rotational speed
of the input shaft. The pump shafts are bearing-mounted with slide
bearings lubricated by the oil flowing through. On each side of the
pump wheels there are pressure plates that seal between the suction
and pressure side.
3 The displacement, i.e. how many cubic centimetres of oil that the pump
can deliver per pump revolution, differs on the various gear pumps.
000660
4
1. Pump housing
NOTE
2. Outlet It is very important that the clearance between the gears and
between the gear and the housing is correct. Clearance that is too
3. Drive wheel small creates wear damage. Clearance that is too large reduces
4. Tooth slot the pump's power output.
5. Intake
6. Following wheel
Hydraulic oil pump brake and steering
Hydraulic oil pump brake and steering
1 2 Hydraulic oil pump brake and steering feds the servo brakes, parking
brake and steering, the residual flow is used for cleaning and
cooling. Distribution of the hydraulic power is handled by valve block
accumulator charging and priority valve on the main valve, see, Main
valve, description, page 10:15.
For a more detailed description of the various functions see:

• Section 4 Brakes, group 4.3 Servo brake system.
• Section 4 Brakes, group 4.5 Parking brake system.
• Section 5 Steering, group 5.2 Power assisted system.
• Temperature control, cleaning and hydraulic oil, function
018780
Hydraulic oil pump, load handling

The load handling hydraulic oil pump feeds the load handling functions
1. Hydraulic oil pump for load handling
with hydraulic pressure. The lift, tilt and attachment control valve on
2. Hydraulic oil pump for brake pressure, steering the main valve distributes the hydraulic pressure between the various
functions, see Main valve, description, page 10:15.
For a more detailed description of the various functions see:

• Section 7 Load handling, group 7.2 Lifting/lowering.
• Section 7 Load handling, group 7.4 Side shift.
• Section 7 Load handling, group 7.5 Spreading.
• Section 7 Load handling, group 7.7 Tilt.
• Section 7 Load handling, group 7.9.1 Twistlocks.

10:8 10 Common hydraulics – Gear pump with fixed displacement
Hydraulic oil pump brake and steering, checking
NOTE
Safety.
˚C
Operating menu, hydraulic oil temperature 000475

pump pressure brakes and steering on the main valve.
014649
Measuring outlet, pump pressure brake and steering

[PM]
6 Close the accumulator drain valve and check the pump pressure
during charging.
NOTE
the lock ring.
014619

10 Common hydraulics – Gear pump with fixed displacement 10:9
Check that the pressure rises to the specified feed pressure on

the pressure plate.
measuring outlet.
015023
Pressure plate, pump pressure brakes and steering
NOTE
the lock ring.
014619

Load handling hydraulic oil pump, checking

˚C
000475

pump pressure load handling on the main valve.
014650
Measuring outlet, pump pressure load handling [P2]
5 Close the accumulator drain valve and the attachment relief valve.
014619

10 Common hydraulics – Gear pump with fixed displacement 10:11
7 Check that the feed pressure corresponds with the pressure plate.
measuring outlet.
015024
Pressure plate, feed pressure load handling
NOTE
the lock ring.
014619

Gear pump with fixed displacement, replacement
NOTE
Safety.

3 Clean the hydraulic oil pumps and the areas around them.
Fastening screws hydraulic oil pump load handling

4 Mark up and detach the hydraulic hoses from the pump.
NOTE
from impurities.
5 Remove the pump.

Remove the attaching bolts, pull the pump forward and lift it away.
6 Transfer the connection adapters to the new pump.
NOTE
Fastening screws hydraulic oil pump brake and
steering
correctly.
7 Check the seal between the pump and transmission, replace if

necessary.
8 Fit the pump and check that the pump's splines engage in the
shaft in the transmission.
Fit the pump's attaching bolts, use locking fluid to lock the bolt and
seal the screw holes in the transmission.
9 Connect the hydraulic hoses in accordance with the markings.
NOTE
Prefill the pump with oil through the pressure connection before it
is put into service.
Bleed the pump if necessary before starting the engine by
detaching the hoses from the pressure side.
NOTE
correctly.

10 Common hydraulics – Pipes and hoses 10:13
NOTE
the lock ring.
11 Switch on the system voltage and start the engine.

12 Check that the hose connections are tight.
014619
13 Check the hydraulic oil level with all hydraulic cylinders fully
retracted. Top up if necessary.
NOTE
If the pump is replaced due to malfunction, change the oil and
filter in the hydraulic system as well.
CAUTION
Do not overfill!


10:14 10 Common hydraulics – Hoses, pipes and valves
10.5 Hoses, pipes and valves

Hoses with ORFS couplings are used almost exclusively. For maximum
service life and function, the following should be observed when
replacing hoses.
1. To avoid stresses in the connection, there should be a length of
straight hose after the connection.
2. The hose must not be twisted. (A twist of 7% reduces service life
by 90%.)
3. Minimise the number of bends by using correct couplings.
4. Avoid sharp bends.
5. Keep the hoses clean internally. Leave the plugs in place as long
as possible when installing.
6. Check the position of the O-rings and tighten to the correct torque,
see section F Technical data.
NOTE
Straight coupling requires a counterhold wrench to prevent damage
to the O-ring.
7. O-rings must not be oiled; O-rings must be dry during assembly.

Hose length
C/L Hose length

Hose length is measured on a hose laid out between the sealing
surfaces. On angled connections, measure from the sealing surface's
centre line [C/L] as illustrated.
Cleanliness
The function and service life of hydraulic components depend to a great
extent on how clean the hydraulic oil is. It is therefore very important to
prevent dirt from entering the brake and hydraulic system.
Some simple advice to keep the hydraulic system clean.

• Always clean the area around a component before starting to work.
001015
• Plug hose connections immediately after disconnecting. If possible,

use correct plugs for the connection type. If plugs are missing, use
C/L line for measuring hose length clean plastic bags and cable ties or tape to seal the connection.
• Never re-use oil that has been drained from the machine.
• Oil drums often contain contaminants.
When filling hydraulic oil, fill through the cover on the hydraulic oil
filters in the tank so that the oil is filtered.

10 Common hydraulics – Main valve 10:15
10.5.4 Main valve

Main valve, description
1 2
3
4
5
6
28
7
27
26 8
10
11
25
24
12
23
22
13
21 14
20 15
015031
19 18 17 16
1. Solenoid valve, lower (Y6004) 16. Measuring outlet servo pressure [PPM]
2. Solenoid valve, lift (Y6005) 17. Adjusting screw accumulator charging pressure
3. Adjuster screw max pressure lift 18. Connection valve block brakes, accumulator charging
[ACC]
4. Solenoid valve hydraulic pressure attachment
(Y6012/Y6062) 19. Measuring outlet accumulator pressure [ACC M]
5. Solenoid valve, tilt in (Y6011) 20. Adjusting screw servo pressure
6. Solenoid valve, tilt out (Y6010) 21. Measuring outlet pump pressure brake and steering
[PM]
7. Adjuster screw max pressure tilt and attachment
22. Connection tilt cylinders, piston side
8. Feed from the hydraulic oil pump brake and steering [P]
23. Connection tilt cylinders, rod side
24. Connection control valve, attachment
25. Connection lift cylinders, piston side
26. Feed hydraulic oil pump load handling [P2]
12. Connection brake cooling [SPOL], to the drive axle
block 27. Return to filter [D]
13. Connection control valve, pilot pressure [LSO] 28. Measuring outlet, pump pressure load handling [P2]
15. Connection servo valves [PP]

10:16 10 Common hydraulics – Main valve
The main valve comprises lift, tilt and attachment control valve which is
integrated with the valve block accumulator charging and priority valve.
Valve block accumulator charging and priority valve
Valve block accumulator charging and priority valve controls the
hydraulic pressure to the brakes, steering and cooling of the brakes
and hydraulic oil. In addition, it supplies the valve block lift, tilt and
attachment control valve with servo pressure.
Accumulator charging valve
The accumulator charging valve is a part of the valve block accumulator

charging and priority valve located on the main valve and distributes
oil from the hydraulic oil pump brakes and steering between pressure
storage and cooling of the wheel brakes.
See section 4 Brakes, group 4.3.3 Accumulator charging valve.
Priority valve
The priority valve is included in the valve block accumulator charging

and priority valve located on the main valve.
See section 5 Steering, group 5.2.2 Priority valve.
Pressure reducer
The pressure reducer is included in the valve block accumulator

charging and priority valve located on the main valve.
See section 7 Load handling, group 7.2.3 Pressure reducer.

Lift, tilt and attachment control valve
The control valve is the second part of the main valve and controls the
hydraulic pressure to the lift and tilt cylinders and to the attachment
control valve.
See section 7 Load handling, group 7.2.5 Lift, tilt and attachment
control valve, 7.4.9 Lift, tilt and attachment control valve and 7.7.5 Lift,
tilt and attachment control valve.

10 Common hydraulics – Main valve 10:17
Main valve, replacement
NOTE
Safety.

3 Place a container tray under the main valve and remove the cover
that sits over the main valve.
4 Mark up and detach the hydraulic hoses from the main valve.
NOTE
from impurities.
5 Mark up and detach the wiring from the main valve.

6 Remove the fastening screws and lift off the main valve. Place the
valve on a clean and protected surface.
7 Transfer the connection adapters to the new main valve.
NOTE
correctly.
NOTE
015103

Main valve mixed up.
8 Mark up the solenoid valves on the new main valve.

9 Lift the main valve into place and fit the fastening screws.
10 Connect the hydraulic hoses to the main valve in accordance
with the marking.
NOTE
correctly.
11 Connect the cable harness to the main valve in accordance with

the marking.

10:18 10 Common hydraulics – Main valve
NOTE
the lock ring.

14 Check that the valve\qs hydraulic connections are sealed.
15 Bleed the brakes, see section 4 Brakes, group 4.3.9 Wheel brakes.
16 Check the steering
Activate the steering gradually to bleed the steering's hydraulic
014619
circuit.
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.
17 Check that the attachment is working.

Activate the lift function, tilt function and the attachment functions
gradually to bleed the hydraulic circuits.
18 Check the supply pressure to the brakes and steering, see
Hydraulic oil pump brake and steering, checking, page 10:8.
19 Check the supply pressure to the load-handling functions, see
Load handling hydraulic oil pump, checking, page 10:10.
20 Check the accumulator charging pressure, see 4 Brakes, group
4.3.3 Accumulator charging valve.
21 Check the brake pressure, see 4 Brakes, group 4.3.5 Brake valve.
22 Check the steering pressure, see 5 Steering, group 5.2.1 Hydraulic
oil pump.
23 Check the servo pressure, see 7 Load handling, group 7.2.3
Pressure reducer.
24 Remove the container tray and replace the cover over the main
valve.
25 Check the oil level in hydraulic oil tank with all hydraulic cylinders
in the retracted position. The oil level should be at the top of the
sight glass. Top up if necessary.
CAUTION
Do not overfill!
26 Test drive the machine and check that all functions work correctly.

10 Common hydraulics – Temperature control, cleaning and hydraulic oil 10:19
10.6 Temperature control, cleaning

and hydraulic oil
Temperature control, cleaning and hydraulic oil,
function description
The hydraulic system's oil is cooled and purified by it circulating
through the wheel brakes, cooler and filters. The cooler has a
temperature-controlled electric fan that prevents overheating.
Temperature control consists of a hydraulic oil tank, hydraulic oil pump,

valve block, hydraulic oil cooler, cooling fan, hydraulic oil filter, fine filter,
hydraulic oil temperature sensor and bypass valve.
Hydraulic oil pump brakes and steering pumps oil (from the tank)
through the brake system's cooling circuit to be cooled in the hydraulic
oil cooler. Some of the oil is filtered by the fine filter. An electric cooling
fan increases the air flow through the cooler when the temperature
needs to be lowered. A bypass valve opens when the oil is cold and
leads the oil directly to the tank in order that the resistance through
the cooler and filter should not be too high. The bypass valve closes
when the oil gets hot and then leads the oil through the cooler and
filter instead. The temperature sensor controls fan activation and
temperature indication in the display.
Excess oil from brakes and steering, and the return oil from load
handling is filtered by the hydraulic oil filter in the hydraulic oil tank.
10, 16 15
D795 D790-2
D797-1
9, 1 1, 14
D 2 4
18 C
SPOL
P2
D P
12 M
7 5
C 19 3 C
6
13
17 1
015037
8 °C 20

1 Hydraulic oil pump for the brakes and See pressure plate on left Gear pump with fixed displacement,
steering pumps oil from the hydraulic oil frame beam. description, page 10:7
tank.
2 Valve block accumulator charging and P < 0.3 MPa See section 4 Brakes, group 4.3.3
priority valve directs oil to steering, charging Accumulator charging valve
of the accumulators, hydraulic oil filter or
through the hydraulic system's cooling
circuit. Surplus oil is routed to the hydraulic
oil filter.

10:20 10 Common hydraulics – Temperature control, cleaning and hydraulic oil

3 The hydraulic oil filter cleans the oil. - Hydraulic oil filter, description, page
10:25
4 Hydraulic oil in the cooling circuit passes - See section 4 Brakes, group 4.3.6 Drive
through the drive axle block to the wheel axle block
brakes.
5 The hydraulic oil cools the wheel brakes. - See section 4 Brakes, group 4.3.9
Wheel brakes.
6 A small amount of oil is guided through the Fine filter hydraulic oil, description, page
fine filter and back to the hydraulic oil tank. 10:29
7 The hydraulic oil cooler cools the oil. - Hydraulic oil cooler, description, page
10:21
8 The hydraulic oil temperature sensor - Sensor, hydraulic oil temperature,
(B776) sends the frame control unit description, page 10:22
(D797-1) a voltage signal proportional to D8: Diagnostic menu, see section 8
the hydraulic oil temperature. Control system, group 8.4.5.1 HYD,
menu 1
9 The frame control unit (D797-1) transmits Checked by the control Section 11 Common electrics, group
oil temperature on the CAN bus. system, error indicated 11.5.3.2 Frame control unit
with error code. D8: Diagnostic menu, see section 8
Control system, group 8.4.5.1 HYD,
menu 1
10 The KID control unit (D795) shows - Section 9 Frame, body, cab and
oil temperature in the operating menu accessories, group 9.1 Controls and
hydraulic oil temperature. instruments.
11 If the hydraulic oil temperature is high, U = 24 V Cooling fan, description, page 10:22
the frame control unit (D797-1) supplies D8: Diagnostic menu, see section 8
voltage to the Cooling fan (M668). Control system, group 8.4.5.1 HYD,
menu 1
12 The cooling fan (M668) increases the - Cooling fan, description, page 10:22
airflow through the hydraulic oil cooler, thus
increasing cooling output
13 If the oil temperature is low or the pressure P = 0.2 MPa Bypass valve, cooler, description, page
through the cooler becomes too high, the 10:24
bypass valve opens and leads the oil past
the cooler.
14 If the hydraulic oil temperature is too high, Checked by the control Section 11 Common electrics, group
the frame control unit (D797-1) transmits a system; error shown with 11.5.3.2 Frame control unit
warning for high hydraulic oil temperature error code. D8: Diagnostic menu, see section 8
on the CAN bus. Control system, group 8.4.5.1 HYD,
menu 1
15 The KIT control unit (D790-2) activates the - Section 9 Frame, body, cab and
hydraulic oil temperature warning light. accessories, group 9.1 Controls and
instruments.
16 The KID control unit (D795) shows the error Checked by the control Section 11 Common electrics, group
code on the display. system; error shown with 11.5.3.12 Control unit, KID
error code.
17 The hydraulic oil pump load handling - Gear pump with fixed displacement,
pumps oil to lift, tilt and attachment control description, page 10:7
valve.
18 Lift, tilt and attachment control valve leads - Section 7 Load handling, group7.2.3 Lift,
the return oil from load handling to the tilt and attachment control valve
hydraulic oil filter.
19 The hydraulic oil filter cleans the oil. - Hydraulic oil filter, description, page
10:25
Hydraulic diagram, see section E Schematics group 10 Common


10 Common hydraulics – Cooler hydraulic oil 10:21
10.6.2 Cooler hydraulic oil

Hydraulic oil cooler, description
The hydraulics use a 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 behind the hydraulic oil
tank.
019465
Hydraulic oil cooler, replacement
NOTE
Safety.

2 Drain the oil from the hydraulic oil tank, see Hydraulic oil, changing,
page 10:27.
3 Mark up and detach the hydraulic hoses from the cooler. Let the
oil in the cooler drain into the receptacle.
1
2 NOTE
3 Plug all connections immediately to protect the hydraulic system
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.
009990
9 Connect the hydraulic hoses to the cooler.
1. Cooling fan NOTE

2. Hydraulic connections
3. Radiator correctly.

10:22 10 Common hydraulics – Cooling fan
10 Fill oil in the hydraulic oil tank, see Hydraulic oil, changing, page
10:27. The oil level should be visible in the sight glass.
CAUTION
Do not overfill!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
10.6.3 Cooling fan

Cooling fan, description
The electric cooling fan is suctioning. The cooling fan is located at
the rear of the cooler. The fan draws air from the machine's outside
through the cooler. Openings in the side cover allows air to pass
through the cooler.
The cooler is supplied with voltage by the frame control unit (D797-1)
at activation. The cooling fan is activated when oil temperature is 65 °C
in the hydraulic oil tank and the fan is deactivated when oil temperature
is 55 °C.
009991
10.6.4 Sensor hydraulic oil temperature

Sensor, hydraulic oil temperature, description
Hydraulic oil temperature sensor (B776) 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. Because of this,
the cooling fan may continue to run after the machine has been parked
and switched off provided that the system voltage is not disconnected.
The hydraulic oil temperature sensor (B776) is supplied voltage by the

frame control unit (D797-1) and sends the control unit a voltage signal
proportional to oil temperature.
009992

10 Common hydraulics – Sensor hydraulic oil temperature 10:23
Sensor, hydraulic oil temperature, replacement
NOTE
Safety.

page 10:27.
3 Disconnect the cable harness from Sensor, hydraulic oil
temperature (B776).
4 Replace Sensor, hydraulic oil temperature (B776).
NOTE
correctly.
5 Connect the cable harness to the sensor.

009992
Sensor, hydraulic oil temperature, (B776)
CAUTION
Do not overfill!
7 Use the display, go to the diagnostic menu, see section 8 Control

DIAG HYD 1(6) system, group 8.4.5.1 HYD, menu 1.
HYDRAULIC OIL TEMP indicates hydraulic oil temperature in ºC. Check that correct
TEMP XXX temperature is shown.
FAN XY
000141
Diagnostic menu HYD, menu 1

10:24 10 Common hydraulics – Bypass valve, cooler
10.6.5 Bypass valve, cooler

Bypass valve, cooler, description
The bypass valve protects the cooler against excess pressure and
boosts the heating of the hydraulic oil by opening a passage past the
cooler directly to the tank if the resistance in the cooler is too great
or if the temperature is too low.
009993
Bypass valve
Bypass valve, cooler, replacement
NOTE
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
1 Machine in service position, section B Safety.

page 10:27.
4 Disconnect the bypass valve from the tank.
NOTE
Note how the bypass valve is turned, the valve is marked with an
arrow that should be pointing in towards the tank.
5 Install the new bypass valve, turn the valve to face the same way
as the old one. Use Loctite when refitting the bypass valve.
009993
Bypass valve

10 Common hydraulics – Breather filter hydraulic oil tank 10:25
CAUTION
Do not overfill!
10.6.6 Breather filter hydraulic oil tank

Breather filter hydraulic oil tank, description
A breather filter of insert type is mounted on the hydraulic oil tank to
protect the tank from impurities. On the top of the filter housing is an
indicator that shows when the filter is clogged and needs to be changed.
009970

Hydraulic oil filter, description
The oil in the hydraulic system is cleaned by two return filters fitted
inside the hydraulic oil tank. The return oil from the load handling
functions and excess oil from brakes and steering goes through the
filters back to the hydraulic oil tank.
019466

10:26 10 Common hydraulics – Hydraulic oil filter
Hydraulic oil filter (return filter), changing
NOTE
Safety.
IMPORTANT
2
On machines with a raised cab: Remove the footstep over the
covers and clean the covers and the area around them.
3 Remove the cover plate (position 1) over the hydraulic oil filter.
1 2 1 3 2 4
4 Lift up the filter unit and place it in the receptacle. Let the hydraulic
oil drain.
5 Separate the filter unit and remove the filter insert. Handle the
filter insert as environmentally hazardous waste. Note the position
of the parts.
018782

2. Filling point hydraulic oil
6 Clean the filter holder's parts. Be especially thorough with the

magnetic rod.
7 Fit the new filters and assemble the filter units.
8 Install the filter units and the covers. Tighten the screws crosswise.
9
On machines with a raised cab: Refit the footstep over the covers.
10 Check the oil level, see Hydraulic oil, level check, page 10:27.
Magnetic rod

10 Common hydraulics – Hydraulic oil 10:27
10.6.8 Hydraulic oil

Hydraulic oil, level check
NOTE
The oil level is checked with the mast down and the attachment in
the 20-foot position.
1 Machine in service position, section B Safety.

2 Check the oil level in the hydraulic oil tank. The oil level should be
in the centre of the sight glass. Top up the oil if necessary. For the
oil grade, see section F Technical data.
Hydraulic oil, changing
NOTE
Safety.
IMPORTANT

2 Remove the filler cap and pump out the hydraulic oil into a
receptacle.
3 When as much oil as possible has been pumped out. Place a
1 2 1 3 2 4 receptacle under the hydraulic oil tank's drain plug and drain the
last of the hydraulic oil.
4 Fit the drain plug when the oil has drained out.
NOTE
018782
5 If the hydraulic oil filters are to be changed, change them before

filling the tank with oil, see Hydraulic oil filter (return filter),
changing, page 10:26.
2. Filling point hydraulic oil

10:28 10 Common hydraulics – Hydraulic oil
6 Fill new hydraulic oil through the filler holes on the filters' covers.
This results in the filtering of the oil that is filled and protects the
hydraulic system from impurities.
Fill oil until the oil level is in the middle of the sight glass. For
volume and quality, see section F Technical data.
CAUTION
Do not overfill!

10 Common hydraulics – Pipes and hoses 10:29

10.6.10 Fine filter hydraulic oil

Fine filter hydraulic oil, description
The fine filter is located behind the hydraulic oil tank on the machine's
right-hand side. The filter is connected in parallel with the hydraulic oil
cooler.
Some of the oil from the cooling circuit passes through the fine filter
and then back to the hydraulic oil tank.
The fine filter cleans a smaller amount of oil but with a higher degree of
filtration when the machine is running.
019467

10:30 10 Common hydraulics – Fine filter hydraulic oil
Fine filter hydraulic oil, replacement
NOTE
Safety.
IMPORTANT

2 Remove the cover.
3 Take out a collection vessel.
4 Lift up the filter insert and place it in the receptacle. Let the
hydraulic oil drain.
5 Fit the new filter insert and refit the cover over the fine filter.

10 Common hydraulics – Other 10:31
10.7 Other
10.7.1 Hydraulic cylinders
Fault tracing, leakage
Fault tracing, leakage
CAUTION
All fault tracing should be carried out with as low a
pressure in the system as possible so that internal
leakage can be detected. High pressure causes the
seals to close tighter, which prevents detection of
internal leakage.
1. Carefully check the source of the leakage before taking any action.
It may be possible to rectify the fault without disassembly.
2. Check for external leakage:
• At cylinder face end welds
• At sleeve coupling welds
• Between cylinder barrel and cylinder head
This could be due to a defective O-ring or damaged O-ring
sealing surfaces.
• Between cylinder head and piston rod
This could be due to a damaged piston rod or damaged or
worn piston rod seal.
3. Check for internal leakage. Pressurise the cylinder and check
whether the piston sinks back.
This could be due to a worn piston seal.
1. Piston rod
2. Scraper
3. Cylinder head
4. Piston rod seal
5. O-ring with support ring
6. Cylinder barrel
7. Sleeve coupling
8. Welded cylinder end face
9. Piston
10. Piston seal, double-acting
11. Example of weld

10:32 10 Common hydraulics – Hydraulic cylinders
Dismantling of cylinders
CAUTION
Before dismantling always check that the piston rod is
clean and free from all residual paint. Also check that
connections and couplings are free from burrs and
impact marks.
Make sure that the chamfer up to the chromium surface
of the piston rod is free from burrs and residual paint.
1 Remove the cylinder from its mounting and undo the connections.
2 Plug the cylinder connections and hoses without delay.
3 If the cylinder is opened - observe the strictest cleanliness!
Inspection of surfaces
Inspect the sealing surfaces. Always bearing mind the function of the
seals and the type of sealing surfaces they have. See the following
descriptions:
• O-ring groove, internal and external
• piston rod seal in the cylinder head
• sealing groove on the piston
• cylinder barrel surface
• piston rod surface. The piston rod is chromium plated with a layer
thickness of 20-50 my. Slight damage to the chromium plating may
not necessarily cause leakage directly.
• all slide surfaces (dynamic surfaces), e.g. cylinder barrel and
piston rod. These are always the hardest to seal.
CAUTION
When fitting the cylinder head:
Fit the cylinder head absolutely straight, ideally by
hand and do not hit with a mallet. If a mallet must be
used, use a plastic or rubber mallet and tap gently.
If the cylinder head is fitted crooked, the sealing lip
of the piston rod seal could be damaged, making an
improper seal. This applies to all types of piston rod
seals.

10 Common hydraulics – Hydraulic cylinders 10:33
Function and removal of the seals

Piston rod seal
Piston rod seal
2 The piston rod seal is the seal that sits in the groove in the cylinder
head and seals against the piston rod. This seal is very exposed to
wear since it is both a dynamic and a static seal, i.e. it seals against
1 a moving surface on the piston rod while the sealing surface with the
cylinder head is fixed. There are different types of piston rod seals:
• Single V-seal
• Pre-stressed V-seal with support ring
3 • Compressible seal
The single V-seal has a V-shaped section with two lips that seal
in opposite directions. The hydraulic pressure acts in the V-shape,
4 pressing the sealing lips out towards the sealing surfaces on the piston
6 rod and in the cylinder barrel. Even minor damage to the sealing lips
can generate large leaks. Examine the sealing lips by carefully using
a fingernail to feel around the seal. To remove, use a screwdriver to
prise the seal outward and bend it up (see illustration). It is extremely
important that the screwdriver is always inserted in the V-shape so that
it cannot touch and thereby damage a sealing surface. A mark from
a screwdriver on a sealing surface can have a devastating effect and
cause major leakage.
001497
1. Hydraulic pressure
2. Seal lip pressed out toward piston rod
3. Seal lip pressed inward toward cylinder head
4. Sealing surface, piston rod
5. Sealing surface, cylinder head
6. Screwdriver

2 The pretensioned V-seal also has an O-ring in the seal's V-shaped

space. The O-ring creates a strong seal at low hydraulic pressure
1 since the O-ring already presses the sealing lips out toward the sealing
surfaces when unloaded. It is just as sensitive to damage as the
V-seal. Examine in the same manner. To remove, use a screwdriver to
prise the seal outward and bend it up (see illustration). It is extremely
important that the screwdriver is always inserted in the V-shape so that
it cannot touch and thereby damage a sealing surface. A mark from
3 a screwdriver on a sealing surface can have a devastating effect and
7
cause major leakage.
6 4
001498
5
6. Screwdriver
7. O-ring
The compressible piston rod seal consists of a solid rubber profile

2
and provides a larger sealing surface than the V-seals. To remove, use
a screwdriver to prise the seal outward and bend it up (see illustration).
1 With this type of seal with sealing surfaces that cover so much of the
3 seal groove, it is particularly important that marks are not made with
the screwdriver.
6
4
5
001499
6. Screwdriver

Support ring and O-ring
Support ring and O-ring

The support ring and O-ring combination is used for sealing between
two fixed surfaces, such as between cylinder barrel and cylinder head.
The purpose of the support ring is to lend rigidity to the O-ring so that it
is not deformed. The O-ring is pressed against the support ring and the
sealing surface by the hydraulic pressure in the cylinder.
3
When the cylinder head is mounted in the barrel: Take extreme care
not to damage the O-ring.
4
2
001506
1
2. O-ring
3. Support ring
Scraper
Scraper
The purpose of the scraper is to scrape the piston rod clean and
øD+10 prevent impurities from entering the cylinder barrel.
1
The scraper must be fitted with a special fitting tool. This tool must
have a greater outer diameter than the scraper so that the press force
against the scraper ceases precisely when the scraper is pressed into
its position. If the scraper were to be pressed in further, the metal
2 capsule would be deformed (see lower illustration), which would impair
the function of the scraper.
4 To prevent the scraper from bottoming in its recess in the cylinder head,
the recess is slightly deeper than the width of the scraper.
3
øD
6
001496
1. Correct assembly tool

2. Scraper, correctly fitted
3. Cylinder head
4. Clearance between scraper and bottom of
cylinder head recess
5. Incorrect assembly tool
6. Deformed scraper

A screwdriver can be used for removal. This must always be applied

1 against the outer edge of the scraper (see illustration). Carefully tap the
screwdriver down between the scraper and the cylinder head and then
2 prise out the scraper. Polish away any damage to the cylinder head.
CAUTION
No tool may be applied from the inside. This could
give rise to burrs on the cylinder head which could in
3 turn damage the piston rod. Burrs may also damage
the piston rod seal when fitting the piston.
001551
1. Screwdriver
2. Scraper
3. Cylinder head
2 On the single-acting V-seal it is always the long side that seals

against the fixed surface and the short side that seals against the
moving surface.
1 To remove, use a screwdriver to prise the seal outward and bend it up
(see illustration). It is extremely important that the screwdriver is always
inserted in the V-shape so that it cannot touch and thereby damage a
sealing surface. A mark from a screwdriver on a sealing surface can
have a devastating effect and cause major leakage.
3
6 4
002370
5
2. Seal pressed out toward cylinder barrel
3. Seal pressed in toward piston
4. Sealing surface, cylinder barrel
5. Sealing surface, piston
6. Screwdriver

The seal must always be fitted as a single assembly together with the
support ring.
Always assemble by hand. No tools should be used as they could

easily damage the surface of the piston.
To facilitate assembly the seal can be heated in hot water to make it

soft.
Lubricate with hydraulic oil.
002950
Double-acting piston seal
Double-acting piston seal

The double-acting seal functions with pressure from both sides, e.g. in
5 4 3 1 6
a steering cylinder.
All of the interior surface of the cylinder barrel is a sealing surface and it
is therefore extremely important that it is completely free from damage.
Exercise caution when fitting the piston in the cylinder barrel, making
sure that the seal is not damaged by the cylinder barrel threads.
2
002951
1. Variable sealing surface to cylinder barrel

2. Fixed sealing surface with piston
3. Guide ring
4. Support ring
5. Piston
6. Cylinder barrel
Dismantling:
1 Remove guide rings and support rings.
2 Move the seal body over to one side of the sealing groove.
3 Press up the material so that there is a gap between seal and
piston.
4 Without damaging the surface of the piston - cut off the seal with
a knife.
5 Carefully examine the seal to find any damage that could cause
leakage. This will be easier if you bend the seal sharply bit by bit
and feel over the sealing surface with a fingernail.
Assembly:
1 All double-acting piston seals are of similar design: a middle seal
body, then support rings and farthest out guide rings.
2 First fit the seal body, then the support rings and finally the guide
rings - all must be done by hand without tools to avoid damage.

Dismantling the steering cylinders

It can prove extremely difficult to extract the piston rod from the cylinder
barrel on steering cylinders. This is because the O-ring in the cylinder
head fastens in the lock ring groove in the cylinder barrel. It is therefore
best to remove the O-ring before trying to withdraw the piston rod from
the cylinder.
1 Unscrew the end washer at the cylinder head.
2 Unscrew the connecting nipple for the hydraulic hose.
3 Insert the piston rod with piston crown until the O-ring is visible
through the nipple hole.
4 Bend the end of a length of heavy-duty steel wire, piano wire or
similar into the shape of a hook. Use this to snag the O-ring.
5 Pull the O-ring up slightly and hold it with a pair of needle-nose
pliers.
6 Continue to pull the O-ring out through the hole.
7 Hold the O-ring steady and cut it with a knife.
8 Rotate the piston rod while pulling the O-ring out through the hole.
9 Remove the lock ring from the cylinder barrel.
10 Carefully extract the piston rod from the cylinder barrel.
002953

11:1
11 Common electrics
Contents 11 Common electrics

11 Common electrics ............................................................................................11:3
11.2 Electric protection .......................................................................................... 11:3
11.2.1 Battery disconnector ................................................................................. 11:3
11.2.2 Fuses ........................................................................................................ 11:3
11.2.3 Control breaker ......................................................................................... 11:3
11.3 Batteries......................................................................................................... 11:4
11.3.1 Starter battery ........................................................................................... 11:4
11.4 Alternator ....................................................................................................... 11:6
11.4.1 Alternator................................................................................................... 11:6
11.5 Distribution of electricity ................................................................................. 11:7
11.5.1 Voltage feed .............................................................................................. 11:7
11.5.2 Electronic box.......................................................................................... 11:14
11.5.3 Control units ............................................................................................ 11:16
11.5.5 Cable harness ......................................................................................... 11:27
11.6 Communication ............................................................................................ 11:36
11.6.1 CAN bus .................................................................................................. 11:36
11.6.2 Redundant CAN bus ............................................................................... 11:38
11.6.3 CAN bus drive-train ................................................................................. 11:40
11.6.4 Communication between PC and machine ............................................. 11:41

11:2

11 Common electrics – Common electrics 11:3
11 Common electrics
11.2 Electric protection
11.2.1 Battery disconnector
Battery disconnector, description
The positive terminals of the batteries connected in series are
A connected to the machine's electrical system via the battery
disconnector. The battery disconnector cuts off all power from the
batteries to the machine's electrical system.
IMPORTANT
Never switch off the voltage with the battery
disconnector when the engine is running. This could
019468
damage the alternator.

A. Position of battery disconnector The battery disconnector must not be used as control
breaker!
11.2.2 Fuses
Fuses, changing
When checking and changing the main fuse:
1 Switch off the system voltage (battery disconnector).
2 Remove the plastic cover.
3 Check that the fuses are intact. Replace if necessary.
The fuses are 25 A or 50 A.
When checking and replacing the fuse:

1 Switch off the system voltage (battery disconnector).
2 Remove the cover from the electrical distribution box.
3 Check and, if necessary, replace fuses.
The fuse plate gives information about each fuse.
11.2.3 Control breaker

Control breaker, description
See Emergency stop switch voltage (15E), function description, page
11:11.

11:4 11 Common electrics – Batteries
11.3 Batteries
11.3.1 Starter battery
Starter battery, description
The machine's electrical system is supplied by two 12 V batteries
connected in series.
The negative terminal is connected to the frame. The positive terminal

is connected to the battery disconnector.
The batteries are charged by the alternator, see Alternator, description),

page 11:6.
WARNING
Battery electrolyte contains corrosive sulphuric acid.
Risk of corrosive injuries! Health hazard!
Use protective glasses and protective gloves when
working with the batteries. Immediately remove any
electrolyte on bare skin. Wash with soap and plenty of
water. If the electrolyte has found its way into your
eyes, rinse immediately with lots of water and contact
a doctor immediately.
WARNING
Risk of explosion!
Personal injury!
During charging, hydrogen gas forms around the
batteries. Sparks could ignite the hydrogen gas,
causing an explosion. Disconnect the battery with the
battery disconnector.
WARNING
Short-circuiting of battery.
Risk of explosion! Fire hazard! Risk of personal injury!
The battery's terminals must not be connected to each
other or to common grounding point (frame).

11 Common electrics – Starter battery 11:5
Starter battery, replacement

2 Disconnect the cables from the battery terminals. Start with the
negative (minus) cable.
3 Replace the batteries.
4 Connect the cables to the battery terminals. Connect the negative
cable last of all.
NOTE
Take great care when reconnecting the cables to prevent short
circuiting.

11:6 11 Common electrics – Alternator
11.4 Alternator
11.4.1 Alternator
Alternator, description)
The alternator generates current during operation and supplies this
to the batteries. The alternator produces AC current and has an
integrated charge regulator.
The alternator is driven by the engine via a belt. Faults are indicated
by the warning lamp for low battery charging.
system, section 8.4.6.4 ENGINE, menu 4.
019469
Alternator, replacement
See supplier documentation, engine.

11 Common electrics – Distribution of electricity 11:7
11.5 Distribution of electricity

11.5.1 Voltage feed
11.5.1.2 Redundant voltage feed of control units
Redundant voltage feed of control units, function

description
1 2 3 4
D1 D3 D4
D2
D793 D794
- +
D8
D790-1 D791
5, 6 8
9 7
D795 D790-2 D797-1
0015056
D9 D7

1 The NC switch, operator's door U = 24 V Section 9 Frame, body, cab and accessories, group
(S 266-LE) or the NC switch, 9.10.2 Doors
passenger door (S 266-RI) sends D1: Diagnostic menu, see section 8 Control
a voltage signal to the cab control system, group 8.4.2.9 LIGHTS, menu 9 or 8.4.11.5
unit (D790-1) when the door is MOVE-CAB, menu 1
opened.
2 The interior lighting switch of the U = 24 V Section 9 Frame, body, cab and accessories, group
KIT control unit (D790-2) sends a 9.6.12 Interior lighting
voltage signal to the cab control D2: Diagnostic menu, see section 8 Control system,
unit (D790-1). group 8.4.2.13 LIGHTS, menu 13
3 Switch, flashing hazard lights U = 24 V Section 9 Frame, body, cab and accessories, group
(S109) sends a voltage signal to 9.6.7 Flashing hazard lights
Control unit, cab (D790-1). D3: Diagnostic menu, see section 8 Control system,
group 8.4.2.5 LIGHTS, menu 5
4 When the ignition switch (S150) U = 24 V Section 9 Frame, body, cab and accessories, group
is turned to position I, it sends a 9.1 Controls and instruments
voltage signal to the cab control D4: Diagnostic menu, see section 8 Control system,
unit (D790-1). group 8.4.1.5 CAN/POWER, menu 5
5 Control unit, cab (D790-1) activates - Cab control unit, description, page 11:17
a hold circuit, which activates the
control unit's control logic.

11:8 11 Common electrics – Voltage feed

6 Control unit, cab (D790-1) activates UK11:7 = 24 V Cab control unit, description, page 11:17
a redundant voltage feed to other U = 24 V
K11:8
control units.
UK11:9 = 24 V
Control unit, cab (D790-1) has 4
outputs for redundant voltage feed UK11:10 = 24 V
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.
7 Control unit, cab (D790-1) supplies UK2:7 = 24 V Frame control unit, description, page 11:18
voltage to the control logic of UK2:8 = 24 V D7: Diagnostic menu, see section 8 Control system,
the other control units via the group 8.4.1.10 CAN/POWER, menu 10
redundant voltage feed.
8 UK2:7 = 24 V Control unit, attachment, description, page 11:20
UK2:8 = 24 V D8: Diagnostic menu, see section 8 Control system,
group 8.4.1.15 CAN/POWER, menu 15
9 UK2:7 = 24 V D9: Control unit KID, description, page 11:26
UK2:8 = 24 V Diagnostic menu, see section 8 Control system,

11 Common electrics – Voltage feed 11:9
11.5.1.3 Ignition voltage (15)
Ignition voltage (15), function description

Battery disconnector In position 1 Battery disconnector, description, page 11:3
Redundant voltage feed Activated. Redundant voltage feed of control units, function description
, page 11:7
Redundant CAN bus Communication Redundant CAN bus, description, page 11:38
established.
- +
K315-2
1 2 K315-1
7 3, 6
D1 D2 D3 3
D794
D793
10 D10
4, 5
D8
D790-1 D791
2, 8
9
D795 D790-2 D797-1
015054
D9

1 Switch, flashing hazard U = 24 V Section 9 Frame, body, cab and accessories, group 9.6.7
lights (S109) sends a Flashing hazard lights
voltage signal to Control D1: Diagnostic menu, see section 8 Control system,
unit, cab (D790-1). group 8.4.2.5 LIGHTS, menu 5
2 When the ignition switch U = 24 V Section 9 Frame, body, cab and accessories, group 9.1
(S150) is turned to position I, Controls and instruments
it sends a voltage signal to D2: Diagnostic menu, see section 8 Control system,
the cab control unit (D790-1). group 8.4.1.5 CAN/POWER, menu 5
3 Cab control unit (D790-1) U = 24 V Cab control unit, description, page 11:17
voltage feeds the ignition D3: Diagnostic menu, see section 8 Control system,
key lock power relay K315-1 group 8.4.1.5 CAN/POWER, menu 5
and the ignition voltage
relay K315-2 in the frame
electronic box.
4 Relay, ignition voltage U = 24 V -
K315-1 supplies voltage
to fuse holder in the cab
electronic box and in the
frame electronic box.
5 The fuses feed voltage to U = 24 V -
control units, relays, solenoid
valves and other electronic
components.


6 Relay, ignition voltage U = 24 V Control unit, engine (D794), description (engine
K315-2 supplies voltage to alternative Volvo TAD760VE), page 11:23.
Control unit, engine (D794). Control unit, engine, description (engine alternative
Cummins QSB6.7 ), page 11:24.
7 The drive-train's CAN-bus Checked by control CAN bus drive-train, description, page 11:40
establishes communication. system, error shown
with error code.
8 Ignition voltage to Control UK1:2 = 24 V Cab control unit, description, page 11:17
unit, cab (D790-1). UK1:3 = 24 V D8: Diagnostic menu, see section 8 Control system,
UK1:4 = 24 V group 8.4.1.7 CAN/POWER, menu 7
9 Ignition voltage to the frame UK2:1 = 24 V Frame control unit, description, page 11:18
control unit (D797-1). UK2:9 = 24 V D9: Diagnostic menu, see section 8 Control system,
UK2:10 = 24 V group 8.4.1.10 CAN/POWER, menu 10
10 Ignition voltage to Control UA1 = 24 V Transmission control unit (D793), description, page 11:22
unit, transmission (D793). D10: Diagnostic menu, see section 8 Control system,

11.5.1.4 Emergency stop switch voltage (15E)
Emergency stop switch voltage (15E), function

description
Condition Reference Reference

value
Redundant voltage Activated. Redundant voltage feed of control units, function description , page 11:7
feed
Ignition voltage Activated. Ignition voltage (15), function description, page 11:9
Control breaker Not activated Section 9 Frame, body, cab and accessories, group 9.1 Controls and
instruments
D794
D793
D5
K3007
3, 4 6
K3009-1 K3009-2
- +
K3002
D4
D2
D7
D790-1 D797-1
1, 2, 5
7
D795 D790-2 D791
015055
1 Ignition voltage is activated by the cab Checked by control Ignition voltage (15), function description,
control unit (D790-1) system, error shown page 11:9
with error code.
2 Control unit, cab (D790-1) supplies voltage UK3009-1/86 = 24 V Cab control unit, description, page 11:17
to Relay, emergency stop switch voltage D2: Diagnostic menu, see section 8 Control
(K3009-1) in the frame electronic box. system, group 8.4.1.6 CAN/POWER, menu
6
3 Relay, emergency stop switch voltage UK3009-2/87 = 24 V Electronic box, description, page 11:15
(K3009-1) supplies voltage to Relay,
emergency stop switch voltage (K3009-2) in
the frame electronic box.
(K3009-1) also sends a voltage signal to the UK3009-2/87= 0 V D4: Diagnostic menu, see section 8 Control
Control unit, cab (D790-1), which verifies system, group 8.4.1.6 CAN/POWER, menu
that Relay, emergency stop switch voltage 6
(K3009-1) is active but Relay, emergency
stop switch voltage (K3009-2) is inactive.
This verifies that the emergency stop switch
is working.
5 Control unit, cab (D790-1) activates Relay, UK3009-2/86 = 24 V Cab control unit, description, page 11:17
emergency stop switch voltage (K3009-2) D5: Diagnostic menu, see section 8 Control
in the electronic box. system, group 8.4.1.6 CAN/POWER, menu
6


K3009-2 supplies voltage to the emergency
stop switch circuit.
7 The attachment control unit (D791) is Emergency stop Control unit, attachment, description, page
voltage fed with emergency stop switch switch in home 11:20
voltage as long as emergency stop switch position: UK2:1 = 24 D7: Diagnostic menu, see section 8 Control
is not depressed. V system, group 8.4.1.15 CAN/POWER,
Attachment control unit D791 is only voltage Emergency stop menu 15
fed by the emergency stop switch, thus all switch in home
attachment functions stop if the emergency position: UK2:9 = 24
stop switch is activated. V
If the emergency stop switch is pressed, Emergency stop
ignition voltage to the cab control unit switch in home
(D790-1) is cut off, thereby cutting off control position: UK2:10 =
current to emergency stop switch voltage 24 V
relay K3009-1, emergency stop switch Emergency stop
voltage relay K3009-2, the tilt relay (K3002) switch in home
and the lift/lower relay (K3007). The power position: UK2:11 =
supply to the control units is cut off and the 24 V
functions cease.
As an extra safety measure, the cab control
unit (D790-1) also transmits the status of the
emergency stop switch the CAN bus. Thus,
functions are also cut off at the signal level.
Emergency stop switch, checking

1 Start the machine and active any load handling function.
2 Activate lift.
3 Press in the emergency stop switch and check that the lift
movement stops.
4 Reset the emergency stop switch (turn in the direction of the
arrows) and check that the lift function is working again.
002084
11.5.1.5 Voltage converter
Voltage converter, description
The voltage converter is located under a protective casing to the left

behind the driver's seat.
The voltage converter converts 24 volts to 12 volts. 12 V power is

available for accessories through a connector in the cab electrical
distribution box and through a socket on the instrument panel.
Connector X067 in cab electronic box (contains 15-voltage, 30-voltage,

ground and 12 V).

Voltage converter, replacement

2 Remove the covers behind the driver's seat.
3 Detach the electrical cables from the converter.
4 Remove the voltage converter.
The voltage converter is located diagonally behind

the driver's seat.

11:14 11 Common electrics – Electronic box
11.5.2 Electronic box

11.5.2.1 Electronic box, cab
Electronic box, cab, description

The electronic box is mounted on the rear wall of the cab, on the left.
7 Located there are:
• Control unit cab (D790-1).
6 • Cab battery voltage circuit fuses for (30), ignition voltage (15)
F58-4 and cab ignition voltage circuit fuses (15) F58-5.
• Buzzer for alarm if, for example, the operator leaves the machine
without the parking brake being applied.
• Connectors.
• Relays.
•
Voltage converter 24 V to 12 V
• Customer accessory connector. Output voltage 24 V, max. 10 A.
Connector 9-pin Universal mate-n-lock. For part number see
1 Spare parts catalogue.
2 NOTE
3 This connector is not fitted on the machine if the machine is
equipped with voltage converter.
5 CAUTION
008693
Connector X067 must be used when connecting extra

electrical equipment. The use of other connections
1. Control unit, cab (D790-1) can lead to overloading of cable harness and product
damage.
2. Diagnostic socket, machine
3. Diagnostic socket CAN Bus drivetrain
4. Fuse holders for cab battery voltage circuit
fuses (30) and the ignition voltage (15) F58 -4
(upper) and cab ignition voltage circuit fuses (15)
F58 -5 (lower).
5. Voltage converter
6. Termination resistor
7. Customer accessory connector (X067)
24V/10A and 12V/20A
Customer accessory connector (X067)
Customer accessory connector (X067)

The connector is designed for customer accessories and contains
3 2 1 connections for 24 V. On machines with voltage converter 24 V to 12 V
there is also a connection for 12 V .
Pin 1. 24 V, ignition voltage, 10 A
4
Pin 2. 24 V, battery voltage, 10 A
014169
Pin 3. Ground
Pin 4. 12 V, ignition voltage, 20 A

11 Common electrics – Electronic box 11:15
11.5.2.2 Electronic box frame
Electronic box, description

The electronic box is fitted on the side of the machine. Also located
5 6
4 there are:
7
3 • Circuit fuses.
2 • Socket for communication with the engine and transmission; see
1 8 Communication between PC and machine, description, page 11:41.
• Main fuses.
9 • Control unit, transmission (D793)

• Power relays for voltage feed to the machine's functions.
10
11
12
13
007958
14
1. Circuit fuses, emergency stop switch voltage
(15E) F58-3
2. Circuit fuses, ignition voltage (15) F58-2
3. Circuit fuses, battery voltage (30) F58-1
4. Diagnostic socket, engine VODIA (Volvo
engine option)
5. Diagnostic socket, transmission
6. Main fuses
7. Control unit, transmission (D793)
8. Connection terminal, attachment
9. Lifting/lowering relay K3007
10. Tilt in/out relay K3002
11. Ignition switch relay K315-2
12. Ignition key lock power relay K315-1
13. Control breaker power relay K3009-1
14. Control breaker power relay K3009-2
-
1
-
2
- 1
3
-
4
5 -
-
6
007184
1. Termination resistor

11:16 11 Common electrics – Control units
11.5.3 Control units

Control units, location
1 2 3
018788
7 6 5
1. Frame control unit (D797-1) 5. Control unit, transmission (D793)
2. Control unit, KID (D795) 6. Control unit, Volvo engine (D794)
3. Control unit KIT (D790-2) 7. Engine control unit, Cummins (D794)
4. Control unit, cab (D790-1) 8. Control unit, attachment (D791-1)

11 Common electrics – Control units 11:17
11.5.3.1 Control unit, cab
Cab control unit, description
2 1 Control unit, cab (D790-1) is the central control unit of the control
system. Control unit, cab (D790-1) sends activation signals to other
units, and controls and monitors their functions. It administrates work
in the control unit network. The control unit controls the redundant
voltage feed and handles communication via a redundant CAN bus
and gateway for CAN bus drive-train. Control unit, cab (D790-1) also
processes all input signals from cab controls and transmits these
5 6 signals on the CAN bus.
4
3
000041
Control unit, cab has four indicator lights that indicate the control unit's
2
function.
1. Connection terminals - fan, working lights,
windscreen wiper Lamp 1 Green light on when there is battery voltage to the
unit. The light is physically controlled by voltage feed
2. Connection terminals, other to the control unit.
3. Light 1, battery voltage Lamp 2 Flashes green when redundant voltage feed to
4. Light 2, redundant voltage feed, redundant control units and redundant CAN bus communication
CAN bus and power supply are active. No power in the system.
5. Light 3, communication Green light when power electronics and 15-voltage
are supplied voltage.
6. Light 4, error indication
Lamp 3 Long single flash yellow during communication with
Control unit, display (D795). This is a basic condition
of fault tracing.
Short single flash yellow during communication
with Control unit, engine (D794) and Control unit,
Double flash yellow (short and long flash) during
communication with the display and engine or
transmission.
Lamp 4 Red light in the event of active error.
Control unit cab, replacement

2 Remove the cover from the electronic box.
3 Detach the connectors from Control unit, cab (D790-1).
4 Replace the control unit.
5 Check that the new control unit corresponds with the machine's
forklift number (Z-number).
6 Calibrate the new control unit. See section 8 Control system,
group 8.5.2.3 Calibrate DRIVE-TRAIN.

11.5.3.2 Frame control unit
Frame control unit, description

The frame control unit (D797-1) processes input data from sensors and
1 sends control signals to relays and solenoid valves.
2 The cab control unit has four indicator lights that indicate the control
unit's function.
3
000043
6 5
1. Light 1, battery voltage
2. Light 2, redundant voltage feed and power
supply
3. Light 3, communication
5. Control signals (inputs and outputs)
6. Power supply (redundant voltage feed for
control units, redundant CAN bus) and input data
Lamp 1 Green light on when there is battery voltage to the unit.

The light is physically controlled by voltage feed to the
control unit.
Lamp 2 Flashes green when one or more of the following
is missing: redundant voltage feed left, redundant
voltage feed right or 15-voltage.
Green light when redundant voltage feed left,
redundant voltage feed right and 15-voltage are
supplied voltage.
Lamp 3 Single yellow flash during communication with the KID
control unit (D795) or cab control unit (D790-1).
Double yellow flash during communication with the KID
control unit (D795) and the cab control unit (D790-1).

Frame control unit, replacement

2 Detach the cables from the frame control unit (D797-1).
5 Check the initiation values for attachment functions; see section 8
Control system, group 8.5.1.1 ELSERVO.
6 The control unit is not calibrated.

11.5.3.5 Control unit, attachment
Control unit, attachment, description

The attachment control unit (D791) processes input data from sensors
1 and sends control signals to relays and solenoid valves of the side
lift attachment.
2
The cab control unit has four indicator lights that indicate the control
3 unit's function.
000043
6 5
1. Light 1, battery voltage
2. Light 2, redundant voltage feed and power
supply
3. Light 3, communication
5. Control signals (inputs and outputs)
6. Power supply (redundant voltage feed for
control units, redundant CAN bus) and input data
Lamp 1 Green light on when there is battery voltage to the unit.

The light is physically controlled by voltage feed to the
control unit.
Lamp 2 Flashes green when one or more of the following
is missing: redundant voltage feed left, redundant
voltage feed right or 15-voltage.
Green light when redundant voltage feed left,
redundant voltage feed right and 15-voltage are
supplied voltage.
Lamp 3 Single yellow flash during communication with the KID
control unit (D795) or cab control unit (D790-1).
Double yellow flash during communication with the KID
control unit (D795) and the cab control unit (D790-1).

Control unit, attachment, replacement

2 Disconnect the cable harness from the control unit.
5 Check the initiation values for attachment functions; see section 8
Control system, group 8.5.1.2 ATTACHMENT.
6 The control unit is not calibrated.

11.5.3.9 Control unit, transmission (D793)
Transmission control unit (D793), description

The transmission control unit (D793) is part of drivetrain control and
1 2 3
handles gearbox function, selection of gear at load and engine speed,
etc.
D
Control unit, transmission (D793) is connected via separate CAN bus
M
E communication to the engine, which is connected to Control unit,
F S cab (D790-1). In turn, Control unit, cab (D790-1) sends drive-train
information on to other units.
The control unit has two function keys and three status lights.
000045
1. Display
2. Status lights
3. Function keys
Function button M Select display group.

Function button S Select display group mode.
Status light D Yellow light indicates test mode.
Status light E Yellow light indicates fault in unit.
Status light F Red light during reset.
Control units can show information in the display in three display

groups with a range of conditions. The function keys M and S are used
to manoeuvre in the display and select display group and condition.
The following status information can be shown in the display:
Display group I
• GPOS - shows transmission's direction of rotation
• VSPD - shows speed in km/h
• dist - shows distance driven in km or miles
Display group II
• CPOS - shows gear position
• Tspd - shows measured turbine speed in km/h or mph
• Espd - shows measured engine speed in rpm
• Ospd - shows measured speed out from the transmission in rpm
• Srat - shows the turbine speed ratio (Tspd)/engine speed (Espd)
• TQ I - shows measured torque (Nm) of transmission in
• Ttmp - shows measured temperature in the oil sump (Celsius or
Fahrenheit)
• Ctmp - shows measured temperature in the converter (Celsius
or Fahrenheit)
Display group III

• Err - shows error codes (current and history)

Control unit, transmission, replacement

2 Disconnect the cable harness from Control unit, transmission
(D793).
1
5 Calibrate the new control unit; see section 8 Control system, group
8.5.2.3 Calibrate DRIVE-TRAIN and section 2 Transmission, group
2.8 Control system, transmission.
007959
11.5.3.10 Control unit, engine (D794)
Control unit, engine (D794), description (engine

alternative Volvo TAD760VE)
The engine control unit (D794) is part of drivetrain control and handles
1 2 3
engine function, fuel injection, etc.
Control unit, engine EDC (D794) is connected via separate CAN bus
communication to the gearbox, which is connected to Control unit,
cab (D790-1). In turn, Control unit, cab (D790-1) sends drive-train
information on to other units.
The control unit is fitted on the engine has no function keys or display.
All functions are controlled via the CAN bus and an external control
system. Diagnostic socket for communication directly with the engine
via Volvo diagnostic tools VODIA is in the frame electronic box, see
007423
Electronic box, description, page 11:15.
1. Connector OEM The control unit monitors the following values in order to optimise
2. Connector Actuator engine performance.
3. Connector Sensor • engine speed

• camshaft position
• boost pressure
• charge air temperature
• coolant temperature
• oil pressure
• water in fuel
• fuel pressure
• coolant level
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the
correct fuel volume and to check the condition of the engine.

Control unit, engine, description (engine alternative

Cummins QSB6.7 )
The engine control unit (D794) is part of drivetrain control and handles
engine function, fuel injection, etc.
1 Engine control unit EDC (D794) is connected via separate CAN bus
communication to the transmission, which is connected to Cab control
unit (D790-1). In turn, Control unit, cab (D790-1) sends drive-train
2 information on to other units.
The control unit is fitted on the engine has no function keys or display.
All functions are controlled via the CAN bus and an external control
3 system.
The control unit monitors the following values in order to optimise

4 engine performance.
• engine speed
• camshaft position
010053
• boost pressure
• charge air temperature
1. Connector from Cummins cable harness
• coolant temperature
2. Connector XD794-3
• oil pressure
3. Connector from Cummins cable harness
• water in fuel
4. Connector XD794-3
• fuel pressure
• coolant level
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the
correct fuel volume and to check the condition of the engine.
Control unit, engine, replacement

See supplier documentation, engine.
CAUTION
Each control unit is individually calibrated to each
engine. Control unit replacement between engines
must not be done under any circumstances.

11.5.3.11 Control unit KIT
Control unit KIT, description
1 2 The KIT control unit (D790-2) handles functions for the gear and
multi-function lever, the direction indicator switch and start key positions
II and III. It also handles the key panel for the control system and its
panel for warning and indicator lights.
Control unit KIT (D790-2) has several individual function keys and
indicator lights.
See the operator's manual for detailed information on warning and

indicator lights and function keys.
000049
1. Panel, warning and indicator lights

2. Panel for keys
Control unit KIT, replacement

3 Detach the KIT control unit (D790-2) from the steering wheel panel.
4 Detach the connector sockets.
5 Remove the warning panel for warning and indicator lights.
7 The KIT control unit (D790-2) is not calibrated.

11.5.3.12 Control unit KID
Control unit KID, description

Control unit KID (D795) displays to the operator information sent by
1 2 the control system, such as speed, in the form of messages, status,
error indications, etc.
There is an indicator light to the right of the display that is activated with
a red light when there is a serious malfunction in the control system.
The error code and information are shown on the display.
See the operator's manual for detailed information about the display.
000051
1. LCD display
2. Series of diodes that serve as an indicator light
for serious malfunction.
Control unit KID, replacement

3 Detach the connector from the KID control unit (D795).
4 Detach the KID control unit (D795) from the steering wheel panel.
6 The KID control unit (D795) is not calibrated.

11 Common electrics – Cable harness 11:27
11.5.5 Cable harness

Connectors, overview
The list includes all connectors on the machine with a brief description
of their locations and to which functions the signals in them are related.
Contact Location Function

X001 Control unit, cab (D790-1) Power supply and ground connection Control unit, cab (D790-1)
X002 Control unit, cab (D790-1) Front windscreen wiper
Heater fan
Actuator motor, recirculation
Rear window wiper
Motor, rotating beacon
Back-up lights
X004 Control unit, cab (D790-1) Water valve
Air distributor
Interior temperature sensor
Ambient temperature sensor
Temperature sensor, outlet fan
Sensor, temperature refrigerant
Air conditioning sensor
Front windscreen wiper motor
X005 Control unit, cab (D790-1) Switch, left panel
Switch, option
Window washer, roof rear
Switch flashing hazard lights (Hazard)
Setting fan speed
Setting temperature
Air distribution
Fan and recirculation controls
Accelerator pedal
Alignment bypass
X006 Control unit, cab (D790-1) Instrument illumination
Switch, working lights
Switch, rotating beacon
Switch, headlights
Switch, option
Seat heater
Accelerator pedal
Declutch pedal
X007 Control unit, cab (D790-1) Control lever
Twistlock
Spreading (positioning)

11:28 11 Common electrics – Cable harness

X008 Control unit, cab (D790-1) Switch, spreading
Switch, bypass
Emergency stop switch
Switch parking brake
Sensor twistlocks
Switch 30-35 stop
Switch, aut. 20-40
Switch, option
Instrument illumination
Switch, electric servo panel
X009 Control unit, cab (D790-1) Background illumination, switches
Switch, horn
X009-2 Control unit, cab (D790-1) Control lever
X010 Control unit, cab (D790-1) Sensor, contact
Water valve
Horn
Relay, seat heating
Relay, working lights
Hour counter
Relay, compressor
Control current relay K315-1, K3009-1, K3009-2, K315-2, K3002 and
K3007
Front windscreen washing
Windscreen wiper, roof
X011 Control unit, cab (D790-1) Ignition
Break contacts (opening switches), cab doors
Interior lighting
Redundant feed, cab control unit (D790-1)
Horn
Break contact (opening switch), seat
Feedback relay K3009-1
X012 Control unit, cab (D790-1) Windscreen wiper, rear
Windscreen wiper, roof
X013 Control unit, cab (D790-1) CAN bus
RS232
X015 Control unit KIT (D790-2) CAN bus
Power supply and ground connection Control unit KIT (D790-2)
X016 Control unit KIT (D790-2) Ignition
X017 Control unit KIT (D790-2) Switch, horn
Control, windscreen wipers
Control, gear
Control, high and low beams
X018 Control unit KIT (D790-2) Sensor, steering wheel angle
Buzzer
Switch, direction indicators
Switch, interior lighting


X020 Control unit, KID (D795) CAN bus
RS232
Power supply and ground connection Control unit KID (D795)
X033 Air conditioning Control, fan
Control, temperature
Control, air distribution
Fan and recirculation controls
Instrument illumination
X034 Air conditioning Heater fan
Water valve
X035 Air conditioning Valve, air distribution
Interior temperature sensor
Temperature sensor, outlet fan
X036 Air conditioning Actuator motor, recirculation
Sensor, temperature refrigerant
X038 Instrument panel, cab Accelerator pedal
Declutch pedal
X039 Electronic box, cab Relay, compressor air-suspension seat
Break contact (opening switch), cab door
Actuator motor, recirculation
Fan motor, heating
Water valve, ECC
Air conditioning sensor
Ambient temperature sensor
X040 Electronic box, cab Alignment bypass
Window washer, roof/rear
Accelerator pedal
X048 Electronic box, cab Termination resistor
X049 Electronic box, cab Termination resistor
X050 Electronic box, cab RS232 Control unit, cab (D790-1)
X051 Electronic box, cab Feedback relay K3009-1
Power supply, Control unit, cab (D790-1)
CAN bus
X052 Electronic box, cab CAN bus
Control relays K315-1, K3009-1, K3009-2 and K315-2
X054 Electronic box, cab Interior lighting
Back-up lights
Revolving beacon
X055 Electronic box, cab Windscreen wiper, roof
Power, CD player
Power, COM radio
X056 Electronic box, cab Revolving beacon
Working lights, cab
X057 Electronic box, cab Windscreen wiper, rear


X058 Electronic box, cab Motor, windscreen washing
Engine heater start inhibitor, bridged
Interior lighting
X060A Extension X060 CAN bus
Interior lighting
X061 Electronic box, cab Ground connection, Control unit, KID (D795)
Ground connection, Control unit KIT (D790-2)
X061A Extension X061 Ground connection, Control unit, KID (D795)
Ground connection, Control unit KIT (D790-2)
X062 Electronic box, cab Horn
Compressed air horn
Map lighting
Cigarette lighter 12V
Windscreen wiper, front
Heater fan motor
Motor, recirculation
X063 Electronic box, cab Sensor, operator-in-seat
Seat heater
Compressed-air damped seat
X065 Electronic box, cab Ambient temperature sensor
X066 Electronic box, cab Accelerator pedal
Interior lighting
X067 Electronic box, cab Customisation
X069 Electronic box, cab Sensor, twistlock open/closed
Twistlock relay
Spreading relay
X070 Electronic box, cab Sensor twistlocks
Spreading relay
X072 To Right Behind Seat Current outlet
X080 Instrument panel, cab Switch, mast/attachment work lights
Switch, high beam
Switch, rotating beacon
Switch, seat heater
Switch, seat heater
X081 Instrument panel, cab Switch, seat heater
Extra sensors
Hour counter
X082 Instrument panel, cab NC switch, cab doors


X090 Electric servo panel, cab Electric servo
Electric servo, lift/lower
Electric servo, tilt
Electric servo, side shift
Electric servo, spreading
Electric servo, auxiliary
X091 Electric servo panel, cab Horn
Switch, spreading
Switch, twistlock
X092 Electric servo panel, cab Switch, twistlock
X168 Electronic box frame Power supply attachment control unit
X201 Electronic box frame Ground connection and power supply, Control unit, transmission
(D793)
X203 Electronic box frame Termination resistor
X204 Front edge of frame Mast work lights
X205 Electronic box frame CAN bus
Control unit, transmission (D793)
X207 Front edge of frame Sensor, contact
Sensor twistlocks
X209 Front edge of frame Power supply, cab control unit (D790-1)
CAN bus, frame control unit (D797-1)
CAN bus, attachment control unit (D791)
X210 Between engine and transmission Power supply and ground connection Control unit, engine (D794)
CAN bus, Control unit, engine (D794)
Low coolant level sensor (engine alternative Cummins QSB6.7 )
D+ alternator (engine alternative Cummins QSB6.7 )
X211 Frame control unit (D797-1) 42-pin connector to frame control unit (D797-1)
X212 Frame control unit (D797-1) Power supply and ground connection, frame control unit (D797-1)
CAN bus, frame control unit (D797-1)
Temperature hydraulic oil
Control breaker voltage
Sensor fuel level
D+ alternator
X214 Front edge of frame CAN bus, attachment control unit (D791)
X215 Electronic box frame Power supply attachment control unit
X230 Beneath driver's seat Sensor, operator-in-seat
X235 Front edge of frame Lift/lower valve
Tilt valve
Mast valves
X236 Engine Low coolant level sensor
X240 Front edge of frame Voltage feed
X241 Front edge of frame Option
X242 Front edge of frame Option


X243 Front edge of frame Low beam rear
High beam rear
Tail light front
X244 Front edge of frame Side shift valve
Spreading valve
Lift, tilt and attachment control valve
X247 Front edge of frame Brake light forward
X248 Front edge of frame Mast position sensor
X251 Control unit, transmission (D793), 60-pin connector for Control unit, transmission (D793)
electronic box frame
X261 Electronic box frame RS232 Control unit, transmission (D793)
X270 Lamp bracket left front High and low beams
Direction indicators
Side marker lights
X271 Lamp bracket right front High and low beams
Side marker lights
X272 Lamp bracket left rear Tail lights
Brake light
Side marker lights
X273 Lamp bracket right rear Tail lights
Brake light
Side marker lights
X275 Rear edge of frame Tail lights
Brake light
Side marker lights
Reverse alarm
X278 Between engine and transmission Electromagnetic clutch, compressor
Sensor pressure refrigerant
Relay, starter motor
X279 Control unit, engine (D794) Signals, Control unit, engine (D794)
CAN bus Drive-train
X280 Engine Coolant level
X281 Electronic box frame Diagnostic socket engine
X286 Engine Resistance, indication preheating active
Resistance, indication water in fuel
X287 Engine Power supply and ground connection Control unit, engine (D794)
X301 Mast Mast position sensor
X400 Attachment control unit (D791) Power supply and ground connection, attachment control unit (D791)
X401 Attachment control unit (D791) CAN bus, attachment control unit
X403 Carriage middle Sensor, alignment right side
Sensor, twistlocks right side
Work lighting, right side


X404 Carriage middle Sensor, alignment left side
Sensor, twistlocks left side
Work lighting, left side
X415 Attachment, right side Indicator light locked twistlocks
Indicator light, unlocked twistlocks
Indicator light alignment
X421 Attachment control unit (D791) 42-pin connector for Control unit attachment (D791)
X422 Attachment control unit (D791) Power supply and earth connection, Control unit attachment (D791)
CAN bus Control unit attachment option (D791)
Control breaker voltage
X425 Carriage middle Sensor, stop at 30' left
Sensor, end position 20'-40' left
X426 Carriage middle Sensor, stop at 30' right
Sensor, end position 20'-40' right
X428 Cab Revolving beacon
X612 Air conditioning Actuator motor, recirculation
X645 Engine Compressor air conditioning
X651 Cab Motor, windscreen washing
X657 Cab Heater fan
X660 Engine Alternator
X690 Cab Accelerator pedal
X759 Engine Coolant level
X774 Cab Ambient temperature
X775 Cab Temperature sensor, cab, fan, refrigerant
X815 Cab Power assisted system
X900 Cab CD player
X901 Voltage converter, cab Voltage converter 24 V/12 V
Socket 24 V

Signal types, general

The machine's control units use a number of different types of signals
to receive signals from sensors and switches and control solenoid
valves, lights, etc. The table below describes the different signal types.
Signal type Explanation Application area

Analogue input signals
Rheostat Resistance input 0–200 Ω. Linear work range with accuracy of 3%. E.g. fuel level sensor.
Temperature Rheostat input with non-linear work area. The resistance value is E.g. hydraulic oil
equivalent to temperature and the work range of approx. -40 till 150 °C. temperature sensor
There are two different resistance curves, one for Control unit, cab and air conditioning
(D790-1) and one for the frame and attachment control units. temperature sensor.
Accuracy is ±0.5 in the interval 0-100 °C (sensor's measurement
inaccuracy not included). Outside of the interval 0-100 °C, accuracy is
±2 °C.
Voltage An analogue signal 0-5 V. The work range is 0.5 to 4.5 V. E.g. accelerator pedal
and analogue cab controls
(operating lever and
heater controls).
Analogue outputs
Current feedback A modulated signal between 0 V and system voltage, i.e. 24 V. The work Hydraulics, e.g.
voltage out, PWM range is 0 to 2 A. lifting/lowering of the
A modulated signal is a digital signal translated to an analogue boom.
(continuous) signal adapted for a purpose, such as solenoid valve control. Used when the
When the slide in a solenoid valve gets hot, resistance drops. This output signal actuates
generates a lower current through the valve spool, which can cause proportional solenoid
the valve's servo pressure to remain constant. An internal ammeter valves.
measures current in the circuit and regulates the voltage level in order to
maintain the desired current value in the valve spool.
Voltage out, PNP A modulated signal between 0 V and system voltage, i.e. 24 V. Requires E.g. interior lighting and
PWM a grounding point as reference. background illumination in
switches.
Voltage out, A modulated signal between 0 V and system voltage, i.e. 24 V. Requires E.g. cab fan.
reversed polarity, 24 V as reference.
NPN PWM
Digital input signals
Digital input signal Signal in, U < 5 V generates logical zero (0) E.g. input signal from a
with pull down and Signal in, U > 16 V generates logical one (1) circuit breaker with search
search lighting lighting.
If there is no signal in, the input is grounded.
Digital input signal Signal in, U < 5 V generates logical zero (0) E.g. position sensors
with pull down Signal in, U > 12 V generates logical one (1) (inductive sensors) and
brake pressure (pressure
If there is no signal in, the input is grounded. switches).
Bandwidth 300 Hz, i.e. designed for slow sensors.
Digital outputs
High side driver, Logical one (1) generates voltage out, U >= 22.5 V E.g. side marker lights,
1.5 A Max. load 1.5 A solenoid valves.
Open load 0.15 A
Max. instantaneous current load, 8 A
High side driver, 5 Logical one (1) generates voltage out, U >= 22.5 V E.g. working lights and
A Max. load 5 A wiper motors.
Open load 0.9 A

Signal type Explanation Application area

High side driver, Logical one (1) generates voltage out, U >= 22.5 V E.g. cooling fan.
10 A Max. load 10 A This output is only
Open load 1.9 A found on the frame and
attachment control units.
H-bridge Logical one (1) generates voltage out, U >= 22.5 V or grounded output, E.g. air conditioning
U=0V water valve (works in both
Max. load 0.5 A directions).
Open load 0.15 A
The H-bridge works with two outputs in a pair. At logical one (1), one
output gives voltage while the other output is grounded. At logical zero
(0), the outputs switch voltage levels.

11:36 11 Common electrics – Communication
11.6 Communication
11.6.1 CAN bus
CAN bus, description
1 2 Communication between the control units takes place using so-called

"CAN buses" (Controller Area Network) based on the ISO 11898
standard and CAN specification 2.0B.
The CAN bus is a fast control bus with logical hardware circuits. A
120 ohm 120 ohm
simple technology that is highly reliable (low error frequency), which is
a requirement for control signals to be able to regulate systems based
on varying conditions and requirements.
CAN specifies:
5 5
• that the signal traffic is carried by "twisted pair" cables.
3 • that termination resistors (position 1) are necessary (adapted to
4 cables' impedance) so that the pulse train (position 4) should
2 obtain a sharp signal.
U [V]
• that the signal valve is given as the potential difference between

the cables, CAN + and CAN - (position 2 and 3).
3 • form of signal messages.
000026
t [S]
Messages are sequential and signal is high (voltage
high) or low (voltage low).
1. Termination resistor (120 ohm)
2. CAN + (voltage high)
3. CAN - (voltage low)
4. Pulse
5. Control unit
Message
Message
There are two types of messages:
A
• CAN Standard, has identity field of 11 bits
• CAN Extended, has identity field of 29 bits
CAN works in messages sent in frames of 8 bytes (64 bits). A complete
B C D E F G
000027
message is approx. 100 bits long. The illustration depicts how a

t [S] message is structured.
Messages are sequential and signal is high (voltage Start bit (B)
high) or low (voltage low).
Indicates that the transmission of a frame, i.e. a message, is now
A. Length message beginning.
B. Start bit
Identity field (C)
C. Identity field/Priority
Indicates what kind of information the message contains, e.g.
D. Control field (length of data segment)
measurement information on engine speed.
E. Data segment
F. Checksum for error detection Does not indicate address to control unit. CAN does not work with
addressing. All control units receive messages and send them on.
G. Acknowledge bit
Control field (D)
Indicates how the length of the data segment that follows.
Data segment (E)
Contains the information to be conveyed to control units in the network.
Checksum for error detection (F)
Calculates a checksum for the message. This makes it possible for the
receiving control unit to detect errors in the sent message.

11 Common electrics – CAN bus 11:37
Acknowledge (G)
The transmitting control unit sets a bit to logical one (1) when the
message is sent. The first control unit to receive the message sends it
on and sets the bit to logical zero (0).
Communication
Communication
The CAN network consists of control units and segments. The segment
(bus) is a twisted pair cable that leads CAN + and CAN - signal levels
from control unit to control unit.
Each control unit measures the potential difference of its two inputs.
3,5 V The potential difference generates logical zero and logical one. The
illustration depicts an approved interval according to the standard for
potential levels. CAN + has a recommended value of 3.5 V and CAN
- has 1.5 V. As a worst case scenario, the potential difference can be
U [V]
0,5 V only 0.5 V and still be approved. In practice, a potential difference of

2 V is recommended for reliable communication.
Pulse trains can only be observed using an oscilloscope, not with an

1,5 V analogue or digital multimeter.
When a message is sent, all control units in the network listen.

Messages are saved in the control unit and relevant information is
processed. The control unit that receives the message first confirms
receipt (sets an acknowledge bit). The transmitting control unit then
000028
t [S] knows that the message has been received by at least one control unit.
Potential levels CAN + and CAN - One control unit at a time sends the message. Other control units listen
and wait until the bus is available. If two messages are to be sent
simultaneously then the sending of the message with the lowest priority
(highest value in identity field) is concluded. This means that messages
do not need to be re-sent in the event of a communication conflict but
only in the event of a bus error (erroneous message).
The CAN bus exchanges around 100 messages per second in the
network.
Different bus systems can be used e.g. random sending or primary

(master) / secondary (slave).
HLP High Layer Protocol

CAN only specifies messages and how communication shall take
place, i.e. one protocol. In order to manage the network the CAN
protocol needs to be supplemented by a HLP which specifies:
• flow control
• transport of data above a length of 8 bits in 8 bit messages
(division)
• how control units are addressed in the network
• how bits in the message's data field should be interpreted

11:38 11 Common electrics – Redundant CAN bus
11.6.2 Redundant CAN bus

Redundant CAN bus, description
The redundant CAN bus handles communication between all of the
D791 D790-1 D790-2 D795 machine's control units except Control unit, transmission (D793) and
CAN R CAN L CAN R CAN L CAN R CAN L
Control unit, engine (D794). These have a separate CAN bus; see
CAN bus drive-train, description, page 11:40.
CAN L CAN R
014682
D797-1
Outline view, redundant CAN bus
Redundant CAN bus means that the control units are connected into a
D790-1 D791 D797-1 network that communicates via a CAN bus (see CAN bus, description,
page 11:36) and that there are double communication routes on the
1 2 network. The network is divided into control units and segments
4 (segments are the cables between the control units). The number of
3 active segments depends on the number of control units the machine
CAN R CAN L
009752
D795 has, which depends on the machine's equipment level (options).
Segment numbering starts from the CAN-R (right)

connection
The network is built on the CAN kingdom principle, which means

D790-1 D791 D797-1 that one control unit is central and is the master unit. In this case, it
is Control unit, cab (D790-1). Other control units in the network are
1 2
secondary (slaves) and handle special areas, e.g. components out
4 3 on the machine.
CAN R CAN L
D795 The control units have two CAN bus connections - CAN L (left) and
015052
CAN R (right). The control units are connected to one another in series
in a loop.
Segment numbering
The redundant CAN bus can handle the loss of a segment. The link
is analysed upon start-up. If a segment has a malfunction, messages
are sent via another route.
If several segments are lost, one or more control units lose

communication and work independently, often with significantly limited
functionality.
CAN bus faults are indicated with an error code and a warning in the
display. If several CAN bus segments are faulty, the system only shows
an error code for the first faulty out segment.

11 Common electrics – Redundant CAN bus 11:39
Connection of redundant CAN bus
Condition Refer- Reference

ence
value
Battery disconnector In position Battery disconnector, description, page 11:3
1
Redundant voltage feed Activated. Redundant voltage feed of control units, function description , page 11:7
5
D790- 2
1, 6 4
S1 D790- 1 S4 D79 5
D79 1 S2 D797-1 S3
2 3
019473
1 Control unit, cab (D790-1) establishes Checked by control Cab control unit, description, page 11:17
redundant CAN bus communication by system, error shown with Diagnostic menu, see section 8 Control
sending a request on the CAN bus via error code. system, group 8.4.1.1 CAN/POWER, menu
CAN R. 1 and 8.4.1.2 CAN/POWER, menu 2
2 The attachment control unit (D791) A clicking sound is Control unit, attachment, description, page
sends a response back on the CAN bus audible when then 11:20
via CAN L and sends the request on via termination resistor is Diagnostic menu, see section 8 Control
CAN R. activated. system, group 8.4.1.1 CAN/POWER, menu
Termination resistors in the control 1 and 8.4.1.2 CAN/POWER, menu 2
nodes ensure communication segment
by segment.
3 The frame control unit (D797-1) sends a A clicking sound is Frame control unit, description, page 11:18
response back on the CAN bus via CAN audible when then Diagnostic menu, see section 8 Control
L and sends the request on via CAN R. termination resistor is system, group 8.4.1.1 CAN/POWER, menu
Termination resistors in the control activated. 1 and 8.4.1.2 CAN/POWER, menu 2
by segment.
4 Control unit KID (D795) sends a A clicking sound is Control unit KID, description, page 11:26
response back on the CAN bus via CAN audible when then Diagnostic menu, see section 8 Control
L and sends the request on via CAN R. termination resistor is system, group 8.4.1.1 CAN/POWER, menu
Termination resistors in the control activated. 1 and 8.4.1.2 CAN/POWER, menu 2
by segment.

11:40 11 Common electrics – CAN bus drive-train

5 The KIT control unit (D790-2) is not A clicking sound is Control unit KIT, description, page 11:25
connected to the redundant CAN bus. audible when then
The KIT control unit (D790-2) does not termination resistor is
communicate until ignition voltage (15) activated.
is activated.
6 If all control units have responded, the Checked by control Diagnostic menu, see section 8 Control
cab control unit (D790-1) deactivates system, error shown with system, group 8.4.1.1 CAN/POWER, menu
the segment to the attachment control error code. 1 and 8.4.1.2 CAN/POWER, menu 2
unit (D791).
If a control unit has not responded,
then Control unit, cab (D790-1) uses
both CAN L and CAN R to keep
communication open and analyses
which segment is faulty.
11.6.3 CAN bus drive-train

CAN bus drive-train, description
4 6 The CAN bus for the drive-train is based on the SAE J1939 standard
where selected messages are used to control the engine and
transmission.
SAE J1939 is a standard from SAE (Society of Automotive Engineers)

for data communication in vehicles. The standard regulates hardware
D790-1 3 5 interface, bit times and message composition.
Control units for engine and transmission come from the respective
transmission and engine supplier.
The machine only uses one model, while there are several engine
alternatives. All engine alternatives use the standard and therefore the
messages for each engine are structured in the same way.
Communication with Control unit, engine (D794) and Control unit,

transmission (D793) are separate from the redundant CAN bus.
The signals can be checked via the diagnostic menu. See section 8
000033
Control system, group 8.4.1.4 CAN/POWER, menu 4.

1 2
1. Redundant CAN bus
2. CAN bus drive-train
3. Control unit, engine (D794)
4. Engine
6. Transmission

11 Common electrics – Communication between PC and machine 11:41
11.6.4 Communication between PC and machine

Communication between PC and machine, description
The machine has three or four sockets for communication between
control units and PC. Two are fitted in electronic box cab and one or
1
two in electronic box frame. It is the socket for communication with the
Volvo engine option that varies.
2
Sockets for programming control units in electronic box cab (position 1)
are used for programming the control units in the cab, on the frame and
on the attachment.
Sockets for CAN bus drive-train in electronic box cab (position 2) are
used for communicating with the engine and transmission via CAN bus.
The VODIA socket in the frame electronic box (position 3) is used to

connect the Volvo's diagnostic tool - VODIA.
The socket for transmission control unit (D793) programming in the

frame electrical distribution box (position 4) is used to program the
transmission control unit (D793).
For further details on communication between computer and machine,

contact Cargotec.
3
4
019471
1. Diagnostic socket, machine

2. Diagnostic socket CAN bus drive-train
3. Diagnostic socket, engine, VODIA
4. Diagnostic socket, transmission

11:42

D:1
D Error codes
Contents D Error codes

D Error codes ........................................................................................................D:3
1 Engine.................................................................................................................D:9
2 Transmission ...................................................................................................D:43
8 Control system ................................................................................................D:70

D:2

D Error codes – Error codes D:3
D Error codes
Error codes, explanation
The error codes are explained in table form for Engine, Transmission
as well as Control system. They are sorted according to error code
number.
The error code table has the following information:

• Code, error code\qs number, shown in field C on display.
C • Description, explanation of the error code and when it\qs
generated.
D E
• Limitation, in case of certain error codes certain functions are
B impaired or limited to protect the machine and operator.
000389
• Action, information of what should be checked to find the cause

of the error code.
B. Error code level (symbol) • Diagnostic menu, reference to suitable diagnostic menu to rectify
the problem, read signal value or check the function.
C. Error code number
In addition to the explanation of the display figure, the description
D. Error cause (symbol) of the diagnostic menus contains reference to circuit diagrams that
are found in section E Schematics and reference to function group
E. Function (symbol) for further information about functions and components.
• Function group is a reference to which function group the error
code is associated. This field is used to search for more information
as necessary. The function group can be used to find different
types of information.
Sections 0-12 contain a description of the function and its
components, component location and work instructions for different
tasks.

D:4 D Error codes – Error codes
Error code menu, description

The control and monitoring system's display is divided into four fields
C where the information is shown (see figure to the left).
• Field B: Error code level is shown with a symbol.
D E
• Field C: Shows error code.
B
000389
• Field D: Shows type of error.
• Field E: Indicates which function is affected by error code.
• Book symbol means that information is available in the operator's
manual.
Field B: Error code level
The control and monitoring system gives error code information in three
levels which are indicated with a symbol in the lower left corner (B)
on the display unit.
• Stop
C Indicates a serious malfunction that may jeopardise the operator's
safety or cause machine failure. The error code must be attended
D E to immediately. Stop working with the machine and contact service
immediately.
000350
• Warning
C Indicates malfunction in machine that should be taken care of as
soon as possible. After the finished work shift with the machine,
D E contact service as soon as possible.
000351
• Information
C Information to the operator that something should be rectified, e.g.
broken bulb. Take action to rectify the cause of the error code as
D E soon as possible. See section 6 Inspection and maintenance in
the operator's manual.
The error code is stored in the error code list under operating
000352
menu for service.

The control and monitoring system gives error codes from three
sub-systems:
• Machine:
C Shown with error code number XXX on display.
D E
B
000389
• Engine:
XX/YY Shown with error code number XXX/YY on display.
D NOTE
B If several error codes come from the engine, the error code level is
001343
shown for the most serious error code.

• Transmission:
XXX/YY Shown with error code number XX/YY on display.
001344

1. Temperature too high/too low.
1 2 3
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
5. Incorrect signal from control.
4 5 6
6. Incorrect signal to bulb.
7. Incorrect signal, for example, open circuit.
7
000396


1. Attachment
1 2 3
2. Rotation of attachment
3. Side shift, attachment
4. Length adjustment attachment
4 5 6 5. Levelling
6. Twistlocks
7. Forks up/down
8. Tilt forks
7 8 9
9. Side shift forks
10. Spreading forks
11. Rotation forks
10 11 12 12. Overload protection
13. Hydraulic functions
14. Brake system
15. Steering
13 14 15 16. Engine
17. Transmission
18. Central lubrication
16 17 18 19. Control unit
20. Hardware-related error
21. Cab
22. Air conditioning
19 20 21 23. Fuel system
24. Headlights
25. Windscreen wipers
22 23 24 26. Battery voltage
27. Bulb for lighting
25 26 27
010153

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 start key to position I.
WARNING
Risk of machine damage.
In the event of error codes of level "WARNING" and
"STOP", serious machine damage may result if the
engine is started.
Do not start the engine until the cause of the error
code has been identified or repaired.
2 Navigate to the service menu and press Enter.

000056
3 The safety menu is shown. Hold Enter depressed for at least

two seconds.
1 23
4 5
000060
4 The error code list is shown on the display. An active error code is
shown on display where field C shows error code number together
with X(Y). X shows sequence number for displayed error code and
(Y) shows total number of active error codes.
Scroll between error codes with key 1 and 2 (arrow function).
001998
Error codes disappear from the list when the cause has been
remedied.

5 Note error code number (field C) to avoid forgetting.

C • Error code level is shown with a symbol in field B
D E • Error code is shown in field C
• Error cause is shown with a symbol in field D
B
000389
• The function affected by the error is shown with a symbol in
field E
The book symbol is an instruction for the operator to read the
operator's manual.
6 Use the error code tables to find more information about the error
code.
7 After the remedial action, check that no active error codes remain
for the function in question.

1 Engine – Engine D:9
1 Engine
Error codes engine, general
When contacting engine suppliers, use the supplier code.
• Display/code indicates error code as shown in the machine, in
accordance with SAE J1939 in SPN/FMI
• The supplier code/J1587 indicates the error code in accordance
with the engine manufacturer's specification.
Table Specifications FMI
FMI Description SAE-text

0 Too high value. Data valid, but higher than normal operating range.
1 Value too low. Data valid, but lower than normal operating range.
2 Incorrect data. Intermittent or incorrect data.
3 Electrical problem. Abnormally high voltage or short-circuit to higher voltage.
4 Electrical problem. Abnormally low voltage or short-circuit to lower voltage.
5 Electrical problem. Abnormally low current or open circuit.
6 Electrical problem. Abnormally high current or short-circuit to ground.
7 Mechanical problem. Incorrect response from mechanical system.
8 Mechanical problem or electrical Abnormal frequency.
problem.
9 Communication error. Abnormal update rate.
10 Mechanical problem or electrical Abnormally wide variations.
problem.
11 Unknown malfunction. Non-identifiable malfunction.
12 Component error. Incorrect unit or component.
13 Incorrect calibration. Values outside calibration values.
14 Unknown malfunction. Special instructions.
15 Too high value. Data valid, but higher than normal operating range. The least serious
level
16 Too high value. Data valid, but higher than normal operating range. Moderately severe
level
17 Value too low. Data valid, but below normal operating range: The least serious level
18 Value too low. Data valid, but below normal operating range: Moderately severe level
19 Communication error. Received network data incorrect
20-30 Reserved for SAE-assignment
31 FMI is not available or the condition Not available or condition exists
that is identified by the SPN exists.

D:10 1 Engine – Engine
Error codes engine (engine alternative

Volvo TAD760VE)
Table Error codes engine (engine alternative Volvo TAD760VE)
Error codes, engine alternative Volvo TAD760VE
Code J1587 Description Limitation Action Connec- Diagnos-

tions and tic menu
compo-
nents
94/1 PID94/1 Low fuel pressure No limitation. Change the fuel filter. - -
(feed). Change the fuel prefilter.
Check whether
pressure can be built up
with the hand pump.
94/3 PID94/3 Sensor fuel No limitation. Check the cable D794/B:16 -
pressure, harness between
short-circuited to control unit and
voltage. component.
Check the sensor.
94/5 PID94/5 Sensor fuel No limitation. Check the cable D794/B:16 -
pressure, harness between
ground or open component.
circuit. Check the sensor.
94/7 PID94/7 Sensor fuel No limitation. Change the fuel filter. D794/B:16 -
pressure, Change the fuel prefilter.
short-circuited to
voltage, ground or Check whether
open circuit. pressure can be built up
with the hand pump.
97/0 PID97/0 Water in fuel. No limitation. Drain water separator. - -
Clean metal filter in
the fuel feed's hose
connection on the
engine.
Check fuel filter and fuel
pre-filter.
97/4 PID97/4 Sensor water-in- No limitation. Check the cable D794/B:8 -
fuel short-circuited harness between
to ground or open control unit and
circuit. component.
Check the sensor.
100/0 PID100/ Low engine oil The engine is Check the oil level. - ENGINE,
0 pressure. switched off. Change oil filter. menu 6
Check the system
pressure valves and
the safety valve in the
lubrication system.
Check the sensor.
100/3 PID100/ Sensor oil No limitation. Check the cable D794/B:11 ENGINE,
3 pressure, harness between menu 6
voltage. component.
Check the sensor.


tions and tic menu
compo-
nents
100/5 PID100/ Sensor oil No limitation. Check the cable D794/B:11 ENGINE,
5 pressure, open harness between menu 6
circuit. control unit and
component.
Check the sensor.
105/0 PID105/ High charge-air The engine is Check that charge-air - ENGINE,
0 temperature. switched off. cooler is clean. menu 7
Check the sensor.
105/4 PID105/ Sensor charge air No limitation. Check the cable D794/A:47 ENGINE,
4 temperature, cable harness between menu 7
ground. component.
Check the sensor.
105/5 PID105/ Sensor charge air No limitation. Check the cable D794/A:47 ENGINE,
5 temperature, cable harness between menu 7
open circuit. control unit and
component.
Check the sensor.
106/0 PID106/ High booster Reduced engine Check turbocharger. - ENGINE,
0 pressure. power. Check the sensor. menu 6
Check fuel quality and
injectors.
106/3 PID106/ Sensor, boost Reduced engine Check the cable D794/A:22 ENGINE,
3 pressure, cable power. harness between menu 7
voltage. component.
Check the sensor.
106/5 PID106/ Sensor, boost Reduced engine Check the cable D794/A:22 ENGINE,
5 pressure, cable power. harness between menu 7
open circuit. control unit and
component.
Check the sensor.
108/2 PID108/ Incorrect signal No limitation. Check the cable - ENGINE,
2 from Sensor, boost harness between menu 6
pressure. control unit and
component.
Check the sensor.
108/3 PID108/ Sensor, boost No limitation. Check the cable D794/A:29 ENGINE,
voltage. component.
Check the sensor.
108/4 PID108/ Sensor boost No limitation. Check the cable D794/A:29 ENGINE,
ground or open component.


tions and tic menu
compo-
nents
110/0 PID110/ High coolant No limitation. Check the coolant level. - ENGINE,
0 temperature. Check that radiator is menu 7
clean.
Check the thermostat.
Check the cap on the
expansion tank.
Check if there is air in
coolant system.
Check the sensor.
110/4 PID110/ Sensor coolant Preheating is Check the cable D794/B:27 ENGINE,
4 temperature, activated even harness between menu 7
short-circuited to if engine is warm. control unit and
ground. component.
Check the sensor.
110/5 PID110/ Sensor coolant Preheating is Check the cable D794/B:27 ENGINE,
5 temperature, cable activated even harness between menu 7
open circuit. if engine is warm. control unit and
component.
Check the sensor.
111/1 PID111/ Low coolant level. No limitation. Check the coolant level; - -
1 fill if necessary.
Check the sensor.
158/1 PID158/ Low battery The engine may Check and charge the D794/B:57, -
1 voltage. be difficult to start. batteries. B:60
Check alternator.
Check the battery
cables.
164/0 PID164/ High fuel pressure. No limitation. Check the fuel pump. - -
0 Check the sensor.
164/2 PID164/ Incorrect signal Engine speed Check the cable D794/B:16 -
2 from Sensor, fuel limited to 1100 harness between
pressure. rpm. control unit and
component.
Check the sensor.
164/4 PID164/ Sensor fuel Engine speed Check the cable D794/B:16 -
4 pressure, limited to 1100 harness between
short-circuited to rpm. control unit and
ground. component.
Check the sensor.
164/5 PID164/ Sensor fuel Engine speed Check the cable D794/B:16 -
5 pressure, open limited to 1100 harness between
circuit. rpm. control unit and
component.
Check the sensor.
190/0 PID190/ Engine speed too No limitation. Ease off throttle or - -
0 high. select higher gear.


tions and tic menu
compo-
nents
626/3 PID45/3 Preheating relay, Preheating cannot Check the cable D794/B:25 ENGINE,
short-circuited to be activated. harness between menu 5
voltage. White smoke with control unit and
cold-start. component.
Starting problems Check the relay.
in cold weather.
626/4 PID45/4 Preheating relay, Preheating Check the cable D794/B:25 ENGINE,
short-circuited to is constantly harness between menu 5
ground. activated. Fuse control unit and
for preheating component.
may fail. Check the relay.
626/5 PID45/5 Preheating relay, Preheating cannot Check the cable D794/B:25 ENGINE,
open circuit be activated. harness between menu 5
or defective White smoke with control unit and
component. cold-start. component.
Starting problems Check the relay.
in cold weather.
629/3 SID254/ Engine control unit The engine does Change the control unit. - -
3 (D794), internal not start.
error.
error.
error.
636/2 SID21/3 Incorrect signal The engine takes Check the cable D794/A:45, -
from Sensor, longer to start harness between A:46
camshaft speed. than normal. The control unit and
engine is running component.
normally once it Check the sensor.
has started.
636/3 SID21/3 Sensor rotation The engine takes Check the cable D794/A:45, -
speed camshaft, longer to start harness between A:46
no signal. than normal. The control unit and
engine is running component.
has started.
636/8 SID21/8 Sensor engine The engine takes Check the cable D794/A:45, -
speed, camshaft, longer to start harness between A:46
abnormal than normal. The control unit and
frequency. engine is running component.
has started.
637/2 SID22/2 Incorrect signal The engine is Check the cable D794/A:37, ENGINE,
from Sensor difficult to start harness between A:38 menu 2
engine speed, and runs rough, if control unit and
flywheel. it runs. component.
Check the sensor.


tions and tic menu
compo-
nents
637/3 SID22/3 Sensor engine The engine is Check the cable D794/A:37, ENGINE,
speed, flywheel, difficult to start harness between A:38 menu 2
abnormal and runs rough, if control unit and
frequency. it runs. component.
Check the sensor.
637/8 SID22/8 Sensor engine The engine is Check the cable D794/A:37, ENGINE,
speed, flywheel, difficult to start harness between A:38 menu 2
abnormal and runs rough, if control unit and
frequency. it runs. component.
Check that the sensor is
connected correctly.
639/2 SID231/ Communication Engine switched Use diagnostic menu to D794/B:51, CAN/POW-
2 error with off: engine cannot find incorrect segment. B:55 ER, menu 3
Control unit, be started. Check the cable
engine (D794), Engine on: engine harness between
configuration error. goes to idle control unit and
and can only be component.
stopped by using Check the control unit.
the emergency
stop.
639/2 SID240/ Communication It may not be Reprogram the control - -
2 error with possible to start unit.
Control unit, the engine.
engine (D794),
configuration error.
engine (D794),
639/9 PSID20 Communication Instruments and Use diagnostic menu to - -
1/9 error with controls do not find incorrect segment.
Control unit, work. Check the cable
engine (D794), harness between
configuration error. control unit and
component.
Check the control unit.
engine (D794),
engine (D794),
651/3 SID1/3 Electric failure, Engine only runs Check the cable D794/A:24 -
injector cylinder 1. on 5 cylinders, harness between
sounds rough control unit and
and has reduced component.
power. Check the injector.


tions and tic menu
compo-
nents
651/7 SID1/7 Incorrect Runs rough at low Check the fuel pressure. D794/A:24 -
compression or rpm and low load. Check valve clearance.
defective injector
cylinder 1. Check the cable
harness between
control unit and
component.
Check the injector.
Perform compression
test and check cylinder
1.
defective injector
harness between
control unit and
component.
Check the injector.
Perform compression
2.


tions and tic menu
compo-
nents
defective injector
harness between
control unit and
component.
Check the injector.
Perform compression
3.


tions and tic menu
compo-
nents
defective injector
harness between
control unit and
component.
Check the injector.
Perform compression
4.
655/7 SID5/7 Incorrect Engine only runs Check that cabling D794/A:48 -
compression or on 5 cylinders, to the injectors is not
defective injector sounds rough damaged.
cylinder 5. and has reduced Check the cable
power. harness between
control unit and
component.
Check the injector.
Perform compression
5.


tions and tic menu
compo-
nents
defective injector
harness between
control unit and
component.
Check the injector.
Perform compression
6.
656/12 SID6/12 Electric failure, Engine only runs Check the cable D794/A:36, -
injector cylinder 6. on 5 cylinders, harness between A:40
677/3 SID39/3 Starter motor relay, The engine does Check the cable D794/B:29 ENGINE,
short-circuited to not start. harness between menu 5
voltage. Engine starts control unit and
immediately when component.
ignition is turned Check the relay.
on.
ground control unit and
component.
Check the relay.
open circuit. not start. harness between menu 5
control unit and
component.
Check the relay.
679/0 PSID97/ Incorrect signal Engine speed Check the cable - -
0 from pressure limited to 1100 harness between
relief valve. rpm. control unit and
Reduced engine component.
power. Check the component.
679/3 SID42/3 Pressure Engine speed Check the cable - -
relief valve, limited to 1100 harness between
voltage. component.
Check the component.


tions and tic menu
compo-
nents
679/4 SID43/4 Pressure Engine speed Check the cable - -
relief valve, limited to 1100 harness between
ground. component.
679/5 SID43/5 Pressure relief Engine speed Check the cable - -
valve, open circuit. limited to 1100 harness between
rpm. control unit and
component.
679/7 PSID97/ Pressure relief Engine speed Check the cable - -
7 valve, mechanical limited to 1100 harness between
defect. rpm. control unit and
11 valve, unidentified limited to 1100 harness between
problem. rpm. control unit and
14 valve, defective limited to 1100 harness between
component. rpm. control unit and
729/3 SID70/3 Sensor Fuse blows. Check the cable D794/B:31 -
preheating, harness between
voltage. component.
729/4 SID70/4 Sensor Engine difficult Check the cable D794/B:31 -
preheating, to start in cold harness between
short-circuited to weather. control unit and
ground. component.
729/5 SID70/5 Sensor Engine difficult Check the cable D794/B:31 -
preheating, open to start in cold harness between
circuit. weather. control unit and
component.
1079/3 SID Reference voltage No limitation. Check the cable D794/B:17 -
232/3 5 V no. 1 to sensor, harness between
voltage. component.
Check the sensor.
1079/4 SID Reference voltage No limitation. Check the cable D794/B:17 -
ground. component.
Check the sensor.


tions and tic menu
compo-
nents
1080/3 SID Reference voltage No limitation. Check the cable D794/A:7 -
voltage. component.
Check the sensor.
1080/4 SID Reference voltage No limitation. Check the cable D794/A:7 -
ground. component.
Check the sensor.
1239/0 PSID Fuel pressure too Engine speed Check fuel feed. - -
96/0 high. limited to 1100
rpm.
High engine
power. (Powerful
engine)
1239/1 PSID Fuel pressure too Engine speed Check fuel filter, change - -
96/1 low limited to 1100 if necessary.
rpm. Check fuel feed.
Reduced engine
power.
1239/4 PSID Sensor fuel Engine speed Check the cable D794/B:16 -
96/4 pressure, limited to 1100 harness between
ground. Reduced engine component.
power. Check the sensor.
Engine difficult to
start.
1239/7 PSID Sensor fuel Engine speed Check the cable D794/B:16 -
96/7 pressure, limited to 1100 harness between
mechanical defect. rpm. control unit and
power. Check the sensor.
Engine difficult to
start.
1239/12 PSID Sensor fuel Engine speed Check the sensor. - -
96/12 pressure, limited to 1100
defective rpm.
component. Reduced engine
power.
Engine difficult to
start.
voltage. Engine starts control unit and
immediately when component.
ignition is turned Check the relay.
on.


tions and tic menu
compo-
nents
ground control unit and
component.
Check the relay.
open circuit. not start. harness between menu 5
control unit and
component.
Check the relay.
1675/9 PSID20 Communication Instruments and Use diagnostic menu to - -
1/9 error with controls do not find incorrect segment.
Control unit, work. Check the cable
engine (D794), harness between
configuration error. control unit and
component.
2791/3 PPID19/ Internal EGR, Internal EGR not Check the cable D794/B:30 -
3 short-circuited to working. harness between
voltage. control unit and
component.
4 short-circuited to working. harness between
ground. control unit and
component.
5 open circuit. working. harness between
control unit and
component.
2791/7 PPID19/ Internal EGR, Internal EGR not Check, Sensor boost D794/B:30 -
7 mechanical defect. working. pressure.
(IEGR)
Contact Volvo Penta
workshop for more
information.
520192 PPID6/5 Sensor piston No limitation. Check the cable D794/B:14 -
/5 cooling pressure, harness between
voltage, ground or component.
open circuit. Check the sensor.


tions and tic menu
compo-
nents
- PPID High fuel pressure. Engine speed Check fuel feed. - -
435/0 limited to 1100
rpm.
High engine
power. (Powerful
engine)
- PPID Low fuel pressure. Engine speed Check fuel filter, change - -
435/4 limited to 1100 if necessary.
rpm. Check fuel feed.
Reduced engine
power.

Error codes engine (engine alternative

Cummins QSB6.7)
Table Error codes engine (engine alternative Cummins QSB6.7)
Error codes, engine alternative Cummins QSB6.7
Code Description Limitation Action Connec- Diagnos-

tions and tic menu
compo-
J1587 nents
84 / 2 P084 / 2 Machine speed sensor Engine speed Check the D794 ENGINE,
circuit: Data erratic, limited to Maximum cable harness menu 2
intermittent or incorrect. Engine Speed between control
The ECU 794 lost the without VSS unit and
machine speed signal. parameter value. component.
Cruise control, Check the
Gear-Down sensor.
Protection, and
Road Speed
Governor will not
work.
84 / 10 P084 / Manipulation of machine Engine speed Check the D794 ENGINE,
10 speed sensor circuit has limited to Maximum cable harness menu 2
been detected: Abnormal Engine Speed between control
change rate. Invalid or without VSS unit and
incorrect machine speed parameter value. component.
signal. The signal indicates Cruise control, Check the
an erratic connection or VSS Gear-Down sensor.
manipulation. Protection, and
Road Speed
Governor will not
work.
91 / 0 P91 / 0 Accelerator pedal or lever Heavy derating - - ENGINE,
position sensor 1: Data valid in power output menu 1
but higher than the normal of the engine.
working range, the most Only emergency
severe level. A frequency operation power.
above 1500 Hz has been
detected on the accelerator
pedal's frequency input to
ECU 794.
91 / 1 P91 / 1 Frequency in the accelerator Heavy derating - - ENGINE,
pedal or lever position sensor in power output menu 1
circuit 1: Data valid but lower of the engine.
than the normal working Only emergency
range, the most severe operation power.
level. A frequency under
100 Hz has been detected
on the accelerator pedal's
frequency input to ECU 794.
91 / 19 P91 System error for SAE J1939 Engine may only Use diagnostic - -
multiplexing accelerator idle or engine will menu to
pedal or lever sensors: not accelerate to full find incorrect
Network data error received. speed. segment.
The machine's OEM control
unit (VECU) detected an
error on its accelerator
pedal.
91 / 2 P31 / 2 Accelerator pedal position - - ENGINE,
sensor. menu 1


tions and tic menu
compo-
J1587 nents
91 / 3 P091 / 3 Accelerator pedal or lever Heavy derating Check the - ENGINE,
position sensor circuit: in power output cable harness menu 1
Short-circuited high. of the engine. between control
High voltage detected in Only emergency unit and
accelerator pedal or lever operation possible. component.
position circuit. Check the
component.
91 / 4 P091 / 4 Accelerator pedal or lever Heavy derating Check the - ENGINE,
position sensor circuit: in power output cable harness menu 1
Voltage lower than normal of the engine. between control
or shorted to low source. Only emergency unit and
Low voltage detected in operation possible. component.
accelerator pedal or lever Check the
position signal circuit. component.
94 / 1 P94 / 1 Fuel pump's delivery Possibly difficult to - D794 -
pressure: Data valid but start, low power,
below normal operational possibly smoke from
range - moderately severe the engine. The
level. The ECU 794 has engine may not be
detected the fuel pressure in possible to start.
the fuel rail is lower than the
commanded performance.
94 / 2 P094 / 2 Injector Metering Rail 1 The ECU 794 - D794 -
Pressure - Data Erratic, will estimate fuel
Intermittent, or Incorrect. pressure, and power
The ECU 794 has detected is reduced.
that the fuel pressure signal
is not changing.
94 / 18 P94 / 0 Fuel pump's delivery None or possible - D794 -
pressure: Data valid engine noise
but higher than normal associated
operational range - with higher
moderately severe level. injection pressures
The ECU 794 has detected (especially at idle or
fuel pressure in the fuel light load). Engine
rail that is higher than the power derate.
commanded pressure.
97 / 3 P097 / 3 Sensor circuit for water in None on Check the D794 -
fuel indicator: Voltage higher performance. No cable harness
than normal or short-circuited water in fuel warning between control
to a high source. High available. unit and
voltage detected on the component.
water in the fuel circuit. Check the
sensor.
97 / 4 P097 / 4 Sensor circuit for water in None on Check the D794 -
fuel indicator: Voltage lower performance. No cable harness
than normal or short-circuited water in fuel warning between control
to a low source. Low voltage available. unit and
detected on the water in the component.
fuel circuit. Check the
sensor.


tions and tic menu
compo-
J1587 nents
97 / 15 P097 / 0 Water-in-fuel indicator - Possible white Drain water - -
Data valid but above normal smoke, loss of from the fuel.
operational range - least power, or hard
severe level. Water has starting.
been detected in the fuel
filter.
100 / 1 P100 / 1 Engine oil duct pressure: Progressive power Check the oil - ENGINE,
Data valid but lower than derate increasing in level in the menu 6
normal operational range, severity from time of engine; fill if
the most severe level. The alert. If the function necessary.
oil pressure signal indicates Engine protection
that the oil pressure is lower cut- off is activated,
than the critical limit for the the engine switches
engine's protection. off 30 seconds after
the red STOP light
starts flashing.
100 / 2 P100 / 2 Oil pressure switch sensor None on Check the D794 ENGINE,
circuit Data erratic, performance. No cable harness menu 6
intermittent or incorrect. engine protection for between control
An error in the engine oil the oil pressure. unit and
pressure switch signal has component.
been detected by ECU 794. Check the
sensor.
100 / 3 P100 / 3 Oil pressure sensor circuit: None on Check the D794 ENGINE,
Voltage higher than normal performance. No cable harness menu 6
or shorted to high source. engine protection for between control
High signal voltage detected the oil pressure. unit and
in engine oil pressure circuit. component.
Check the
sensor.
100 / 4 P100 / 4 Oil pressure sensor circuit: None on Check the D794 ENGINE,
Voltage lower than normal or performance. No cable harness menu 6
shorted to low source. Low engine protection for between control
signal voltage detected in the oil pressure. unit and
engine oil pressure circuit. component.
Check the
sensor.
100 / 18 P100 / 1 Engine oil duct pressure: None on Check the oil - ENGINE,
Data valid but lower than performance. level in the menu 6
normal operational range, engine; fill if
moderately severe level. necessary.
Engine oil pressure signal
indicates that the engine oil
pressure is lower than the
limit for engine protection
warning.
102 / 2 P102 /2 Intake manifold pressure Engine power Check the D794 ENGINE,
sensor circuit: Manifold derate. cable harness menu 6
Pressure Sensor Circuit - between control
Data Erratic, Intermittent or unit and
Incorrect. The ECU 794 has component.
detected an intake manifold Check the
pressure signal that is too sensor.
high or low for current engine
operating conditions.


tions and tic menu
compo-
J1587 nents
102 / 2 P102 /2 Intake manifold pressure Derate in power Check the D794 ENGINE,
sensor circuit: Incorrect output of the engine. cable harness menu 6
data. An error in the intake between control
manifold pressure sensor unit and
signal has been detected by component.
ECU 794. Check the
sensor.
102 / 3 P102 / 3 Intake manifold pressure Derate in power Check the D794 ENGINE,
sensor circuit: Voltage output of the engine. cable harness menu 6
higher than normal or between control
shorted to high source. High unit and
signal voltage detected in component.
the intake manifold pressure Check the
circuit. sensor.
102 / 4 P102 / 4 Intake manifold pressure Derate in power Check the D794 ENGINE,
sensor circuit: Voltage lower output of the engine. cable harness menu 6
than normal or short-circuited between control
to low source. Low signal unit and
voltage detected in the intake component.
manifold pressure circuit. Check the
sensor.
103 / 10 P103 / Turbocharger speed: Possible-low-power Check the D794 -
10 Incorrect change rate estimated cable harness
detected. Turbocharger turbocharger speed between control
speed sensor detected an will be used. unit and
incorrect speed value. component.
Check the
sensor.
103 / 16 P103 / 0 Turbocharger number 1 Engine power Check the D794 -
speed high: Warning level. derate. The component.
High turbocharger speed has ECU 794 uses
been detected. an estimated
turbocharger speed.
103 / 18 P103 / 1 Turbocharger number 1 Engine power Check the D794 -
speed low: Warning level. derate. The component.
Low turbocharger speed has ECU 794 uses
been detected by ECU 794. an estimated
turbocharger speed.
105 / 0 P105 / 0 Temperate intake manifold Progressive power Check the - ENGINE,
1: Data valid but higher derate increasing in coolant level menu 7
than normal operational severity from time of in the engine;
range, the most severe alert. If the function fill if necessary.
level. The intake manifold air Engine protection Check that
temperature signal indicates cut- off is activated, the charge
that the air temperature in the engine switches air cooler is
the intake manifold is higher off 30 seconds after clean, clean if
than the critical limit for the red STOP light necessary.
engine protection. starts flashing.
Check that the
fan belts are
intact. Check
the sensor.


tions and tic menu
compo-
J1587 nents
105 / 3 P105 / 3 Intake manifold air Possible white Check cable D794 ENGINE,
temperature sensor circuit: smoke. Fan will harness menu 7
Voltage higher than normal stay ON if controlled between control
or shorted to high source. by the ECU 794. No unit and
High signal voltage detected engine protection for component.
in the intake manifold air intake manifold air Check the
temperature circuit. temperature. sensor.
105 / 4 P105 / 4 Intake manifold air Possible white Check cable D794 ENGINE,
temperature sensor circuit: smoke. Fan will harness menu 7
Voltage lower than normal or stay ON if controlled between control
short-circuited to low source. by the ECU 794. No unit and
Low signal voltage detected engine protection for component.
in the intake manifold air intake manifold air Check the
temperature circuit. temperature. sensor.
105 / 15 P105 / 0 Intake manifold temperature Progressive power Check the D794 ENGINE,
high: Data valid but higher derate increasing in coolant level menu 7
than normal operational severity from time of in the engine;
range, the least severe alert. fill if necessary.
level. The intake manifold air Check that
temperature signal indicates the charge
that the air temperature in air cooler is
the intake manifold is higher clean, clean if
than the warning limit for necessary.
engine protection.
Check that the
fan belts are
intact. Check
the sensor.
108 / 2 P108 / 2 Barometric pressure: Data Engine power Check cable - -
erratic, intermittent or derate. harness
incorrect. The pressure between control
sensor for the ambient air unit and
pressure reads an erratic component.
value on power-up. Check the
sensor.
108 / 3 P108 / 3 Barometric pressure sensor Engine power Check cable D794 -
circuit: Voltage higher than derate. harness
normal or shorted to high between control
source. High signal voltage unit and
detected in barometric component.
pressure sensor circuit. Check the
sensor.
108 / 4 P108 / 4 Barometric pressure sensor Engine power Check cable D794 -
circuit: Voltage lower than derate. harness
normal or shorted to low between control
source. Low signal voltage unit and
detected in barometric component.
pressure sensor circuit. Check the
sensor.


tions and tic menu
compo-
J1587 nents
110 / 0 P110 / 0 Engine coolant temperature: Progressive power Check the - ENGINE,
Data valid but higher than derate increasing in coolant level. menu 7
normal operational range, severity from time of Check that
the most severe level. The alert. If the function radiator is
engine coolant temperature Engine protection clean.
signal indicates that the cut- off is activated,
coolant temperature is the engine switches Check if there
higher than the critical limit off 30 seconds after is air in coolant
for engine protection. the red STOP light system.
starts flashing. Check the
cap on the
expansion tank.
Check the
sensor.
Check the
thermostat.
110 / 2 P110 / 2 Engine coolant temperature: The ECU 794 will Check cable D794 ENGINE,
Data erratic, intermittent estimate engine harness menu 7
or incorrect. The engine coolant temperature. between control
coolant temperature reading unit and
does not change when component.
operating conditions change. Check the
sensor.
110 / 3 P110 / 3 Engine coolant temperature Possible white Check cable D794 ENGINE,
sensor circuit 1: Voltage smoke. Fan will harness menu 7
higher than normal or stay ON if controlled between control
shorted to high source. by the ECU 794. No unit and
High signal voltage or open engine protection for component.
circuit detected in the engine the engine coolant Check the
coolant temperature circuit. temperature. sensor.
110 / 4 P110 / 4 Engine coolant temperature Possible white Check cable D794 ENGINE,
sensor circuit 1: Voltage smoke. Fan will harness menu 7
lower than normal or shorted stay ON if controlled between control
to low source. Low signal by the ECU 794. No unit and
voltage detected in the engine protection for component.
engine coolant temperature the engine coolant Check the
circuit. temperature. sensor.
110 / 15 P110 / 0 Engine coolant temperature Progressive power Check the D794 ENGINE,
high: Data valid but higher derate increasing in coolant level. menu 7
than normal operational severity from time of Check that
range, the least severe alert. radiator is
level. The engine coolant clean.
temperature signal indicates
that the coolant temperature Check if there
is higher than the warning is air in coolant
limit for engine protection. system.
Check the
cap on the
expansion tank.
Check the
sensor.
Check the
thermostat.


tions and tic menu
compo-
J1587 nents
110 / 16 P110 / 0 Engine coolant temperature: Progressive power Check the D794 ENGINE,
Data valid but higher than derate increasing in coolant level. menu 7
normal operational range, severity from time of Check that
moderately severe level. The alert. radiator is
engine coolant temperature clean.
signal indicates that the
coolant temperature is Check if there
higher than the warning limit is air in coolant
for engine protection. system.
Check the
cap on the
expansion tank.
Check the
sensor.
Check the
thermostat.
111 / 1 P111 / 1 Coolant level: Data valid Progressive power Check the - -
but lower than normal derate increasing coolant level;
operational range, the most in severity from fill if necessary.
severe level. Low coolant time of alert. If the Check the
level detected. function Motor cut- sensor.
off is activated, the
engine switches off
in 30 seconds after
the red STOP light
starts flashing.
111 / 3 P111 / 3 Radiator coolant level sensor None on Check cable D794 -
circuit: Voltage higher than performance. harness
normal or shorted to high between control
source. High signal voltage unit and
detected in the engine component.
coolant level circuit. Check the
sensor.
111 / 4 P111 / 4 Radiator coolant level sensor None on Check cable D794 -
circuit: Voltage lower than performance. harness
normal or shorted to low between control
source. Low signal voltage unit and
detected in the engine component.
coolant level circuit. Check the
sensor.
157 / 0 P94 / 0 Injector Metering Rail None or possible - D794 -
Number 1 Pressure - Data engine noise
Valid But Above Normal associated
Operating Range - Most with higher
Severe Level. The ECU injection pressures
794 has detected that fuel (especially at idle or
pressure in the rail fuel is light load). Engine
higher than the commanded power derate.
pressure.
157 / 2 P157 / 2 Injector Metering Rail 1 The ECU 794 - D794 -
Pressure - Data Erratic, will estimate fuel
Intermittent, or Incorrect. the pressure, and power
ECU 794 has detected that is reduced.
the fuel pressure signal is
not changing.


tions and tic menu
compo-
J1587 nents
157 / 3 P157 / 3 Injector measurement Power and or speed - D794 -
channel number 1, pressure derate.
sensor circuit: Voltage higher
than normal or shorted to
high source. High signal
voltage detected in the fuel
rail fuel pressure sensor
circuit.
157 / 4 P157 / 4 Injector measurement Power and or speed - D794 -
channel number 1, pressure derate.
sensor circuit: Voltage lower
than normal or short-circuited
to low source. Low signal
voltage detected in the fuel
rail fuel pressure sensor
circuit.
157 / 16 P157 / 0 Injector measurement None or possible - D794 -
channel 1, pressure Data engine noise
valid but higher than associated
normal operational range with higher
- moderately severe level. injection pressures
The ECU 794 has detected (especially at idle or
that the fuel pressure is light load). Engine
higher than the commanded power derate.
pressure.
157 / 18 P157 / 1 Fuel pump's delivery Possibly difficult to - D794 -
pressure low: Data valid start, low power
but lower than normal or smoke from the
operational range - engine. The engine
moderately severe level. may not be possible
The ECU 794 has detected to start.
that the fuel pressure is
lower than the commanded
pressure.
167 / 1 P167 / 1 Charging system voltage Warning lamp Check batteries D794 -
low: Data valid but lower illuminated until and alternator.
than normal operational very low battery
range, the most severe level. voltage condition is
Very low battery voltage corrected.
detected by battery voltage
monitoring.
167 / 16 P167 / 0 Charging system voltage Amber warning Check fuses. D794 -
high: Data valid but higher lamp illuminated Check batteries
than normal operational until high battery and alternator.
range, moderately severe voltage condition is
level. High battery voltage corrected.
monitoring.
167 / 18 P167 / 1 Charging system voltage Amber lamp will Check batteries D794 -
low: Data valid but lower light until low battery and alternator.
than normal operational voltage condition is
range, moderately severe corrected.
level. Low battery voltage
monitoring.


tions and tic menu
compo-
J1587 nents
168 / 16 P168 / 0 Battery 1 Voltage - Data Possible electrical Check fuses. D794 -
Valid but Above Normal damage to Check batteries
Operational Range - all electrical and alternator.
Moderately Severe Level. components.
ECU 794 supply voltage is
above the maximum system
voltage level.
168 / 18 S168 / 1 Battery 1 Voltage - Data Engine may stop Check fuses. D794 -
Valid but Below Normal running or be difficult Check batteries
Operational Range - to start. and alternator.
Moderately Severe Level.
ECU 794 supply voltage is
below the minimum system
voltage level.
171 / 3 P171 / 3 Outdoor temperature sensor, - D794 -
circuit error: Abnormally high
voltage or short-circuit to
higher voltage.
171 / 4 P171 / 4 Outdoor temperature sensor, - D794 -
circuit error: Abnormally low
voltage or short-circuit to
lower voltage.
190 / 0 P190 / 0 Engine crankshaft Fuel injection Ease off the - -
speed/position: Data valid disabled until engine throttle or select
but higher than the normal speed fails below higher gear.
working range: The most the overspeed limit.
severe level. The engine
speed signal indicates the
engine speed over the
engine protection limit.
190 / 2 P190 / 2 Engine crankshaft The engine may Check cable D794 -
speed/position: Data erratic, misfire when harness
intermittent or incorrect. steering switches between control
Engine speed sensor on from the primary to unit and
the crankshaft uneven the backup speed component.
synchronised. sensor. The engine Check the
power derates while sensor.
the engine is driven
with the backup
speed sensor.
190 / 2 P190 / 2 Engine crankshaft The engine runs Check cable D794 -
speed/position: Data erratic, unevenly. Can be harness
intermittent or incorrect. The difficult to start. The between control
signal from the crankshaft engine is driven unit and
sensor missing. by backup speed component.
sensor. Engine Check the
power derated. sensor.
251 / 2 P251 / 2 Real-time clock power supply None on - - -
open circuit: Data erratic, performance. Data
intermittent or incorrect. The in the ECU 794 will
real time clock has no power. not have accurate
time and date
information.


tions and tic menu
compo-
J1587 nents
441 / 3 P441 / 3 Auxiliary temperature sensor None on Check cable D794 -
input signal 1: Voltage performance. harness
higher than normal or between control
shorted to high source. unit and
High signal voltage or open component.
circuit detected in the OEM Check the
auxiliary temperature circuit. sensor.
441 / 4 P441 / 4 Auxiliary temperature None on Check cable D794 -
sensor circuit input signal 1: performance. harness
Voltage lower than normal or between control
short-circuited to low source. unit and
Low voltage detected in the component.
OEM auxiliary temperature Check the
circuit. sensor.
558 / 2 S230 / 2 Accelerator pedal or lever Engine only running Check cable D794 -
idle validation circuit: Data at idle. harness
erratic, intermittent or between control
incorrect. Voltage detected unit and
simultaneously on the component.
validating switches for both Check
idling and not idling. component.
558 / 4 S230 / 4 Accelerator pedal or lever Engine only running Check cable D794 -
idle validation circuit: at idle. harness
Voltage lower than normal between control
or short-circuited to low unit and
source. No voltage detected component.
simultaneously on the Check
validating switches for both component.
idling and not idling.
558 / 13 S230 / Accelerator pedal or lever Engine only running Check cable D794 -
13 idle validation circuit: Not at idle. harness
calibrated. Voltage in between control
the validation circuits for unit and
idling and not idling does component.
not correspond with the Check
accelerator pedal position. component.
611 / 2 P089 / 2 Validation of auxiliary Intermediate speed - D794 -
transfer speed switch (PTO): control switch
Data erratic, intermittent or may not operate
incorrect. The position of correctly.
the transfer speed protection
switch 1 does not correspond
with the position of the
validation switch for the
transfer speed protection.
611 / 3 S232 / 3 Circuit for sensor supply Engine only running - D794 -
voltage 4: Voltage higher at idle.
than normal or shorted
to high source. High
voltage detected at +5 volt
sensor supply circuit to the
accelerator pedal position
sensor.


tions and tic menu
compo-
J1587 nents
611 / 4 S232 / 4 Circuit for sensor supply 3: Possible hard - D794 -
Voltage lower than normal or starting and rough
short-circuited to low source. running.
Low voltage detected at +5
volt sensor supply circuit
to the accelerator pedal
position sensor.
611 / 4 S232 / 4 Circuit for sensor supply Engine will only die. - D794 -
voltage 4: Voltage lower than
normal or short-circuited
to low source. Low
voltage detected at +5
volt sensor supply circuit
to the accelerator pedal
position sensor.
611 / 15 S151 / 0 Turbocharger compressor Fuel is limited in an - D794 -
outlet temperature: Data attempt to decrease
higher than normal. High the calculated
outlet temperature for the turbocharger
turbocharger compressor compressor outlet
calculated by ECU 794. temperature.
612 / 2 P190 / 2 The engine's magnetic Fuelling to the - D794 -
crankshaft speed/position injectors is disabled,
sensor has lost both signals: and the engine
Data erratic, intermittent or cannot be started.
incorrect. ECU 794 has
detected that the signals
from the primary and backup
engine speed sensor are
reversed.
627 / 2 S251 / 2 No power without the Possibly no Check fuses. D794 -
ignition switch turned off: noticeable Check batteries
Data erratic, intermittent or performance impact, and alternator.
incorrect. The supply voltage or the engine
to ECU 794 temporarily falls stops or is hard
below 6.2 volt, or ECU 794 to start. Incorrect
not allowed to shutdown information, release
correctly (battery voltage information and
maintained for 30 seconds maintenance
after the ignition has been monitoring data
turned off). may be incorrect.
627 / 2 S251 / 2 No power supply with the Possibly no Check fuses. D794 -
ignition on: Data erratic, noticeable Check batteries
intermittent or incorrect. The performance impact, and alternator.
supply voltage to ECU 794 or the engine
temporarily falls below 6.2 stops or is hard
volt, or ECU 794 not allowed to start. Incorrect
to shutdown correctly information, release
(battery voltage maintained information and
for 30 seconds after the maintenance
ignition has been turned off). monitoring data
may be incorrect.
627 / 2 S254 / Injectors power supply: Possible smoke, Check fuses. D794 -
12 Bad Intelligent Device or low power, engine Check batteries
Component. The ECU 794 misfire, and/or and alternator.
measured injector boost engine will not start.
voltage is low.


tions and tic menu
compo-
J1587 nents
629 / 12 S254 / Engine control unit: Critical Engine may not Check the D794 -
12 internal error. Error internally start. control unit.
in ECU 794 related to
memory hardware failures
or internal ECU 794 voltage
supply circuits.
629 / 12 S254 / Engine control unit, warning No performance Check the D794 -
12 internal hardware error. effects or possible control unit.
Incorrect intelligent unit or severe power
component. derate.
630 / 2 S253 / 2 Engine control unit data lost: Possibly no Reprogram D794 -
Data erratic, intermittent or noticeable the software
incorrect. Serious data loss performance impact, in Control unit,
from ECU 794. or the engine engine (D794).
stops or is hard
to start. Incorrect
information, release
information and
maintenance
monitoring data
may be incorrect.
630 / 31 S240 / 11 Error occurs in the engine Possibly no - D794 -
control unit calibration noticeable
programme memory (RAM). performance impact,
Serious data loss from ECU or the engine
794. stops or is hard
to start. Incorrect
information, release
information and
maintenance
monitoring data
may be incorrect.
633 / 31 S018 / 11 Fuelling Actuator Number Possible low power. - D794 -
1 Circuit Error Conditions
Exists. Fuel pump actuator
circuit resistance too high or
too low.
639 / 9 S231 / 9 Timeout error for SAE J1939 One or more Use diagnostic - CAN/POW-
multiplexer-PNG: Abnormal multiplexed units not menu to ER, menu 2
update rate. Cummins working correctly. find incorrect
ECU 794 did not receive a One or more segment.
multiplexed message from symptoms may
an OEM-VECU by the time occur.
limit or not at all.
639 / 13 S231 / SAE J1939 Multiplexing At least one Use diagnostic - CAN/POW-
13 Configuration Error - Out of multiplexed devices menu to ER, menu 2
Calibration. The ECU 794 will not operate find incorrect
expected information from a properly. segment.
multiplexed device but only
received a portion of the
necessary information.
641 / 3 S027 / 3 VGT actuator driver circuit Possible low power. - D794 -
- voltage above normal or Power switched off
shorted to high source. to the turbocharger's
actuator motor.


tions and tic menu
compo-
J1587 nents
641 / 4 S027 / 4 VGT actuator driver circuit Possible low power. - D794 -
- voltage below normal, or Power switched off
shorted to low source. to the turbocharger's
actuator motor.
644 / 2 S030 / 2 Input signal from Primary or Check cable - -
external speed request secondary engines harness
(synchronisation of multiple may be shut down. between control
units): Data erratic, unit and
intermittent or incorrect. The component.
accelerator pedal input signal Check
to the primary or secondary component.
motor for synchronisation of
multiple devices is less than
3 percent or greater than 97
percent.
647 / 3 S033 / 3 Fan control circuit: Voltage The fan may stay on Check cable D794 -
higher than normal or shorted continuously or not harness
to high source. Open circuit run at all. between control
or high voltage detected in unit and
the fan control circuit. component.
Check
component.
647 / 4 S033 / 4 Fan control circuit: Voltage The fan may stay on Check cable D794 -
lower than normal or shorted continuously or not harness
to low source. Low signal run at all. between control
voltage detected in the fan unit and
control circuit when this is component.
requested. Check
component.
651 / 5 S001 / 5 Circuit injector magnetic coil Engine can misfire Check cable D794 -
drive cylinder 1: Current or possibly run harness
lower than normal or open rough. between control
circuit. High resistance unit and
or no current detected on component.
injector no. 1, pin DRIVE or Check the
RETURN. injector.
651 / 7 S001 / 7 Injector magnetic coil drive The engine is Check cable D794 -
cylinder 1: Mechanical switched off. harness
system not responding between control
correctly or incorrectly unit and
adjusted. Accidental fuel component.
supply detected in cylinder Check the
no. 1. injector.
RETURN. injector.


tions and tic menu
compo-
J1587 nents
no. 2. injector.
RETURN. injector.
no. 3. injector.
RETURN. injector.
no. 4. injector.
RETURN. injector.
no. 5. injector.


tions and tic menu
compo-
J1587 nents
RETURN. injector.
no. 6. injector.
677 / 3 S39 / 3 Starter relay circuit: Voltage Either the engine Check cable D794 ENGINE,
higher than normal or shorted will not start or harness menu 5
to high source. Open circuit the engine will not between control
or high voltage detected in have starter lockout unit and
the start locking circuit. protection. component.
Check the relay.
677 / 4 S39 / 4 Starter relay circuit: Voltage The engine will not Check cable D794 ENGINE,
lower than normal or shorted have starter lockout harness menu 5
to low source. Low voltage protection. between control
detected in the start locking unit and
circuit. component.
Check the relay.
697 / 3 S057 / 3 Auxiliary PWM drive no. 1: Cannot control - D794 -
Voltage higher than normal transmission.
or shorted to high source.
High signal voltage detected
in the analogue torque
circuit.
697 / 4 S057 / 4 Auxiliary PWM drive no. 1: Cannot control - D794 -
Voltage lower than normal or transmission.
shorted to low source. Low
signal voltage detected in
the analogue torque circuit.
703 / 11 S051 /11 Auxiliary Equipment Sensor Possible engine Check cable D794 -
Input #3 (OEM Switch) - power derate. harness
Root Cause Not Known. between control
unit and
component.
Check the
component.
723 / 2 S064 / 2 Engine backup crankshaft Possible low power. Check cable D794 -
speed/position sensor no. harness
2: Data erratic, intermittent between control
or incorrect Engine speed unit and
sensor on the crankshaft component.
uneven synchronised. Check the
sensor.


tions and tic menu
compo-
J1587 nents
723 / 2 S064 / 2 Engine Speed Sensor Can be difficult to Check cable D794 -
(Camshaft) Error - Data start. Engine power harness
Erratic, Intermittent, or derate. between control
Incorrect. The ECU 794 unit and
has detected an error in the component.
camshaft position sensor Check the
signal. sensor.
723 / 7 S064 / 7 Engine speed/position The engine runs Check cable D794 -
sensor camshaft and at lower power. harness
crankshaft, misaligned: Abnormal smoke, between control
Mechanical system not difficult to start and unit and
responding correctly erratic idling can component.
or incorrectly adjusted. occur. Check the
Mechanical misalignment sensor.
between the crankshaft and
camshaft speed sensors.
729 / 3 S070 / 3 Circuit for intake air heater The intake air Check cable D794 -
no. 1: Voltage higher heaters may be harness
than normal or shorted to ON or OFF all the between control
high source. High voltage time. unit and
detected at the intake air component.
heater signal circuit. Check
component.
729 / 4 S070 / 4 Circuit for intake air heater The intake air Check cable D794 -
no. 1: Voltage lower heaters may be harness
than normal or shorted to ON or OFF all the between control
low source. Low voltage time. unit and
detected at the intake air component.
heater signal circuit. Check
component.
974 / 3 P974 / 3 Circuit for remote accelerator Remote accelerator Check cable D794 -
pedal or lever position pedal not working. harness
sensor 1: Voltage higher Remote accelerator between control
than normal or shorted to pedal position set to unit and
high source. High voltage zero percent. component.
detected at the remote Check
accelerator pedal position component.
circuit.
974 / 4 P974 / 4 Circuit for remote accelerator Remote accelerator Check cable D794 -
pedal or lever position pedal not working. harness
sensor 1: Voltage lower than Remote accelerator between control
normal or short-circuited pedal position set to unit and
to low source. Low zero percent. component.
voltage detected in remote Check
accelerator pedal position component.
signal.
974 / 19 P29 Data error for SAE J1939 The engine does not Use diagnostic - CAN/POW-
multiplexing remote react to the remote menu to ER, menu 2
accelerator pedal or lever: accelerator pedal. find incorrect
Network data error received. Perhaps the engine segment.
The machine's OEM control is only running at
unit (VECU) detected idle. The primary
an error on the remote accelerator or the
accelerator pedal. one in the cab can
possibly be used.


tions and tic menu
compo-
J1587 nents
1043 / 3 S221 / 3 Supply voltage circuit for Engine only running Check cable D794 -
accelerator pedal or lever at idle. harness
position sensor: Voltage between control
higher than normal or unit and
shorted to high source. component.
High voltage detected in the Check
voltage supply circuit for the component.
accelerator pedal or lever
position sensor.
1043 / 4 S221 / 4 Supply voltage circuit for Engine will only die. Check cable D794 -
accelerator pedal or lever harness
position sensor: Voltage between control
lower than normal or unit and
shorted to low source. component.
Low voltage detected in the Check
voltage supply circuit to the component.
accelerator pedal or lever
position sensor.
1043 / 4 S221 / 4 Supply voltage circuit for Possible hard Check cable D794 -
engine speed/position starting and rough harness
sensor (crankshaft): Voltage running. between control
lower than normal or shorted unit and
to low source. Low voltage component.
detected on ECU 794 voltage Check
supply cable to the engine component.
speed sensor.
1072 / 3 S028 / 3 Engine brake actuator circuit Engine brake on Check cable D794 -
no. 1: Voltage higher than cylinders 1, 2, and 3 harness
normal or shorted to high cannot be activated between control
source. Open circuit or high or exhaust brake will unit and
voltage detected on the not operate. component.
signal circuit for the motor Check
brake solenoid coil no. 1. component.
1072 / 4 S028 / 4 Engine brake actuator Engine brake on Check cable D794 -
circuit no. 1: Voltage lower cylinders 1, 2, and 3 harness
than normal or shorted to cannot be activated between control
low source. Low voltage or exhaust brake will unit and
detected in signal circuit for not operate. component.
the motor brake solenoid coil Check
no. 1. component.
1073 / 3 S029 / 3 Engine brake actuator circuit Engine brake on Check cable D794 -
no. 2: Voltage higher than cylinders 4, 5, and 6 harness
normal or shorted to high cannot be activated. between control
source. Open circuit or high unit and
voltage detected on the component.
signal circuit for the motor Check
brake solenoid coil no. 2. component.
1073 / 4 S029 / 4 Engine brake actuator Engine brake on Check cable D794 -
circuit no. 2: Voltage lower cylinders 4, 5, and 6 harness
than normal or shorted to cannot be activated. between control
low source. Low voltage unit and
detected in signal circuit for component.
the motor brake solenoid coil Check
no. 2. component.


tions and tic menu
compo-
J1587 nents
1075 / 3 S126 / 3 Electrical lift pump for the Engine can be - D794 -
engine fuel delivery circuit: difficult to start.
Voltage higher than normal
High signal voltage or open
circuit detected in the fuel lift
pump's signal circuit.
1075 / 4 S126 / 4 Electrical lift pump for the Engine can be - D794 -
engine fuel delivery circuit: difficult to start.
Voltage lower than normal or
short-circuited to low source.
Low signal voltage detected
in fuel lift pump circuit.
1079 / 3 S212 / 3 Circuit for sensor supply Engine power Check cable D794 -
voltage no. 1: Voltage higher derate. harness
than normal or shorted to between control
high source. High voltage unit and
detected in the sensor supply component.
circuit no. 1. Check the
sensor.
voltage no. 1: Voltage derate. harness
lower than normal or shorted between control
to low source. Low voltage unit and
sensor.
no. 2: Voltage higher derate. harness
than normal or shorted to between control
high source. High voltage unit and
sensor.
voltage no. 2: Voltage derate. harness
lower than normal or shorted between control
to low source. Low voltage unit and
sensor.
1137 / 2 S114 / 2 Synchronisation switch for Multiple Unit - D794 -
multiple units: Data erratic, Synchronisation
intermittent or incorrect. feature is disabled.
Synchronised ON/OFF
switch for multiple units and
supplementary synchronised
ON/OFF switch for multiple
units have different values in
ECU 794.


tions and tic menu
compo-
J1587 nents
1172 / 3 /3 Intake temperature sensor Engine power - D794 -
circuit for compressor derate.
turbocharger no. 1: Voltage
higher than normal or
shorted to high source. High
signal voltage detected in the
intake temperature sensor
circuit for the compressor
turbocharger.
1172 / 4 /4 Intake temperature sensor Engine power - D794 -
circuit for compressor derate.
turbocharger no. 1: Voltage
lower than normal or shorted
to low source. Low signal
voltage detected in the
intake temperature sensor
circuit for the compressor
turbocharger.
1347 / 3 S126 / 3 Circuit for the fuel high Engine runs - D794 -
pressure solenoid valve: badly and with
Voltage higher than normal derated power.
or shorted to high source. Fuel rail pressure
Electronic fuel control becomes higher
actuator short-circuited high. than requested.
1347 / 4 S126 / 4 Circuit for the fuel high The engine runs - D794 -
pressure solenoid valve: poorly when idling
Voltage lower than normal and has low power.
or shorted to low source. Fuel pressure
Electronic fuel control becomes higher
actuator short-circuited low. than requested.
1347 / 7 S126 / 7 Fuel pump pressure Engine will not run or - D794 -
attachment 1: Mechanical possible low power.
system not responding
correctly or incorrectly
adjusted. Pumping
imbalance between the
front and rear pump pistons
have been detected.
1347 / 7 S126 / 7 Fuel Pumping Element Engine will not run or - D794 -
Number 1 (Front) - possible low power.
Mechanical System Not
Responding Properly or Out
of Adjustment.
1378 / 31 S153 / 11 It is time to change the None on - D794 -
lubricating oil and filter. performance;
Change the engine oil and maintenance
filter. reminder only.
1388 / 3 P223 / 3 Circuit for auxiliary pressure None on - D794 -
sensor, input signal 1: performance.
Voltage higher than normal
High signal voltage detected
in the OEM pressure circuit.


tions and tic menu
compo-
J1587 nents
1388 / 4 P223 / 4 Circuit for auxiliary pressure None on - D794 -
sensor, input signal 1: performance.
Voltage lower than normal or
shorted to low source. Low
signal voltage detected in
the OEM pressure circuit.
2047 / xx Undetectable error code - Contact the D794 -
from the engine. Error codes engine supplier
above 2047 cannot be shown for further
in the display. Possible error information.
code: 2789.
2789 / 15 /0 Exhaust temperature: Data Derate in power - D794 -
higher than normal. High output of the
exhaust temperature has engine in attempt
been calculated by the to decrease the
electronic control system. calculated exhaust
gas temperature
value.

2 Transmission – Transmission D:43
2 Transmission
Error codes transmission (TE13/17FF)
When contacting the transmission suppliers, use the supplier code.
• Display indicates the error code as it appears in the machine.
• Supplier code denotes the error code according to the transmission
manufacturer's specification (SAE J1939 in SPN/FMI).
Control unit transmission can generate two states with reduced

functionality to protect the transmission in the event of serious
malfunctions:
Limp-home
In this condition only gear 1-2 in each direction can be used. If the
error occurs in a higher gear then downshifting to gear 1 or 2 must
take place manually.
Shut-down
In this mode the transmission is permanently in neutral as there is no

oil pressure to enable gear selection.
Error codes transmission Dana TE17000
Connec-
Diag-
tions and
Description Limitation Action nostic
Dis- Supplier compo-
menu
play code nents
00/50 7F09D/C Memory error Transmission - - -

in control unit locked in neutral
transmission. (Shut-down).
20/60 7F065/1 Logical error Pressure Transmission Check the cable harness D793/A2 - -
sensor gear 1/3 locked in neutral between control unit and B7651
(B7651), no pressure (Shut-down). sensor.
when pressure is Check the sensor.
expected.
20/61 7F065/0 Logical error Pressure Transmission Check the cable harness D793/A2 - -
sensor gear 1/3 locked in neutral between control unit and B7651
(B7651), pressure (Shut-down). sensor.
when depressurised is Check the sensor.
expected.
21/00 7F069/1 Pressure sensor Transmission Check feed pressure to - -
(1) has too low oil locked in neutral transmission.
pressure. (Shut-down). Save information about
the current pressure
and when the problem
occurred.

D:44 2 Transmission – Transmission
Connec-
Diag-
tions and
menu
play code nents
21/01 7F069/0 Pressure sensor Transmission Check feed pressure to - -

(1) has too high oil locked in neutral transmission.
occurred.
22/00 7F06A/1 Pressure sensor Transmission Check feed pressure to - -
occurred.
22/01 7F06A/0 Pressure sensor Transmission Check feed pressure to - -
occurred.
23/00 7F06B/1 Pressure sensor Transmission Check feed pressure to - -
occurred.
23/01 7F06B/0 Pressure sensor Transmission Check feed pressure to - -
occurred.
24/00 7F06C/1 Pressure sensor Transmission Check feed pressure to - -
occurred.
24/01 7F06C/0 Pressure sensor Transmission Check feed pressure to - -
occurred.
30/04 7F090/1 Low battery voltage. Control unit saves Check the cable harness - CAN/P-
stored information to the control unit. OWER,
to flash memory Check alternator, battery menu 15
and restarts to clear and cable harness
memory. between battery and
alternator.
30/05 7F090/0 High battery voltage. Control unit receives Check voltage feed. - CAN/P-
reduced proportional If auxiliary start equipment OWER,
control precision is connected, disconnect menu 15
depending on it.
reduced PWM work
cycle.

Connec-
Diag-
tions and
menu
play code nents
31/00 7F093/1 Reference voltage Control unit receives Check the voltage feed. - CAN/P-
sensor 8 V, too low. reduced sensor Check the control unit. OWER,
signals. menu 15
31/01 7F093/0 Reference voltage Control unit receives Check the voltage feed. - CAN/P-
sensor 8 V, too high. reduced sensor Check the control unit. OWER,
signals. menu 15
34/00 7F0BB/31 Sensor fault on a Control unit locks Check the wiring between D793/G3 - -
speed sensor. transmission in the control unit and all B7510
neutral. speed sensors. D793/B3 -
Check all speed sensors. B7520
D793/F3 -
B7530
D793/D3 -
B7580
34/01 7F0BC/1 Measured turbine rpm Control unit locks Check the wiring between D793/G3 - -
at start-up is too low. transmission in the control unit and all B7510
neutral. speed sensors. D793/B3 -
Check that all speed D793/F3 -
sensors are connected B7530
to the correct input on D793/D3 -
Control unit transmission B7580
(D793).
Check the feed pressure
from the transmission's oil
pump.
34/02 7F0BD/0 Measured drum rpm Transmission Check the wiring between D793/G3 - -
at start-up is too high. locked in neutral the control unit and all B7510
(Shut-down). speed sensors. D793/B3 -
(D793).
34/03 7F0BE/0 Internal rotation Transmission Check the wiring between D793/G3 - -
speeds indicate that locked in neutral the control unit and all B7510
there is no system (Shut-down). speed sensors. D793/B3 -
pressure, despite that Check all speed sensors. B7520
there should be.
(D793).
D793/C1
Check the feed pressure -Y6096
pump. D793/C1
-Y6096
Check Servo valve
forward/reverse (Y6096).

Connec-
Diag-
tions and
menu
play code nents
34/04 7F0BE/1 Internal rotation Transmission Check the wiring between D793/G3 - -
speeds indicate locked in neutral the control unit and all B7510
that there is system (Shut-down). speed sensors. D793/B3 -
pressure when there Check all speed sensors. B7520
should not be.
(D793).
D793/C1
Check the feed pressure -Y6096
pump. D793/C1
-Y6096
Check Servo valve
forward/reverse (Y6096).
38/00 7F0B3/0 Disengaged Control unit indicates Check 4WD/2WD - -
4WD/2WD-selector the error. selector.
has jammed in Check if digital feedback
engaged position is on and connected to
or the feedback signal control unit.
is wrong.
38/01 7F0B3/1 Engaged 4WD/2WD Control unit indicates Check 4WD/2WD - -
selector has jammed the error. selector.
in the disengaged Check if digital feedback
position or the is on and connected to
feedback signal is control unit.
wrong.
39/00 7F0B4/0 Disengaged Control unit indicates Check Low/High gear - -
Low/High-selector the error. selector.
has jammed in Check if digital feedback
engaged position is on and connected to
or the feedback signal control unit.
is wrong.
39/01 7F0B4/1 Engaged Low/High Control unit indicates Check Low/High gear - -
selector has jammed the error. selector.
in the disengaged Check if digital feedback
position or the is on and connected to
feedback signal is control unit.
wrong.
40/06 7F05E/2 Wrong direction from Control unit locks Check cabling to gear - TRA-
the gear selector. transmission in selector with regards NSM,
neutral. to forward and reverse menu 2
signal.
40/08 7F041/1F The seat's direction Control unit locks Check seat direction or - -
was changed when transmission in show the driver how the
the parking brake was neutral. seat is turned as per the
not activated, and/or correct procedure.
the gear selector was
not in neutral, and/or
the machine was not
stationary.
41/06 7F05F/2 Incorrect gear Control unit doesn't Check cabling to gear - TRA-
selection from the allow change of selector with regards to NSM,
gear selector. range, however, signal range. menu 2
operation of machine
is possible.

Connec-
Diag-
tions and
menu
play code nents
42/04 7F080/1 Actual gear ratio too Control unit indicates Check transmission with - TRA-
low. that one or several purpose to understand if NSM,
clutches are slipping. and, if that is the case, menu 6
Transmission which clutch is slipping.
locked in neutral Check the set gear ratio
(Shut-down). for the control unit.
42/05 7F080/0 Actual gear ratio too Control unit indicates Check transmission with - TRA-
high. that one or several purpose to understand if NSM,
clutches are slipping. and, if that is the case, menu 6
Transmission which clutch is slipping.
locked in neutral Check the set gear ratio
(Shut-down). for the control unit.
43/03 7F063/4 Signal from sensor oil Control unit indicates Check the cable harness D793/H3 - TRA-
temperature (B7660) the error. between control unit and B7660 NSM,
outside valid interval. component. menu 10
Check the sensor.
43/07 7F063/10 Torque converter's Control unit indicates Check the transmission oil D793/H3 - TRA-
temperature exceeds the error to make cooler, clean if necessary. B7660 NSM,
100 °C. operator aware of Check the thermostat menu 10
the warning's level. in the transmission oil
cooler.
43/08 7F063/0 Torque converter's The control unit Check the transmission oil D793/H3 - TRA-
temperature exceeds protects the cooler, clean if necessary. B7660 NSM,
120 °C. transmission and Check the thermostat menu 10
does not allow the in the transmission oil
temperature in the cooler.
torque converter
to exceed the
maximum limit.
The control unit locks
the transmission in
neutral position, the
engine is restricted
to 50 % of max. rpm.
44/10 7F0C6/9 No signal for - Use diagnostic menu to - CAN/P-
accelerator pedal find incorrect segment. OWER,
position from Engine menu 3
control unit (D794).
45/06 7F048/2 Invalid combination Control unit limits the Check the speed sensors. - -
for redundant digital machine's speed to
speed inputs. the reduced speed.
46/05 7F036/F Max. torque for - - - -
inching has been
exceeded.
47/01 7F07B/10 Transmission has Control unit indicates Let up the accelerator - -
exceeded the limit the error. pedal and slow down the
value for upper rpm. machine.
50/00 7F010/4 Pressure sensor Transmission Check the cable harness D793/A2 - TRA-
gear 1/3 (B7651), locked in neutral between control unit and B7651 NSM,
short-circuited to (Shut-down). sensor. menu 10
ground. Check the sensor.

Connec-
Diag-
tions and
menu
play code nents
50/01 7F010/3 Pressure sensor gear Transmission Check the cable harness D793/A2 - TRA-
1/3 (B7651), not locked in neutral between control unit and B7651 NSM,
connected or open (Shut-down). component. menu 10
50/04 7F010/11 Pressure sensor Control unit indicates Check the cable harness D793/A2 - TRA-
gear 1/3 (B7651), error and uses lowest between control unit and B7651 NSM,
value below lowest value in its settings. component. menu 10
calibrated value. Check the sensor.
50/05 7F010/F Pressure sensor Control unit indicates Check the cable harness D793/A2 - TRA-
gear 1/3 (B7651), error and uses between control unit and B7651 NSM,
value above highest highest value in component. menu 10
calibrated value. its settings. Check the sensor.
51/00 7F011/4 Sensor oil The control unit limits Check the cable harness D793/H3 - TRA-
temperature (B7660) the transmission's between control unit and B7660 NSM,
short-circuited to temperature sensor. menu 10
ground. measurement to Check the sensor.
the lowest value
in its settings,
which results in
poor temperature
compensation.
51/01 7F011/3 Sensor oil temperature The control unit limits Check the cable harness D793/H3 - TRA-
(B7660) not connected the transmission's between control unit and B7660 NSM,
or open circuit. temperature sensor. menu 10
measurement to Check the sensor.
the highest value
in its settings,
which results in
poor temperature
compensation.
51/04 7F011/11 Sensor oil temperature The control unit limits Check the cable harness D793/H3 - TRA-
(B7660), value below the transmission's between control unit and B7660 NSM,
lowest calibrated temperature component. menu 10
value. measurement to Check the sensor.
the lowest value in
its settings.
51/05 7F011/F Sensor oil temperature The control unit limits Check the cable harness D793/H3 - TRA-
(B7660), value above the transmission's between control unit and B7660 NSM,
highest calibrated temperature component. menu 10
value. measurement to Check the sensor.
the highest value in
its settings.
52/00 7F012/4 Temperature The control unit limits Check the cable harness D793/J3 - TRA-
monitor torque the transmission's between control unit and S2210 NSM,
converter (S2210) temperature sensor. menu 10
short-circuited to measurement to Check the sensor.
ground. the highest value
in its settings,
which results in
poor temperature
compensation.

Connec-
Diag-
tions and
menu
play code nents
52/01 7F012/3 Temperature monitor The control unit limits Check the cable harness D793/J3 - TRA-
torque converter the transmission's between control unit and S2210 NSM,
(S2210) is not temperature sensor. menu 10
connected. measurement to Check the sensor.
the highest value
in its settings,
which results in
poor temperature
compensation.
52/04 7F012/11 Temperature monitor The control unit limits Check the cable harness D793/J3B TRA-
torque converter the transmission's between control unit and - S2210 NSM,
(S2210), value below temperature component. menu 10
lowest calibrated measurement to Check the sensor.
value. the lowest value
in its settings,
which results in
poor temperature
compensation.
52/05 7F012/F Temperature monitor The control unit limits Check the cable harness D793/J3B TRA-
torque converter the transmission's between control unit and - S2210 NSM,
(S2210), value above temperature component. menu 10
highest calibrated measurement to Check the sensor.
value. the highest value
in its settings,
which results in
poor temperature
compensation.
53/00 7F013/4 Analogue input signal Depending on which Check the cable harness - -
3, short circuit to function is on the pin: between control unit and
ground. Pressure feedback: component.
Transmission locked Check the component.
to gear 1 and 2
(Limp-home).
Sensor oil pressure:
Control unit locks
transmission in
neutral.
Other: Control unit
uses the lowest
value in its settings.
53/01 7F013/3 Analogue input signal Depending on the Check the cable harness - -
3 is not connected. function on the pin: between control unit and
Pressure feedback: component.
to gear 1 and 2
(Limp-home).
Control unit locks
transmission in
neutral.
Other: Control unit
uses the lowest
53/04 7F013/11 Analogue input signal Control unit indicates Check the cable harness - -
3, the value is below error and uses lowest between control unit and
lowest calibrated value in its settings. component.
value. Check the component.

Connec-
Diag-
tions and
menu
play code nents
53/05 7F013/F Analogue input signal Control unit indicates Check the cable harness - -
3, the value is above error and uses between control unit and
highest calibrated highest value in component.
value. its settings. Check the component.
54/00 7F014/4 Reference voltage - Check the cable harness D793/M1 CAN/P-
sensor 5 V between control unit and - S2210, OWER,
short-circuiting to component. B7667, menu 15
ground. Check the sensor. B6069
54/01 7F014/3 Reference voltage - Check the cable harness D793/M1 CAN/P-
sensor 5 V between control unit and - S2210, OWER,
short-circuited to component. B7667, menu 15
voltage. Check the sensor. B6069
55/00 7F015/4 Analogue input signal, Depending on which Check the cable harness - -
short circuit to ground. function is on the pin: between control unit and
to gear 1 and 2
(Limp-home).
Control unit locks
transmission in
neutral.
Other: Control unit
uses the lowest
5 is not connected. function is on the pin: between control unit and
to gear 1 and 2
(Limp-home).
Control unit locks
transmission in
neutral.
Other: Control unit
uses the lowest

Connec-
Diag-
tions and
menu
play code nents
56/00 7F016/4 Pressure sensor Depending on which Check the cable harness D793/S1 - TRA-
gear 2 (B7652), function is on the pin: between control unit and B7652 NSM,
short-circuited to Pressure feedback: component. menu 10
ground. Transmission locked Check the component.
to gear 1 and 2
(Limp-home).
Control unit locks
transmission in
neutral.
Other: Control unit
uses the lowest
56/01 7F016/3 Pressure sensor gear Depending on which Check the cable harness D793/S1 - TRA-
2 (B7652), is not function is on the pin: between control unit and B7652 NSM,
connected. Pressure feedback: component. menu 10
to gear 1 and 2
(Limp-home).
Control unit locks
transmission in
neutral.
Other: Control unit
uses the lowest
56/04 7F016/11 Pressure sensor Control unit indicates Check the cable harness D793/S1 - TRA-
gear 2 (B7652), error and uses lowest between control unit and B7652 NSM,
value below lowest value in its settings. component. menu 10
calibrated value. Check the component.
56/05 7F016/F Pressure sensor Control unit indicates Check the cable harness D793/S1 - TRA-
gear 2 (B7652), error and uses between control unit and B7652 NSM,
value above highest highest value in component. menu 10
calibrated value. its settings. Check the component.
to gear 1 and 2
(Limp-home).
Control unit locks
transmission in
neutral.
Other: Control unit
uses the lowest

Connec-
Diag-
tions and
menu
play code nents
to gear 1 and 2
(Limp-home).
Control unit locks
transmission in
neutral.
Other: Control unit
uses the lowest
to gear 1 and 2
(Limp-home).
Control unit locks
transmission in
neutral.
Other: Control unit
uses the lowest
to gear 1 and 2
(Limp-home).
Control unit locks
transmission in
neutral.
Other: Control unit
uses the lowest

Connec-
Diag-
tions and
menu
play code nents
60/00 7F01A/6 Sensor rpm When only one rpm Check cable between the D793/C3 - TRA-
drum (B7520) signal that is not the control unit and sensor. B7520 NSM,
short-circuited to engine rpm signal is Check the sensor. menu 6
ground. incorrect, the control
unit calculates the
missing rpm.
If several rpm
signals or if the
engine rpm signal
are defective, the
transmission control
unit locks gear 1-2
(Limp-home).
60/01 7F01A/5 Sensor rpm drum When only one rpm Check cable between the D793/C3 - TRA-
(B7520) not signal that is not the control unit and sensor. B7520 NSM,
connected. engine rpm signal is Check the sensor. menu 6
incorrect, the control
unit calculates the
missing rpm.
If several rpm
signals or if the
engine rpm signal
are defective, the
unit locks gear 1-2
(Limp-home).
60/03 7F01A/A Sensor drum speed Control unit indicates Check cable between D793/C3 - TRA-
(B7520), value outside the error. control unit and B7520 NSM,
limit values. component. menu 6
Check component.
60/04 7F01A/1 Sensor rpm drum This message Check transmission to D793/C3 - TRA-
(B7520), pulse count is given as find out if and which clutch B7520 NSM,
too low. supplementary is slipping. menu 6
information for Check transmission's
malfunctions in the settings for gear ratio in
transmission. control unit.
60/05 7F01A/0 Sensor rpm drum This message Check transmission to D793/C3 - TRA-
too high. supplementary is slipping. menu 6

Connec-
Diag-
tions and
menu
play code nents
61/00 7F01B/6 Sensor rpm output When only one rpm Check cable between the D793/E3 - TRA-
shaft (B7580) signal that is not the control unit and sensor. B7580 NSM,
unit calculates the
missing rpm.
If several rpm
signals or if the
engine rpm signal
are defective, the
unit locks gear 1-2
(Limp-home).
61/01 7F01B/5 Sensor rpm output When only one rpm Check cable between the D793/E3 - TRA-
shaft (B7580) not signal that is not the control unit and sensor. B7580 NSM,
unit calculates the
missing rpm.
If several rpm
signals or if the
engine rpm signal
are defective, the
unit locks gear 1-2
(Limp-home).
61/03 7F01B/A Sensor rpm output Control unit indicates Check cable between D793/E3 - TRA-
shaft (B7580), value the error. control unit and B7580 NSM,
outside limit values. component. menu 6
Check the sensor.
61/04 7F01B/1 Sensor rpm output This message Check transmission to D793/E3 - TRA-
shaft (B7580), pulse is given as find out if and which clutch B7580 NSM,
count too low. supplementary is slipping. menu 6
61/05 7F01B/0 Sensor rpm output This message Check transmission to D793/E3 - TRA-
shaft (B7580), pulse is given as find out if and which clutch B7580 NSM,
count too high. supplementary is slipping. menu 6
62/00 7F01C/6 Sensor engine When only one rpm Check cable between the D793/F3 - TRA-
rpm (B7530), signal that is not the control unit and sensor. B7530 NSM,
unit calculates the
missing rpm.
If several rpm
signals or if the
engine rpm signal
are defective, the
unit locks gear 1-2
(Limp-home).

Connec-
Diag-
tions and
menu
play code nents
62/01 7F01C/5 Sensor engine When only one rpm Check cable between the D793/F3 - TRA-
rpm (B7530), not signal that is not the control unit and sensor. B7530 NSM,
connected or has engine rpm signal is Check the sensor. menu 6
open circuit. incorrect, the control
unit calculates the
missing rpm.
If several rpm
signals or if the
engine rpm signal
are defective, the
unit locks gear 1-2
(Limp-home).
62/03 7F01C/A Engine speed Transmission in Use diagnostic menu to - -
information not Limp-home. find incorrect segment.
available.
62/04 7F01C/1 Sensor engine rpm This message Check transmission to D793//F3 - TRA-
62/05 7F01C/0 Sensor engine rpm This message Check transmission to D793/F3 - TRA-
62/06 7F07A/1 No engine speed Transmission in Check sensor engine rpm D793/F3 - TRA-
information when Limp-home. speed. B7530 NSM,
the turbine speed is Check component's menu 6
calculated. position.
63/00 7F01D/6 Sensor rpm When only one rpm Check cable between the D793/G3 - TRA-
turbine (B7510) signal that is not the control unit and sensor. B7510 NSM,
unit calculates the
missing rpm.
If several rpm
signals or if the
engine rpm signal
are defective, the
unit locks gear 1-2
(Limp-home).

Connec-
Diag-
tions and
menu
play code nents
63/01 7F01D/5 Sensor rpm turbine When only one rpm Check cable between the D793/G3 - TRA-
(B7510) not signal that is not the control unit and sensor. B7510 NSM,
unit calculates the
missing rpm.
If several rpm
signals or if the
engine rpm signal
are defective, the
unit locks gear 1-2
(Limp-home).
63/03 7F01D/A Sensor rpm turbine Control unit indicates Check cable between D793/G3 - TRA-
(B7510), value outside the error. control unit and B7510 NSM,
limit values. component. menu 6
Check component.
63/04 7F01D/1 Sensor rpm turbine This message Check transmission to D793/G3 - TRA-
63/05 7F01D/0 Sensor rpm turbine This message Check transmission to D793/G3 - TRA-
70/00 7F020/4 Servo valve Transmission locked Check the cable harness D793/B1 TRA-
forward/reverse to gear 1 and 2 between control unit and - Y6096, NSM,
(Y6096), short- (Limp-home). servo valve. D793/C1 - menu 8
circuited to each Check the servo valve. Y6096
other, signal cable
short-circuited to
voltage, or plus cable
short-circuited to
ground.
(Y6096), open circuit (Limp-home). servo valve. D793/C1 - menu 8
or short to voltage. Check the servo valve. Y6096
70/02 7F020/6 Servo valve Transmission Check the cable harness D793/B1 TRA-
forward/reverse locked in neutral between control unit and - Y6096, NSM,
(Y6096) control (Shut-down). servo valve. D793/C1 - menu 9
current above 1400 Check the servo valve. Y6096
mA.
70/03 7F020/8 Servo valve Transmission Check the cable harness D793/B1 TRA-
forward/reverse locked in neutral between control unit and - Y6096, NSM,
(Y6096) control (Shut-down). servo valve. D793/C1 - menu 9
current outside Check the servo valve. Y6096
approved range.
Incorrect impedance.

Connec-
Diag-
tions and
menu
play code nents
(Y6096), not (Limp-home). servo valve. D793/C1 - menu 9
connected. Check the servo valve. Y6096
71/00 7F021/4 Solenoid valve gear Transmission locked Check the cable harness D793/D1 TRA-
selection 1/3 (Y6075), to gear 1 and 2 between control unit and - Y6075, NSM,
short-circuited to each (Limp-home). solenoid valve. D793/E1 - menu 8
other, signal cable Check the solenoid valve. Y6075
short-circuited to
voltage, or plus-cable
short-circuited to
frame ground.
71/01 7F021/3 Solenoid valve Transmission locked Check the cable harness D793/D1 TRA-
gear selection 1/3 to gear 1 and 2 between control unit and - Y6075, NSM,
(Y6075) open circuit (Limp-home). solenoid valve. D793/E1 - menu 8
or short-circuited Check the solenoid valve. Y6075
voltage.
71/02 7F021/6 Solenoid valve gear Transmission Check the cable harness D793/D1 TRA-
selection 1/3 (Y6075), locked in neutral between control unit and - Y6075, NSM,
control current higher (Shut-down). solenoid valve. D793/E1 - menu 9
than 1400 mA. Check the solenoid valve. Y6075
control current outside (Limp-home). solenoid valve. D793/E1 - menu 9
approved interval Check the solenoid valve. Y6075
(incorrect impedance).
not connected. (Limp-home). solenoid valve. D793/E1 - menu 9
Check the solenoid valve. Y6075
72/00 7F022/4 Servo valve Transmission locked Check the cable harness D793/F1 TRA-
gear 2 (Y6069), to gear 1 and 2 between control unit and - Y6069, NSM,
short-circuited to (Limp-home). solenoid valve. D793/G1 - menu 8
each other, signal Check the solenoid valve. Y6069
cable short-circuited
to voltage, or plus
to ground.
72/01 7F022/3 Servo valve gear 2 Transmission locked Check the cable harness D793/F1 TRA-
(Y6069) open circuit to gear 1 and 2 between control unit and - Y6069, NSM,
or short-circuited (Limp-home). solenoid valve. D793/G1 - menu 8
voltage. Check the solenoid valve. Y6069
72/02 7F022/6 Servo valve gear Transmission Check the cable harness D793/F1 TRA-
2 (Y6069) control locked in neutral between control unit and - Y6069, NSM,
current above 1400 (Shut-down). solenoid valve. D793/G1 - menu 9
mA. Check the solenoid valve. Y6069
72/03 7F022/8 Servo valve gear Transmission locked Check the cable harness D793/F1 TRA-
2 (Y6069), control to gear 1 and 2 between control unit and - Y6069, NSM,
current outside (Limp-home). solenoid valve. D793/G1 - menu 9
approved interval Check the solenoid valve. Y6069
(incorrect impedance).

Connec-
Diag-
tions and
menu
play code nents
72/09 7F022/5 Servo valve gear Transmission locked Check the cable harness D793/F1 -
2 (Y6069), not to gear 1 and 2 between control unit and - Y6069,
connected. (Limp-home). component. D793/G1 -
Check the solenoid valve. Y6069
73/00 7F023/4 Analogue output Transmission locked Check the cable harness - -
signal 3, cables to gear 1 and 2 between control unit and
short-circuited to (Limp-home). component.
each other, signal Check the component.
to voltage, or plus
to ground.
signal 3, open circuit to gear 1 and 2 between control unit and
or short-circuited (Limp-home). component.
voltage. Check the component.
73/02 7F023/6 Analogue output Transmission Check the cable harness - -
signal 3, control locked in neutral between control unit and
current above 1400 (Shut-down). component.
mA. Check the component.
signal 3, control to gear 1 and 2 between control unit and
current outside (Limp-home). component.
approved interval Check the component.
(wrong impedance).
signal 3 not to gear 1 and 2 between control unit and
connected. (Limp-home). component.
74/00 7F024/4 Analogue output Control unit indicates Check the cable harness - -
signal 4, short circuit the error. between control unit and
to ground. component.
signal 4 not connected the error. between control unit and
or short-circuited to component.
signal 4 not the error. between control unit and
connected. component.

Connec-
Diag-
tions and
menu
play code nents
signal 4, control the error. between control unit and
current above 1400 component.
signal 6, control the error. between control unit and
current above 1400 component.
signal 6, output signal the error. between control unit and
outside approved component.
interval (wrong Check the component.
impedance).
signal 6 not the error. between control unit and
connected. component.
77/02 7F02F/1F All gear packages Transmission - - -
disengaged. locked in neutral
(Shut-down).
80/00 7F027/4 Solenoid valve drive Transmission locked Check the cable harness D793/K1 - Dana
forward (Y6300), to gear 1 and 2 between control unit and Y6300 TRA-
cable short-circuited (Limp-home). solenoid valve. NSM,
to ground. Check the solenoid valve. menu 7
80/01 7F027/3 Solenoid valve drive Transmission locked Check the cable harness D793/K1 - Dana
forward (Y6300), to gear 1 and 2 between control unit and Y6300 TRA-
cable is not connected (Limp-home). solenoid valve. NSM,
or short-circuited to Check the solenoid valve. menu 7
voltage.
80/09 7F027/5 Solenoid valve drive Transmission locked Check the cable harness D793/K1 - TRA-
forward (Y6300), not to gear 1 and 2 between control unit and Y6300 NSM,
connected. (Limp-home). solenoid valve. menu 7
Check the solenoid valve.
81/00 7F028/4 Solenoid valve drive Transmission locked Check the cable harness D793/E2 - TRA-
reverse (Y6300), to gear 1 and 2 between control unit and Y6300 NSM,
cable short-circuited (Limp-home). solenoid valve. menu 7
to frame ground. Check the solenoid valve.
reverse (Y6310), to gear 1 and 2 between control unit and Y6310 NSM,
to voltage. Check the solenoid valve.

Connec-
Diag-
tions and
menu
play code nents
reverse (Y6310), not to gear 1 and 2 between control unit and Y6310 NSM,
connected. (Limp-home). component. menu 7
82/00 7F029/4 Solenoid valve gear Transmission locked Check the cable harness D793/F2 - TRA-
selection 1/3 (Y6075), to gear 1 and 2 between control unit and Y6075 NSM,
to ground. Check the solenoid valve.
82/01 7F029/3 Solenoid valve gear Transmission locked Check the cable harness D793/F2 - TRA-
selection 1/3 (Y6075), to gear 1 and 2 between control unit and Y6075 NSM,
to frame voltage. Check the solenoid valve.
82/09 7F029/5 Digital output signal 3 Transmission locked Check the cable harness D793/F2 - TRA-
not connected. to gear 1 and 2 between control unit and NSM,
(Limp-home). solenoid valve. menu 7
83/00 7F02A/3 Digital output signal 3, Transmission locked Check the cable harness D793/K2 - TRA-
cable short-circuited to gear 1 and 2 between control unit and NSM,
to ground. (Limp-home). component. menu 7
83/01 7F02A/4 Digital output signal 3, Transmission locked Check the cable harness D793/K2 - TRA-
cable short-circuited to gear 1 and 2 between control unit and NSM,
to voltage. (Limp-home). component. menu 7
85/01 7F02C/31 Towing detected Control unit indicates - - -
the error.
90/90 7F0A0/1F Deficient software Transmission - - -
in Control unit locked in neutral
transmission (D793). (Shut-down).
90/xx - 7F000/0 System error. Transmission Note time and contact D793/A:20 -
99/xx locked in neutral Cargotec support.
(Shut-down).
9xxx 7F0F0/xx Communication error Transmission Note time and contact - -
CAN bus drive-train. locked in neutral Cargotec support.
One error code per (Shut-down).
message
92/01 7F0F2/1 Shifting has no Transmission - - -
direction. locked in neutral
(Shut-down).
92/02 7F0F2/2 Doubled direction. Transmission Note time and contact - -
locked in neutral Cargotec support.
(Shut-down).
92/03 7F0F2/3 Doubled shifting. Transmission Note time and contact - -
(Shut-down).
92/04 7F0F2/4 Doubled pulse pattern. Transmission Note time and contact - -
(Shut-down).
92/06 7F0F2/6 Wrong digital input Transmission Note time and contact - -
signal. locked in neutral Cargotec support.
(Shut-down).

Connec-
Diag-
tions and
menu
play code nents
92/07 7F0F2/7 Digital input signal Transmission Note time and contact - -
in conflict with gear locked in neutral Cargotec support.
selector's position. (Shut-down).
"Transmission locked locked in neutral Cargotec support.
in neutral" wrong. (Shut-down).
doubled assignment. locked in neutral Cargotec support.
(Shut-down).
92/10 7F0F2/A Digital output signal Transmission Note time and contact - -
doubled assignment. locked in neutral Cargotec support.
(Shut-down).
92/11 7F0F2/B Digital output Transmission Note time and contact - -
signal selected on locked in neutral Cargotec support.
unconfigured output. (Shut-down).
92/12 7F0F2/C Digital output signal Transmission Note time and contact - -
wrong. locked in neutral Cargotec support.
(Shut-down).
92/13 7F0F2/D Digital output Transmission Note time and contact - -
signal selected on locked in neutral Cargotec support.
transmission cable. (Shut-down).
92/14 7F0F2/E Wrong assignment in Transmission Note time and contact - -
speed sensor 1-2. locked in neutral Cargotec support.
(Shut-down).
92/15 7F0F2/F Wrong assignment in Transmission Note time and contact - -
speed sensor 3. locked in neutral Cargotec support.
(Shut-down).
92/16 7F0F2/10 Doubled assignment Transmission Note time and contact - -
in speed sensor. locked in neutral Cargotec support.
(Shut-down).
92/17 7F0F2/11 Wrong feed voltage Transmission Note time and contact - -
selected. locked in neutral Cargotec support.
(Shut-down).
92/18 7F0F2/12 Doubled input signal. Transmission Note time and contact - -
(Shut-down).
92/19 7F0F2/13 Cabling sensor Transmission Note time and contact - -
pressure in conflict locked in neutral Cargotec support.
with cabling analogue (Shut-down).
input signal.
92/20 7F0F2/14 Wrong configuration Transmission Note time and contact - -
for servo motor or locked in neutral Cargotec support.
brake valve (analogue (Shut-down).
output signal 4-5-6).
92/21 7F0F2/1E Incorrect configuration Transmission Note time and contact - -
for parking brake. locked in neutral Cargotec support.
(Shut-down).
92/30 7F0F2/1E Wrong configuration Transmission Note time and contact - -
for full-flow selection locked in neutral Cargotec support.
and earlier digital (Shut-down).
problem-solving.

Connec-
Diag-
tions and
menu
play code nents
93/00 7F0F3/0 Initiation of statistical Transmission Switch off the machine - -

data in flash memory, locked in neutral and switch off the main
caused by firmware (Shut-down). electric power.
update or memory
conflict.
update or memory
conflict.
update or memory
conflict.
update or memory
conflict.
update or memory
conflict.
update or memory
conflict.
93/10 7F0F3/A Initiation of statistical Control unit indicates Switch off the machine - -
data in flash memory, the error. and switch off the main
caused by firmware electric power.
update or memory
conflict.
93/11 7F0F3/B Initiation of stored Control unit indicates Switch off the machine - -
error data in flash the error. and switch off the main
memory, caused by electric power.
firmware update or
memory conflict.
94/00 7F0F4/0 Initiation of stored Transmission Switch off the machine - -
error data in flash locked in neutral and switch off the main
memory, caused by (Shut-down). electric power.
firmware update or
memory conflict.
firmware update or
memory conflict.
firmware update or
memory conflict.

Connec-
Diag-
tions and
menu
play code nents

firmware update or
memory conflict.
firmware update or
memory conflict.
firmware update or
memory conflict.
firmware update or
memory conflict.
95/71 7F09B/1F Control unit cannot Transmission -
interpret input data. locked in neutral
(Shut-down).
99/95 7F0CA/1F Overload of - - - -
CAN-bus detected:
Transmission control
unit could not currently
handle all incoming
information, due to too
many CAN requests.
E0/01 7F0E1/F Machine's speed is - - - -
too high to enable
downshift.
E1/01 7F0E2/F Machine speed is too - - - -
high to enable change
of travel direction.
E2/01 7F0E3/F Engine rpm is too - - - -
high to enable change
of travel direction or
select same travel
direction again.
E3/00 7F0E4/E Machine's speed - - - -
limitation is activated.
E3/01 7F0E4/F Machine's speed - - - -
limitation is activated
regardless of if speed
is above the limit
value.
E3/02 7F0E4/10 Machine's speed is - - - -
higher than the upper
limit value.
E4/00 7F0E5/11 Abnormal speed Transmission - - -
reduction. disengages
automatic
transmission for a
time.

Connec-
Diag-
tions and
menu
play code nents
E4/01 7F0E5/F Abnormal Transmission - - -

acceleration. disengages
automatic
transmission for a
time.
E5/01 7F0E0/D Time with active gear - Calibrate the - -
exceeded time for transmission.
recalibration.
E6/00 7F0E6/1F Operator not sitting - - - -
in driver's seat and
gear selector is not in
neutral and/or parking
brake is not activated.
E7/01 7F0E7/F Turbine speed exceed Control unit forces - - -
the limit value. the engine to idle to
prevent damage.
E8/01 7F0E8/F Conditions to switch - - - -
between 2WD and
4WD not satisfied.
The machine must be
stationary.
E9/01 7F0E9/F Conditions to switch - - - -
between High and
Low not satisfied.
The machine must be
stationary.
xx/49 - Undefined failure. Control unit indicates - - -
the error - action
depends on problem.
E.1.0 7F0FA - Calibration drive mode Calibration Download correct - -
1-05 7F0FD pressure, unexpected cancelled. parameters and repeat
algorithm response. calibration.
Ensure the unit machine
does not move.
Check response on
engine rpm.
E.1.06 7F0FA - Calibration drive mode Control unit indicates Measure the clutch's - -
7F0FD/6 pressure, turbine the error and pressure to detect
rpm's signal does calibration is leakage.
not go down to the cancelled. Check the signal from
min. value. during Turbine rpm sensor.
calibration.
Check set speed to detect
slipping clutch.
7-09 7F0FD pressure, unexpected cancelled. parameters and repeat
does not move.
Check response on
engine rpm.
E.1.10 7F0FA - Calibration drive Calibration Find the reason for - -
7F0FD/A mode pressure, cancelled. calibration being
transmission error cancelled.
during calibration.

Connec-
Diag-
tions and
menu
play code nents
E.1.11-1 7F0FA - Calibration drive mode Calibration Download correct - -

3 7F0FD pressure, unexpected cancelled. parameters and repeat
does not move.
Check response on
engine rpm.
7F0FD/E pressure, the turbine the error and pressure to detect
rpm does not drop calibration is leakage.
during calibration. cancelled. Check the signal from
Turbine rpm sensor.
7F0FD pressure, unexpected cancelled. parameters and repeat
does not move.
Check response on
engine rpm.
7F0FD/10 pressure, turbine rpm the error and pressure to detect
is too low to start calibration is leakage.
calibration. cancelled. Check the signal from
Turbine rpm sensor.
7-24 7F0FD pressure, unexpected cancelled. parameters and continue
Check if the machine
starts to move.
Check response on
engine rpm.
E.1.25 7F0FA - Calibration drive mode Control unit indicates Calibrate at higher - -
7F0FD/19 pressure, mesh start the error and temperatures (90-100
point is too early calibration is °C).
during calibration. Too cancelled. Check the speed sensors
much pull. (error codes 42/04 or
42/05).
Check the servo valves.
7F0FD/1A pressure, mesh start the error and temperatures (90-100
point cannot be found. calibration is °C).
cancelled. Check the speed sensors
(error codes 42/04 or
42/05).
7F0FD pressure, unexpected cancelled. parameters and continue
Check if the machine
starts to move.
Check response on
engine rpm.

Connec-
Diag-
tions and
menu
play code nents
7F0FD/1C pressure, turbine rpm the error and pressure to detect
does not reach 0 rpm calibration is leakage.
at completion phase cancelled. Check the signal from
of calibration. Turbine rpm sensor.
7F0FD/1D pressure, turbine the error and temperatures (90-100
rpm does not reach calibration is °C).
up to correct value at cancelled. Check the speed sensors
release phase of mesh (error codes 42/04 or
starting point during 42/05).
calibration.
E.2.0 7F0FA - Calibration Calibration Download correct - -
1-05 7F0FD optimisation of fill time, cancelled. parameters and repeat
unexpected algorithm calibration.
response. Ensure the unit machine
does not move.
Check response on
engine rpm.
E.2.06 7F0FA - Calibration Control unit indicates Measure the clutch's - -
7F0FD/6 optimisation of fill time, the error and pressure to detect
turbine rpm's signal calibration is leakage.
does not go down to cancelled. Check the signal from
the min. value. during Turbine rpm sensor.
calibration.
slipping clutch.
does not move.
Check response on
engine rpm.
E.2.10 7F0FA - Calibration Calibration Find the reason for - -
7F0FD/A optimisation of fill time, cancelled. calibration being
during calibration.
E.2.11-1 7F0FA - Calibration drive mode Calibration Download correct - -
3 7F0FD pressure, unexpected cancelled. parameters and repeat
does not move.
Check response on
engine rpm.
7F0FD/E optimisation of fill the error and pressure to detect
time, the turbine rpm calibration is leakage.
does not drop during cancelled. Check the signal from
calibration. Turbine rpm sensor.

Connec-
Diag-
tions and
menu
play code nents

7F0FD optimisation of fill time, cancelled. parameters and repeat
does not move.
Check response on
engine rpm.
E.2.16 7F0FA - Calibration optimising Control unit indicates Measure the clutch's - -
7F0FD/10 filling time, turbine the error and pressure to detect
rpm is too low to start calibration is leakage.
calibration. cancelled. Check the signal from
Turbine rpm sensor.
7-24 7F0FD optimisation of fill time, cancelled. parameters and continue
response. Check if the machine
starts to move.
Check response on
engine rpm.
E.2.25 7F0FA - Calibration Control unit indicates Calibrate at higher - -
7F0FD/19 optimisation of fill the error and temperatures (90-100
time, mesh start point calibration is °C).
is too early during cancelled. Check the speed sensors
calibration. Too much (error codes 42/04 or
pull. 42/05).
E.2.26 7F0FA - Calibration Control unit indicates Calibrate at higher - -
7F0FD/1A optimisation of fill the error and temperatures (90-100
time, mesh start point calibration is °C).
cannot be found. cancelled. Check the speed sensors
42/05).
7F0FD optimisation of fill time, cancelled. parameters and continue
starts to move.
Check response on
engine rpm.
7F0FD/1C optimisation of fill the error and pressure to detect
time, turbine rpm does calibration is leakage.
not reach 0 rpm at cancelled. Check the signal from
completion phase of Turbine rpm sensor.
calibration.
E.2.29 7F0FA - Calibration optimising Control unit indicates Calibrate at higher - -
7F0FD/1D filling time, turbine the error and temperatures (90-100
rpm does not reach calibration is °C).
up to correct value at cancelled. Check the speed sensors
release phase of mesh (error codes 42/04 or
starting point during 42/05).
calibration.

Connec-
Diag-
tions and
menu
play code nents

does not move.
Check response on
engine rpm.
7F0FD/6 optimisation of fill time, the error and pressure to detect
turbine rpm's signal calibration is leakage.
does not go down to cancelled. Check the signal from
the min. value. during Turbine rpm sensor.
calibration.
slipping clutch.
E.3.0 7F0FA - Calibration of control Calibration Download correct - -
7-09 7F0FD current for pressure, cancelled. parameters and repeat
does not move.
Check response on
engine rpm.
E.3.10 7F0FA - Calibration of control Calibration Find the reason for - -
7F0FD/A current for pressure, cancelled. calibration being
during calibration.
E.3.11-1 7F0FA - Calibration of control Calibration Download correct - -
3 7F0FD current for pressure, cancelled. parameters and repeat
does not move.
Check response on
engine rpm.
E.3.14 7F0FA - Calibration of control Control unit indicates Measure the clutch's - -
7F0FD/E current for pressure, the error and pressure to detect
the turbine rpm calibration is leakage.
does not drop during cancelled. Check the signal from
calibration. Turbine rpm sensor.
7F0FD current for pressure, cancelled. parameters and repeat
does not move.
Check response on
engine rpm.
7F0FD/10 current for pressure, the error and pressure to detect
turbine rpm is too low calibration is leakage.
to start calibration. cancelled. Check the signal from
Turbine rpm sensor.

Connec-
Diag-
tions and
menu
play code nents

7-24 7F0FD current for pressure, cancelled. parameters and continue
starts to move.
Check response on
engine rpm.
E.3.25 7F0FA - Calibration of control Control unit indicates Calibrate at higher - -
7F0FD/19 current for pressure, the error and temperatures (90-100
mesh start point calibration is °C).
is too early during cancelled. Check the speed sensors
calibration. Too much (error codes 42/04 or
pull. 42/05).
7F0FD/1A current for pressure, the error and temperatures (90-100
mesh start point calibration is °C).
cannot be found. cancelled. Check the speed sensors
42/05).
7F0FD current for pressure, cancelled. parameters and continue
starts to move.
Check response on
engine rpm.
7F0FD/1C current for pressure, the error and pressure to detect
turbine rpm does calibration is leakage.
not reach 0 rpm at cancelled. Check the signal from
completion phase of Turbine rpm sensor.
calibration.
7F0FD/1D current for pressure, the error and temperatures (90-100
turbine rpm does not calibration is °C).
reach up to correct cancelled. Check the speed sensors
value at release phase (error codes 42/04 or
of mesh starting point 42/05).
during calibration.

D:70 8 Control system – Control system
8 Control system
Error codes machine
Error codes marked with * do not apply to the machine, but can be
shown with an error in the cable harness to the control unit.
Connections
and Diagnos-
Code Description Limitation Action components tic menu Group
1 Communication - Use diagnostic menu to D797-1 CAN/POW- 11.6.2
error with frame find incorrect segment. ER, menu Redundant
control unit 1-3 CAN bus
(D797-1)
2 * Communication - Use diagnostic menu to D797-2 CAN/POW- 11.6.2
error with frame find incorrect segment. ER, menu Redundant
control unit 1-3 CAN bus
(D797-2).
3 Communication - Use diagnostic menu to D791-1 CAN/POW- 11.6.2
error with Control find incorrect segment. ER, menu Redundant
unit, attachment 1-3 CAN bus
(D791-1).
8 Communication - Use diagnostic menu to D795 CAN/POW- 11.6.2
error with Control find incorrect segment. ER, menu Redundant
unit KID (D795). 1-3 CAN bus
11 Error in cable, CAN - Use diagnostic menu to Varies CAN/POW- 11.6.2
network, segment find incorrect segment. depending ER, menu Redundant
1. on machine 1-3 CAN bus
configuration.
configuration.
configuration.
network, segment find incorrect segment. depending ER, menu 2 Redundant
4. on machine and 3 CAN bus
configuration.
configuration.
19 * Accelerator pedal Accelerator Calibrate the D790-1/K6:12 – CALIBRA- 1. Engine
2 VBFS not pedal for accelerator pedal. R690-2 TION:
calibrated. reversing does See section 8 Control DRIVE-
not work. system, group TRAIN,
Engine speed 8.5.2.3 Calibrate menu 5 and
limited to idle. DRIVE-TRAIN. 6
20 Accelerator pedal Accelerator Calibrate the D790-1/K6:11 – CALIBRA- 1. Engine
not calibrated. pedal does not accelerator pedal. R690-1 TION:
work. Engine See section 8 Control DRIVE-
speed limited system, group TRAIN,
to idle. 8.5.2.3 Calibrate menu 1 and
DRIVE-TRAIN. 2

8 Control system – Control system D:71
Connections
and Diagnos-
21 Communication Gear selection Use diagnostic menu to D790-1/K13:1 – CAN/POW- 11.6.3 CAN
error with Control not working. check communication. D793/M2 ER, menu 4 bus drive-train
unit, transmission Check the cable D790-1/K13:2 –
(D793). harness between D793/L2
Control unit, cab
(D790-1) and Control
unit, transmission
(D793).
22 Communication Engine does Use diagnostic menu to Volvo: D790- CAN/POW- 11.6.3 CAN
error with Control not respond check communication. 1/K13:1, K13:2 ER, menu 4 bus drive-train
unit, engine (D794). to commands Check the cable – D794/2, 1
from the cab. harness between Cummins:
Control unit, cab D790-1/K13:1,
(D790-1) and Control K13:2 –
unit, engine (D794). D794/46, 37
23 The set-up file No controls in Contact Cargotec. D790-1 - 11.5.3.1
cannot be read in the cab are Control unit,
Control unit, cab working. cab
(D790-1).
24 Power supply to Cab fan not Check fuse F58-5/3 D790-1/K2:8 – - 9.4.3 Cabin
cab fan below 18 V. working. 58-5/3:2 fan
25 Interference during Error code Switch the ignition off D794 ENGINE, 11.5.3.10
software download. stored in and on. menu 8 Engine control
26 Buffer for error Control unit, unit
Repeat software
27 codes from Control engine (D794). download.
unit, engine (D794),
28 active error code
when downloading.
29
30
31 Incorrect power Controls in cab Check fuse F58-5/1. D790-1/K1:2, CAN/POW- 11.5.1.3
supply to Control not working. Check cabling between K1:3, K1:4 – ER, menu 7 Ignition
unit, cab (D790-1). the control unit and F58-5/1:1, 1:2 voltage (15)
Voltage below 18 V the component with
or above 32 V. diagnostic menu.
32 Incorrect 5 V Analogue Check the wiring D790-1/K4:5, CAN/POW- 11.5.3.1
reference voltage controls in between the control K 5:11, K5:13, ER, menu 7 Control unit,
to analogue cab cab not unit and component K7:2, K 9:7 cab
controls. Voltage working (mini- with the diagnostic
below 4.9 V or wheel/steering menu.
above 5.1 V. lever and Check component.
controls for air
conditioning).
33 No feedback signal Control Check fuse F58-3/8. D790-1/K11:13 CAN/POW- 11.5.1.4
for emergency stop breaker Check cabling between – K3009-1/87 ER, menu 5 Emergency
switch voltage from cannot be the control unit and stop switch
Relay, emergency disengaged. the component with voltage (15E)
stop switch voltage All hydraulic diagnostic menu.
(K3009-1). functions are
blocked.
34 Incorrect signal Parking brake Check cabling between D791-1/K8:5 – HYD, menu 4.5 Parking
from Switch, cannot be the control unit and S107/7 5 brake
parking brake released. the component with D791-1/K8:13 –
(S107), indicates diagnostic menu. S107/1
released and Check the switch.
applied at same
time or nothing at
all.

Connections
and Diagnos-
35 Interference during Error code Switch the ignition off D793 TRANSM, 11.5.3.9
software download. stored in and on. menu 13 Transmission
36 Buffer for error Control unit, control unit
Repeat software
37 codes from Control transmission download.
unit, transmission (D793).
38 (D793), active
error code when
39 downloading.
40
41 Transistor has been Wiper rear not Check cabling between D790-1/K2:4 – CAB, menu 9.5.7 Wiper
triggered due to working. the control unit and M650-2/53 3 motor rear
short circuit or open the component with
circuit in circuit for diagnostic menu.
rear wiper motor Check the motor.
(M650-2).
42 Transistor has been Revolving Check cabling between D790-1/K2:5 – LIGHTS, 9.6.8
triggered due to beacon not the control unit and H428 menu 6 Revolving
short circuit or open working. the component with beacon
rotating beacon Check the component.
(H428).
43 Transistor has been Left cab Check bulb. D790-1/K2:6 – LIGHTS, 9.6.5 Back-up
triggered due to reversing light Check cabling between E405L menu 8 lights
short circuit or open not working. the control unit and
circuit in circuit for the component with
left reversing light diagnostic menu.
(E405L).
44 Transistor has been Right cab Check bulb. D790-1/K2:7 – LIGHTS, 9.6.5 Back-up
triggered due to reversing light Check cabling between E405R menu 8 lights
short circuit or open not working. the control unit and
right reversing light diagnostic menu.
(E405R).
45 Transistor has been Wiper front not Check cabling between D790-1/K2:1 – CAB, menu 9.5.5 Wiper
triggered due to working. the control unit and M650-1/53 2 motor front
front wiper motor Check the component.
(M650-1).
46 Transistor has been Cab fan not Check cabling between D790-1/K2:2 – CLIMATE, 9.4.3 Cabin
triggered due to working. the control unit and M657/2 menu 6 fan
fan motor (M657). Check the motor.
47 Transistor has been Recirculation Check cabling between D790-1/K2:3 – CLIMATE, 9.4.2 Fresh
triggered due to damper to the control unit and M612/3 menu 6 air filter and
short circuit or open ventilation not the component with recirculation
circuit in circuit working. diagnostic menu. damper
for recirculation Check the motor.
actuating motor
(M612).
48 Transistor has been Heat in cab Check cabling between D790-1/K4:1 – CLIMATE, 9.4.5 Water
triggered due to cannot be the control unit and Y673/5 menu 7 valve
short circuit or open adjusted. the component with
water valve (Y673). Check the motor.

Connections
and Diagnos-
49 Transistor has been Heat in cab Check cabling between D790-1/K4:2 – CLIMATE, 9.4.5 Water
triggered due to cannot be the control unit and Y673/6 menu 7 valve
short circuit or open adjusted. the component with
water valve (Y673). Check the motor.
50 Transistor has been Air distribution Check cabling between D790-1/K4:3 – CLIMATE, 9.4.14 Air
triggered due to in cab cannot the control unit and Y672/5 menu 8 distributor
short circuit or open be adjusted. the component with
actuating motor Check the motor.
(Y672).
51 Transistor has been Air distribution Check cabling between D790-1/K4:4 – CLIMATE, 9.4.14 Air
triggered due to in cab cannot the control unit and Y672/6 menu 8 distributor
short circuit or open be adjusted. the component with
actuating motor Check the motor.
(Y672).
52 * Transistor has been Bypass of Check component. D790-1/K5:3 – - -
triggered due to external top Check the wiring.
short circuit or open lift attachment
circuit in circuit for not working.
bypass of external
top lift attachment.
53 Transistor has been Windscreen Check cabling between D790-1/K5:4 – CAB, menu 9.5.4 Washer
triggered due to washer rear the control unit and M651-2 1 motor and
short circuit or and roof not the component with reservoir
open circuit in working. diagnostic menu.
circuit for roof and Check the motor.
rear washer motor
(M651-2).
54 Transistor has been Flashing Check cabling between D790-1/K5:5 – LIGHTS, 9.6.7 Flashing
triggered due to hazard lights the control unit and S109/ menu 7 hazard lights
short circuit or open not working. the component with
flashing hazard light Check the switch.
switch (S109).
55 Transistor has been Reduced or no Check bulbs for D7901/K6:1, K LIGHTS, 9.1 Controls
triggered due to background background lighting, 8:15, K 9:2, all menu 14 and
short circuit or open lighting in replace if necessary. inputs of type A instruments
circuit in circuit for instruments Check the cable Digital in
background lighting and controls. harness for background
in switches and lighting.
instruments.
56 Transistor has been Work lights 20' Check cabling between D790-1/ K7:8 – LIGHTS, 9.6.10
triggered due to not working. the control unit and R3017-2/86 menu 12 Working
short circuit or open the component with lights, cab
relay for 20' working Check the component.
lights.
57 Transistor has been Indicator light Check cabling between D790-1/ K7:9 – - 7.1.1 Control
triggered due to for levelling the control unit and S815/7 levers/Joy-
short circuit or open lock in joystick the component with stick
circuit in circuit for not working. diagnostic menu.
indicator light for Check the component.
levelling lock in
joystick (S815).

Connections
and Diagnos-
58 * Transistor has been Twistlock on Check cabling between D790-1/ K7:10 EXT- 7.9.2
triggered due to external top the control unit and – K3005/86 ATTACH, Twistlocks
short circuit or open lift attachment the component with menu 6
circuit in circuit for does not work. diagnostic menu.
relay for twistlock Check the component.
on external top
lift attachment
(K3005).
59 * Transistor has been Spreading on Check cabling between D790-1/ K7:11 – EXT- 7.10.5.1
triggered due to external top the control unit and K3006/86 ATTACH, Spreading
short circuit or open lift attachment the component with menu 6
circuit in circuit for does not work. diagnostic menu.
relay for spreading Check the component.
on external top
lift attachment
(K3006).
60 Transistor has been Seat heating Check cabling between D790-1/ K10:7 CAB, menu 9.3.3 Heating
triggered due to does not work. the control unit and – K383/86 8 coil
relay for heating Check the component.
element in driver's
seat (K383).
61 Transistor has been Work lights 40' Check cabling between D790-1/ K10:8 LIGHTS, 9.6.10
triggered due to not working. the control unit and – K3017-1/86 menu 12 Working
short circuit or open the component with lights, cab
relay for 40' working Check the component.
lights (K3017-1).
63 Transistor has been No ignition Check cabling between D790-1/K10:10 CAN/POW- 11.5.1.3
triggered due to voltage to the control unit and – K315-1/86 ER, menu 5 Ignition
short circuit or open the machine's the component with voltage (15)
circuit in circuit for Control units. diagnostic menu.
relay for ignition Check the component.
voltage (K315-1).
64 The transistor has No emergency Check cabling between D790-1/K10:11 CAN/POW- 11.5.1.4
been triggered due stop switch the control unit and – K3009-1/86 ER, menu 6 Emergency
to short circuit or voltage to the component with stop switch
open circuit in the machine's diagnostic menu. voltage
circuit for Relay, Control units. Check the component.
emergency stop
switch voltage
(K3009-1).
65 The transistor has No emergency Check cabling between D790-1/K10:12 CAN/POW- 11.5.1.4
been triggered due stop switch the control unit and – K3009-2/86 ER, menu 6 Emergency
to short circuit or voltage to the component with stop switch
open circuit in the machine's diagnostic menu. voltage
circuit for Relay, Control units. Check the component.
emergency stop
switch voltage
(K3009-2).
66 Transistor has been Windshield Check cabling between D790-1/K10:13 CAB, menu 9.5.4 Washer
triggered due to washer not the control unit and – M651-1, 1 motor and
short circuit or open working. the component with M651-2 reservoir
windscreen washer Check the component.
motor (M651-1,
M651-2).

Connections
and Diagnos-
67 Transistor has been Wiper roof not Check cabling between D790-1/K10:14 CAB, menu 9.5.6 Wiper
triggered due to working. the control unit and – M650-3 4 motor roof
roof wiper motor Check the motor.
(M650-3).
68 * Transistor has been Pause heater Check cabling between D790-1/K10:15 - 9.4 Heating,
triggered due to not working. the control unit and – M667 ventilation
short circuit or the component with and air
open circuit in diagnostic menu. conditioning
circuit for circulation Check the motor.
pump, pause heater
(M667).
69 Transistor has been No voltage Check cabling between D790-1/K10:16 - 11.5.1.3
triggered due to feed to the control unit and – K315-2/86 Ignition
short circuit or open engine and the component with voltage (15)
circuit in circuit for transmission. diagnostic menu.
relay for drivetrain Check the component.
ignition voltage
(K315-2).
71 Transistor has been Interior lighting Check bulb. D790-1/K11:6 – LIGHTS, 9.6.11 Interior
triggered due to in cab not Check cabling between E434-1 menu 9 lighting cab
short circuit or open working. the control unit and
cab interior lighting diagnostic menu.
(E434-1).
75 Relay ignition The cab Check cabling between - CAN/POW- 11.5.1.3
voltage (K315-1) control unit the control unit and ER, menu 5 Ignition
has jammed in (D790-1) still the component with voltage
position on. has a power diagnostic menu.
supply and is Check the component.
thereby active.
80 No signal from Air Check the drive belt for D797-1/K1:40 – CLIMATE, 9.4.10
Pressure switch, conditioning the compressor for air S246 menu 3 Pressure
air conditioning not working. conditioning. switch
(S246), despite the Check that compressor
AC compressor for air conditioning is
being activated. activated.
Check cabling between
the control unit and
the component with
diagnostic menu.
81 Incorrect signal Air distribution Check cabling between D790-1/K4:7 – CLIMATE, 9.4.6 Fresh
from Damper motor cannot be the control unit and Y672/9 menu 4 air and
(Y672). Signal adjusted. the component with recirculation
voltage below 0.2 V diagnostic menu. damper
or above 4.8 V. Check the motor.
85 Incorrect signal Accelerator Check cabling between D790-1/K6:11 – ENGINE, 1 Engine
from accelerator pedal for the control unit and B690-1/2 menu 1
pedal (B690-1). driving forward the component with
Signal voltage does not work. diagnostic menu.
below 0.2 V or Engine speed Check the component.
above 4.8 V. limited to idle.
86 * Incorrect signal Accelerator Check the wiring D790-1/K6:12 – VBFS, 1 Engine
from extra pedal for between the control B690-2/2 menu 4
accelerator pedal reversing does unit and component
(B690-2). Signal not work. with the diagnostic
voltage below 0.2 V Engine speed menu.
or above 4.8 V. limited to idle. Check component.

Connections
and Diagnos-
87 Error signal from Lift and lower Check cabling between D790-1/K7:3 – ELSERV, 7.1.1 Control
Control lever not working. the control unit and R8071/3 menu 1 lever
lifting/lowering the component with (P1)
(R8071). Signal diagnostic menu.
voltage below 0.2 V Check the lever.
or above 4.8 V.
88 Error signal from Tilt not Check cabling between D790-1/K7:4 – ELSERV, 7.1.1 Control
Control lever tilt working. the control unit and R8072/3 menu 1 lever
(R8072). Signal the component with (P2)
voltage below 0.2 V diagnostic menu.
or above 4.8 V. Check the lever.
89 Error signal from Side shift not Check cabling between D790-1/K7:5 – ELSERV, 7.1.1 Control
Control lever side working. the control unit and R8073/3 menu 1 lever
shift (R8073). the component with (P3)
Signal voltage diagnostic menu.
below 0.2 V or Check the lever.
above 4.8 V.
90 * Error signal from Spreading not Check cabling between D790-1/K7:6 – ELSERV, 7.1.1 Control
Control lever working. the control unit and R8074/3 menu 2 lever
spreading (R8074). the component with (P4)
above 4.8 V.
91 * Error signal from Extra load Check the wiring D790-1/K7:7 ELSERV, 7.1.1 Control
Control lever extra handling between the control –R8075-1/3 menu 2 lever
function (R8075-1). function not unit and component (P5)
Signal voltage working. with the diagnostic
below 0.2 V or menu.
above 4.8 V. Check component.
92 * Incorrect signal Joystick Check cabling between D790-1/K9:8 – EL-STE- 5.1.2 Mini-
from Steering control or the control unit and R825-1/H1 ERING, wheel
lever (R825-1) mini-wheel not the component with menu 1 5.1.3 Joystick
or Mini-wheel working. diagnostic menu.
(R825-1). Signal Check the switch.
voltage below 0.2 V
or above 4.8 V.
93 * Incorrect signal Joystick Check cabling between D790-1/K9:9 – EL-STE- 5.1.2 Mini
from Mini-wheel control or the control unit and R825-2/H2 ERING, steering wheel
(R825-2). Signal mini-wheel not the component with menu 1
voltage below 0.2 V working. diagnostic menu.
or above 4.8 V. Check the switch.
94 Incorrect signal Cab heat Check cabling between D790-1/K10:4 – CLIMATE, 9.4.5 Water
from Water valve, cannot be the control unit and Y673/9 menu 4 valve
cab heating (Y673). adjusted. the component with
below 0.2 V or Check the motor.
above 4.8 V.
95 * Error signal from Extra load Check cabling between D790-1/K9:9 – ELSERV, 7.1.1 Control
Control lever extra handling the control unit and R8075-2/3 menu 2 lever
function (R8075-2). function not the component with (P7)
Signal voltage working. diagnostic menu.
above 4.8 V.

Connections
and Diagnos-
96 Incorrect signal Air Check cabling between D790-1/K4:8 – CLIMATE, 9.4.17
from Sensor, conditioning the control unit and B775-1/2 menu 1 Sensor cab
cab temperature not working. the component with temperature
(B775-1). diagnostic menu.
Sensor indicates Check the sensor.
temperature below
-43 °C or above 105
°C.
97 Incorrect signal Air Check cabling between D790-1/K4:9 – CLIMATE, 9.4.18 Sensor,
from Sensor, conditioning the control unit and B774/2 menu 2 ambient
outer temperature not working. the component with temperature
(B774). diagnostic menu.
Temperature signal Check the sensor.
above 105 °C.
98 Incorrect signal Air Check cabling between D790-1/K4:10 – CLIMATE, 9.4.16 Sensor,
from Sensor, outlet conditioning the control unit and B775-2/2 menu 2 temperature
fan temperature not working. the component with outlet fan
(B775-2). diagnostic menu.
Sensor indicates Check the sensor.
temperature below
°C.
99 Incorrect signal Air Check cabling between D790-1/K4:11 – CLIMATE, 9.4.12 Sensor
from Sensor, conditioning the control unit and B775-3/2 menu 2 temperature
refrigerant not working. the component with refrigerant
temperature diagnostic menu.
(B775-3). Check the sensor.
Sensor indicates
temperature below
°C.
101 Redundant voltage - Check cabling between D797-1/K2:7 CAN/POW- 11.5.1.2
feed left to the control unit and ER, menu Redundant
frame control unit the component with 10 voltage feed
(D797-1) does not diagnostic menu. of control units
reach destination. Check the control unit.
feed right to the control unit and ER, menu Redundant
frame control unit the component with 10 voltage feed
(D797-1) does not diagnostic menu. of control units
103 Incorrect power No electric Check fuse F58-2/1, D797-1/K2:1, CAN/POW- 11.5.1.3
supply to Control power feed to replace if necessary. K2:9, K2:10 – ER, menu Ignition
unit, frame components. Check cabling between F58-2/1:1, 1:2 10 voltage (15)
(D797-1). Voltage the control unit and
below 18 V or above the component with
32 V. diagnostic menu.
104 Incorrect Functions Check fuse F58-2:1 and D797-1/K2:11 – CAN/POW- 11.5.1.4
emergency stop normally replace if necessary. F58-2/1:1 ER, menu Emergency
switch voltage to supplied Check the wiring 10 stop switch
frame control unit emergency between the control voltage
(D797-1). stop switch unit and component
voltage have with the diagnostic
no feed. All menu.
hydraulic
functions are Check component.
blocked.

Connections
and Diagnos-
105 Incorrect 5 V Incorrect Check cabling between D797-1/K1:8 CAN/POW- 8.2.1
reference voltage function, lift the control unit and – B768-1/1, ER, menu Overload
to pressure sensor. and tilt sensor. the component with B768-2/1 11 protection
Voltage below 4.9 V diagnostic menu.
or above 5.1 V. Check the sensor.
106 Transistor has been Cooling fan Check cabling between D797-1/K1:14 – HYD, menu 10.6.3 Cooling
triggered due to hydraulic oil the control unit and M668/1 1 fan
hydraulic oil cooling Check the motor.
fan (M668).
107 Transistor has been Mast work Check bulb. D797-1/K1:1 LIGHTS, 9.6.9 Working
triggered due to lights not Check the bulb holder. – E404L-1, menu 10 lights mast
short circuit or open working. E404R-1
circuit in circuit Check cabling between
for mast work the control unit and
lights (E404R-1, the component with
E404L-1). diagnostic menu.
108 Transistor has been High beam not Check bulb. D797-1/K1:15 LIGHTS, 9.6.1
triggered due to working. Check the bulb holder. – E402L-1, menu 3 Headlights
short circuit or E402R-1
open circuit in Check cabling between
circuit for high the control unit and
beam (E402R-1, the component with
E402L-1). diagnostic menu.
109 Transistor has been Low beams not Check bulb. D797-1/K1:28 – LIGHTS, 9.6.1
triggered due to working. Check the bulb holder. E400L, E400R menu 3 Headlights
short circuit or open
circuit in circuit for Check cabling between
low beam (E400L, the control unit and
E400R). the component with
diagnostic menu.
111 Transistor has been Running lights Check bulb. D797-1/K1:2 LIGHTS, 9.6.2 Running
triggered due to not working. Check the bulb holder. – H416-1, menu 2 lights
short circuit or open H416-2,
circuit in circuit Check cabling between H417-1, H417-2
for running lights the control unit and
(H416-1, H416-2, the component with
H417-1, H417-2). diagnostic menu.
112 Transistor has been Cooling fan Check cabling between D797-1/K1:3 – HYD, menu 4.8.9 Cooling
triggered due to brake oil not the control unit and M674/1 2 fan
short circuit or open working. the component with
brake oil cooling fan Check the motor.
(M674).
113 Transistor has been Lift and lower Check cabling between D797-1/K1:4 ELSERV, 7.2.5 Control
triggered due to not working. the control unit and – Y6004/1, menu 3 and valve, lift and
short circuit or open the component with Y6005/1 4 tilt
circuit in circuit diagnostic menu.
for solenoid valve, Check the solenoid
lift mast (Y6005) valves.
and solenoid valve,
lower mast (Y6004).
114 Transistor has been Tilt not Check cabling between D797-1/K1:5 ELSERV, 7.7.5 Control
triggered due to working. the control unit and – Y6010/1, menu 5 and valve, lift and
short circuit or open the component with Y6011/1 6 tilt
tilt in (Y6011) and valve.
solenoid valve, tilt
out (Y6010)

Connections
and Diagnos-
115 Transistor has been Left direction Check bulb. D797-1/K1:30 – LIGHTS, 9.6.6 Direction
triggered due to indicator not Check the bulb holder. H422/1, H426/1 menu 4 indicators
short circuit or open working.
for left direction the control unit and
indicator (H422, the component with
H426). diagnostic menu.
116 Transistor has been Right direction Check bulb. D797-1/K1:31 – LIGHTS, 9.6.6 Direction
triggered due to indicator not Check the bulb holder. H423/1, H427/1 menu 4 indicators
for right direction the control unit and
indicator (H423, the component with
H427). diagnostic menu.
117 Transistor has been Starter motor Check cabling between D797-1/K1:32 – ENGINE, 1.11 Start and
triggered due to not working. the control unit and K315/85 menu 5 stop
start relay (K315) Check the component.
for starter motor.
118 Transistor has been Tail lights not Check bulb. D797-1/K1:33 LIGHTS, 9.6.3 Tail
triggered due to working. Check the bulb holder. – H412L/1, menu 2 lights
short circuit or open H412R/1
tail light (H412L, the control unit and
H412R). the component with
diagnostic menu.
119 Transistor has been Brake light left Check bulb. D797-1/K1:7 – LIGHTS, 9.6.4 Brake
triggered due to not working. Check the bulb holder. H411L/1 menu 8 light
short circuit or open
for left brake light the control unit and
(H411L). the component with
diagnostic menu.
120 Transistor has been Brake light Check bulb. D797-1/K1:9 – LIGHTS, 9.6.4 Brake
triggered due to right not Check the bulb holder. H411R/1 menu 8 light
right brake light the control unit and
(H411R). the component with
diagnostic menu.
121 The transistor has Reverse alarm Check cabling between D797-1/K1:10 – LIGHTS, 9.7.5 Back-up
been triggered due not working. the control unit and H965/1 menu 8 alarm
to short circuit or the component with
open circuit in circuit diagnostic menu.
for Back-up warning Check the component.
device (H965).
122 Transistor has been Air Check cabling between D797-1/K1:25 – CLIMATE, 9.4.7
triggered due to conditioning the control unit and M645/1 menu 6 Compressor
123 circuit in circuit for diagnostic menu. D797-1/K1:29 –
electromagnetic M645/1
clutch of AC
compressor
(M645).
NOTE! Error code
122 and 123 apply
to the same user.

Connections
and Diagnos-
124 Transistor has been Pressurising Check cabling between D797-1/K1:39 – HYD, menu 7.4.9 Lift,
triggered due to of attachment the control unit and Y6062/1 6 tilt and
short circuit or open control valve the component with attachment
circuit in circuit does not work. diagnostic menu. control valve
for solenoid valve, No attachment Check the solenoid
hydraulic pump functions valve.
disengagement working.
(Y6062).
125 * Transistor has been Regeneration Check cabling between D797-1/K1:11 – ELSERV, 7.2.6 Valve
triggered due to not working. the control unit and Y6051/1 menu 15 block lift
short circuit or open the component with cylinder
for solenoid valve Check component.
regeneration, lift,
right (Y6051).
126 * Transistor has been Regeneration Check cabling between D797-1/K1:12 – ELSERV, 7.2.6 Valve
triggered due to not working. the control unit and Y6052/1 menu 15 block lift
short circuit or open the component with cylinder
for solenoid valve Check component.
regeneration, lift,
left (Y6052).
132 Vehicle Data file Some - - - -
missing. functions in
machine not
working.
133 * Faulty signal from Scales, Check the sensor. D797-1/K1:21 – HYD, menu 7.2.8 Sensor
hydraulic pressure regeneration Check cabling between B768-1/3 3 hydraulic
sensor for lift and slack the control unit and OLS, menu pressure lift
cylinder (B768-1). chain logic, the component with 1 cylinder
not working. diagnostic menu.
Overload
system not
working. Error
code 150
activated.
134 * Faulty signal from Overload Check the sensor. D797-1/K1:22 – HYD, menu 7.7.8
hydraulic pressure system not Check cabling between B768-2/3 3 Hydraulic
sensor for tilt working. Error the control unit and OLS, menu pressure
cylinder (B768-2). code 150 the component with 1 sensor, tilt
activated. diagnostic menu. cylinder
135 * No feedback signal - Check that cooling fan D797-1/K2:6 – HYD, menu 4.8.9 Cooling
from brake oil is working. M674/2 2 fan
cooling fan (M674). Check cabling between
the component with
diagnostic menu.
137 Error signal from Lift mast not Check cabling between D797-1/K1:16 – ELSERV, 7.2.5 Control
Solenoid valve working. the control unit and Y6005/2 menu 3 valve, lift and
lift mast (Y6005). the component with tilt
Return current does diagnostic menu.
not correspond with Check the solenoid
control current. valve.

Connections
and Diagnos-
138 Error signal from Lower mast not Check cabling between D797-1/K1:17 – ELSERV, 7.2.5 Control
Solenoid valve working. the control unit and Y6004/2 menu 4 valve, lift and
lower mast (Y6004). the component with tilt
139 Incorrect signal Tilt in not Check cabling between D797-1/K1:18 – ELSERV, 7.7.5 Control
from Solenoid working. the control unit and Y6011/2 menu 5 valve, lift and
valve, tilt in (Y6011). the component with tilt
140 Incorrect signal Tilt out not Check cabling between D797-1/K1:19 – ELSERV, 7.7.5 Control
from Solenoid working. the control unit and Y6010/2 menu 6 valve, lift and
valve, tilt out the component with tilt
(Y6010). Return diagnostic menu.
current does not Check the solenoid
correspond with valve.
control current.
141 Transistor has been Parking brake Check cabling between D797-1/K1:34 – HYD, menu 4.5.3 Solenoid
triggered due to cannot be the control unit and Y642/1 5 valve parking
short circuit or open released. the component with brake
for parking brake Check the solenoid
solenoid valve valve.
(Y642).
142 Transistor has been Pressurising Check cabling between D797-1/K1:35 – HYD, menu 7.4.9 Lift,
triggered due to of attachment the control unit and Y6012/6062/1 6 tilt and
short circuit or open control valve the component with attachment
circuit in circuit does not work. diagnostic menu. control valve
for solenoid valve, No attachment Check the solenoid
hydraulic pump functions valve.
disengagement working.
(Y6012/6062).
143 * Transistor has been Spreading Check cabling between D797-1/K1:36 – EXT- 7.10.5
triggered due to and twistlocks the control unit and Y6039/6018/1 ATTACH, Separate top
short circuit or on top lift the component with menu 5 lift attachment
open circuit in cir- attachment not diagnostic menu.
cuit for solenoid working. Check the solenoid
valve, lock twist- valve.
locks/spreading out
(Y6039/6018).
144 * Transistor has been Spreading Check cabling between D797-1/K1:37 – EXT- 7.10.5
triggered due to and twistlocks the control unit and Y6040/6019/1 ATTACH, Separate top
short circuit or on top lift the component with menu 5 lift attachment
open circuit in cir- attachment not diagnostic menu.
cuit for solenoid working. Check the solenoid
valve, open twist- valve.
locks/spreading in
(Y6040/6019).
145 * High brake oil Reduced Check that cooling fan D797-1/K2:6 – HYD, menu 4.8.10 Sensor
temperature. braking is working. B772/1 2 brake oil
capacity. If the Check that the radiator temperature
temperature is not clogged.
continues to
rise, speed is Check the brake oil
limited to 5 level.
km/h. Check the sensor.

Connections
and Diagnos-
146 * Incorrect signal Speed limited Check the sensor. D797-1/K2:6 – HYD, menu 4.8.10 Sensor
from Sensor, brake to 5 km/h. Check cabling between B772/1 2 brake oil
oil temperature the control unit and temperature
(Y772). Signal the component with
voltage below 0.2 V diagnostic menu.
or above 4.8 V.
147 High temperature Reduced Check that cooling fan D797-1/K2:13 – HYD, menu 10.6.4 Sensor
hydraulic oil. braking is working. B776/1 1 hydraulic oil
capacity. If the Check that the radiator temperature
temperature is not clogged.
continues to
rise, speed is Check the sensor.
limited to 5
km/h.
148 Incorrect signal Incorrect Check the sensor. D797-1/K2:13 – HYD, menu 10.6.4 Sensor
from Sensor, temperature Check cabling between B776/1 1 hydraulic oil
hydraulic oil display. the control unit and temperature
temperature the component with
(B776). diagnostic menu.
149 Incorrect signal Incorrect Check the sensor. D797-1/K2:15 CAB, menu 1.2.2 Sensor
from fuel level display of fuel Check cabling between –B757/1 7 fuel level
sensor (B757). volume (empty the control unit and
Resistance above or full). the component with
180 Ω. diagnostic menu.
150 * Defective overload Overload Check if there are error - OLS, menu 8.2.1
protection. system not codes for sensors in the 1–7 Overload
This error code working. All overload system. protection
cannot be removed lift functions
with Reset. run at reduced
speed.
193 Transistor has been Right front Check bulb. D797-1/K1:36 – VBFS, 9.6.4 Brake
triggered due to brake light not Check the bulb holder. H410R/1 menu 8 light
right front brake the control unit and
light (H410R). the component with
diagnostic menu.
194 Transistor has been Left front Check bulb. D797-1/K1:37 – VBFS, 9.6.4 Brake
triggered due to brake light not Check the bulb holder. H410L/1 menu 8 light
left front brake light the control unit and
(H410L). the component with
diagnostic menu.
feed left to the control unit and ER, menu Redundant
attachment control the component with 15 voltage feed of
unit (D791-1) diagnostic menu. Control units
does not reach Check the control unit.
destination.
feed right to the control unit and ER, menu Redundant
frame control unit the component with 15 voltage feed of
(D791-1) does not diagnostic menu. Control units

Connections
and Diagnos-
253 Incorrect power Functions Check fuse F58-3/1, D791-1/K2:1, CAN/POW- 11.5.1.4
supply to Control normally replace if necessary. K2:9, K2:10 – ER, menu Emergency
unit, attachment supplied Check cabling between F58-3/1:1 15 stop switch
(D791-1). Voltage emergency the control unit and voltage
below 18 V or above stop switch the component with
32 V. voltage have diagnostic menu.
no feed. No
attachment
functions
working.
254 Incorrect Functions Check fuse F58-3/1, D791-1/K2:11 – CAN/POW- 11.5.1.4
emergency stop normally replace if necessary. F58-3/1:1 ER, menu Emergency
switch voltage supplied Check cabling between 15 stop switch
to Control unit, emergency the control unit and voltage
attachment stop switch the component with
(D791-1). voltage have diagnostic menu.
no feed. No
attachment
functions
working.
255 Incorrect 5 V - Check cabling between D791-1/K1:8 CAN/POW- 11.5.1 Power
reference voltage the control unit and ER, menu supply
to pressure sensor. the component with 16
Voltage below 4.9 V diagnostic menu.
or above 5.1 V. Check the sensor.
256 Transistor has been Central Check cabling between D791-1/K1:14 – OPT, menu 9.14.1 Pump
triggered due to lubrication the control unit and M693-2/1 2 unit
short circuit or open attachment not the component with
circuit in circuit working. diagnostic menu.
for central unit for Check the component.
central lubrication
(M693-2).
257 Transistor has been Work light Check bulb. D791-1/K1:1 LIGHTS, 9.6.12
triggered due to attachment left Check the bulb holder. – E404L, menu 13 Work light
short circuit or open not working. E404UL, attachment
circuit in circuit Check cabling between E404LL-3/1
for attachment the control unit and
work lights, left the component with
(E404L-3). diagnostic menu.
258 Transistor has been Work light Check bulb. D791-1/K1:15 LIGHTS, 9.6.12
triggered due to attachment Check the bulb holder. – E404R, menu 13 Work light
short circuit or open right not E404UR, attachment
circuit in circuit working. Check cabling between E404LR-3/1
for attachment the control unit and
work lights, right the component with
(E404R-3). diagnostic menu.
259 Transistor has been Warning signal Check the buzzer. D791-1/K1:28 – ATTACH, 7.5.7 Buzzer,
triggered due to for automatic Check cabling between H9003/1 menu 21 automatic
short circuit or spreading not the control unit and spread
open circuit in working. the component with 20"-40"
circuit for warning diagnostic menu.
signal, automatic
spreading (H9003).
260 * Transistor has been Levelling of Check cabling between D791-1/K1:42 ATTACH, -
triggered due to attachment not the control unit and – Y637-1/1, menu 15
short circuit or open working. the component with Y637-2/1
control valve for Check the solenoid
levelling clockwise valve.
(Y637-1, Y637-2).

Connections
and Diagnos-
261 Transistor has been Spreading Check cabling between D791-1/K1:16 – ATTACH, 7.5.2 Control
triggered due to left in of the control unit and Y6019L/2 menu 18 valve
short circuit or open attachment not the component with attachment
spreading left in valve.
(Y6019L).
triggered due to left out of the control unit and Y6018L/2 menu 17 valve
circuit in circuit functioning. diagnostic menu.
spreading left out valve.
(Y6018L).
triggered due to right in of the control unit and Y6019R/2 menu 20 valve
spreading right in valve.
(Y6019R).
triggered due to right out of the control unit and Y6018R/2 menu 19 valve
circuit in circuit functioning. diagnostic menu.
spreading right out valve.
(Y6018R).
265 * Transistor has been Levelling left of Check cabling between D791-1/K1:19 – ATTACH, -
triggered due to attachment not the control unit and Y6036/2 menu 13
short circuit or open working. the component with
for levelling, left Check the solenoid
(Y6036). valve.
266 * Transistor has been Levelling right Check cabling between D791-1/K1:19 – ATTACH, -
triggered due to of attachment the control unit and Y6036/2 menu 14
short circuit or not working. the component with
open circuit in diagnostic menu.
circuit for solenoid Check the solenoid
valve, levelling right valve.
(Y6035).
267 Transistor has been Side shift left of Check cabling between D791-1/K1:18 – ATTACH, 7.4.2 Control
triggered due to attachment not the control unit and Y6020/2 menu 11 valve
short circuit or open working. the component with attachment
solenoid valve, side Check the solenoid
shift left (Y6020). valve.
268 Transistor has been Side shift right Check cabling between D791-1/K1:18 – ATTACH, 7.4.2 Control
triggered due to of attachment the control unit and Y6021/2 menu 12 valve
short circuit or open not working. the component with attachment
solenoid valve, side Check the solenoid
shift right (Y6021). valve.
269 Transistor has been Twistlock not Check cabling between D791-1/K1:7 – ATTACH, 7.9.1.2
triggered due to working. the control unit and Y6040/1 menu 9 Control valve
short circuit or open the component with attachment
solenoid valve for Check the solenoid
locked twistlocks valve.
(Y6040).

Connections
and Diagnos-
270 Transistor has been Twistlock not Check cabling between D791-1/K1:9 – ATTACH, 7.9.1.2
triggered due to working. the control unit and Y6039/1 menu 9 Control valve
short circuit or open the component with attachment
solenoid valve for Check the solenoid
open twistlocks valve.
(Y6039).
271 The transistor has Twistlocks and Check cabling between D791-1/K1:10 CAN/POW- 7.9.1.2
been triggered due spreading not the control unit and – B769L/A, ER, menu Control valve
to short circuit or working. the component with B769R/A, 16 attachment
open circuit in circuit diagnostic menu. B777L/A,
for Voltage feed, Check the sensor. B777R/A,
position sensor B7203L/A,
attachment. B7203R/A,
B7204L/A,
B7204R/A,
B7205LL/A,
B7205RL/A
272 The transistor has Indicator Check bulb. D791-1/K1:25 – ATTACH, 7.9.1
been triggered due light, open Check the bulb holder. H562/1 menu 10 Twistlocks
to short circuit twistlock/lock
or open circuit tongue not Check cabling between
in the circuit for working. the control unit and
Indicator light, open the component with
twistlocks (H562). diagnostic menu.
273 The transistor has Indicator Check bulb. D791-1/K1:29 – ATTACH, 7.9.1
been triggered due light, locked Check the bulb holder. H563/1 menu 10 Twistlocks
to short circuit twistlock/lock
or open circuit tongues not Check cabling between
in the circuit for working. the control unit and
Indicator light, the component with
locked twistlocks diagnostic menu.
(H563).
274 The transistor has Indicator light, Check bulb. D791-1/K1:39 – ATTACH, 7.9.1
been triggered due attachment Check the bulb holder. H564/1 menu 10 Twistlocks
to short circuit or alignment not
open circuit in circuit working. Check cabling between
for Indicator light, the control unit and
alignment (H564). the component with
diagnostic menu.
287 Error signal from Spreading left Check cabling between D791-1/K1:16 ATTACH, 7.5.2 Control
the Solenoid valve not working. the control unit and – Y6019L/2, menu 17 valve
spreading left in the component with Y6019R/2 and 18 attachment
(Y6019L) and diagnostic menu.
Solenoid valve Check the solenoid
spreading left out valve.
(Y6018L). Return
current does not
correspond with
control current.
288 Error signal from Spreading right Check cabling between D791-1/K1:17 ATTACH, 7.5.2 Control
the Solenoid valve not working. the control unit and – Y6019R/2, menu 19 valve
spreading right the component with Y6018R/2 and 20 attachment
in (Y6019R) and diagnostic menu.
spreading right out valve.
(Y6018R). Return
current does not
correspond with
control current.

Connections
and Diagnos-
289 Error signal from Side shift of Check cabling between D791-1/K1:18 ATTACH, 7.4.2 Control
Solenoid valve attachment not the control unit and – Y6020/2, menu 11 valve
for side shift working. the component with Y6021/2 and 12 attachment
left (Y6020) and diagnostic menu.
for side shift right valve.
(Y6021). Return
current does not
correspond with
control current.
290 * Error signal from Levelling of Check cabling between D791-1/K1:19 ATTACH, -
Solenoid valve attachment not the control unit and – Y6035/2, menu 13
levelling right working. the component with Y6036/2 and 14
(Y6036) and diagnostic menu.
levelling left valve.
(Y6035). Return
current does not
correspond with
control current.
291 * Transistor has been Indicator light Check bulb. D791-1/K1:34 – ATTACH, -
triggered due to for upper Check the bulb holder. H564UL/1 menu 23
short circuit or open alignment not
circuit in circuit working. Check cabling between
for indicator light, the control unit and
upper alignment the component with
(H564UL). diagnostic menu.
292 Transistor has been Spreading in of Check cabling between D791-1/K1:35 – ATTACH, 7.5.2 Control
triggered due to attachment not the control unit and Y6019/1 menu 14 valve
short circuit or working. the component with attachment
open circuit in diagnostic menu.
circuit for solenoid Check the solenoid
valve, spreading in valve.
(Y6019).
298 Sensor twistlock - Check that Sensors, D791-1/K2:13 ATTACH, 7.9.1.7
left side indicates twistlock, are clean and menu 8 Sensor
both locked and correctly adjusted. twistlocks
open twistlock at Check cabling between
the same time. the control unit and
the component with
diagnostic menu.
299 Sensor twistlock - Check that Sensors, D791-1/K2:15 ATTACH, 7.9.1.7
right side indicates twistlock, are clean and menu 8 Sensor
both locked and correctly adjusted. twistlocks
open twistlock at Check cabling between
the same time. the control unit and
the component with
diagnostic menu.
300 Sensor, alignment, Twistlock not Check that Sensors, - ATTACH, 7.9.1.6
indicates working. alignment, are clean menu 7 Sensor
unreasonable and correctly adjusted. alignment
distance. Check that the contact
pin runs smoothly.
Check cabling between
the component with
diagnostic menu.

Connections
and Diagnos-
451 Redundant voltage - Check cabling between D795/K1:7 CAN/POW- 11.5.1.2
feed left to Control the control unit and ER, menu 9 Redundant
unit KID (D795) the component with voltage feed
does not reach diagnostic menu. of control units
destination.
452 Redundant voltage - Check cabling between D795/K1:8 CAN/POW- 11.5.1.2
feed right to Control the control unit and ER, menu 9 Redundant
unit KID (D795) the component with voltage feed
does not reach diagnostic menu. of control units
destination.
460 No messages Incorrect Use diagnostic menu to D795/K1:10, CAN/POW- 11.6.2
received on CAN values in check the CAN bus. K1:11, K1:12, ER, menu Redundant
buffer 1. operating K1:13 1, 2, 17 CAN bus
menus.
461 No messages Error codes Use diagnostic menu to D795/K1:5, CAN/POW- 11.6.2
received on CAN from other check the CAN bus. K1:6 ER, menu Redundant
buffer 2. Control units 1, 2, 17 CAN bus
cannot be
shown.
500 Time for service. - Check that servicing - - C Preventive
has been performed. maintenance
If servicing has been
performed following
the Cargotec service
schedule, reset the
service indicator; see
section 8 Control
system, group 8.2.4
Service indicator.

D:88

E:1
E Schematics
Contents E Schematics
Schematics......................................................................................................... E:3
Common hydraulics ........................................................................................ E:3
Hydraulic diagrams, compilation ................................................................ E:3
Hydraulic diagrams..................................................................................... E:4
Common electrics ........................................................................................... E:6
Circuit diagram, description ....................................................................... E:6
Component designations ........................................................................... E:8
Circuit diagrams, compilation ..................................................................... E:8

E:2

E Schematics – Schematics E:3
E Schematics
Common hydraulics
Hydraulic diagrams, compilation
Designation Drawing number
Hydraulic diagrams, page E:4 A58447.0200

E:4
13 13 17
1 2 1
12 16
6 7 14
3 3
VDCT01.03GB
4
15
5 11
a b c d e f g h
18 d a b
9 20
34 8 19
a
36 35
b
10
e c
32
Workshop Manual DCT 80-90

21
E Schematics – Common hydraulics
Hydraulic diagrams
24 24
22
31 30 25 25 23 23
28
33 29
27
26
019474 [A58447.0200 ver. 05]

E Schematics – Common hydraulics E:5
1. Wheel brakes 17. Spreading cylinder right spreader beam

2. Drive axle block 18. Main valve
3. Brake cylinder a Solenoid valve hydraulic pressure attachment
(Y6012/6062)
4. Parking brake caliper
b Relief valve, attachment
5. Make-contact (closing switch) declutch (S220)
c Servo valve, lift (Y6005)
6. Make-contact (closing switch) brake light (S216)
d Servo valve, lower (Y6004)
7. Brake valve
e Servo valve, tilt in (Y6011)
8. Valve block brake system
f Servo valve, tilt out (Y6010)
a Accumulator drain valve
19. Lift, tilt and attachment control valve
b Solenoid valve, parking brake (Y642)
20. Valve block accumulator charging and priority valve
9. Switch (NC) low brake pressure (S204)
21. Accumulator lift cylinder
22. Load control valve
11. Accumulator brake system
23. Lift cylinder
12. Side shift cylinder
24. Overcentre valve
13. Lock cylinder, twistlock
25. Tilt cylinder
14. Overcentre valve
26. Hydraulic oil tank
15. Control valve, attachment
27. Breather filter
a Servo valve, side shift left (Y6020)
28. Hydraulic oil pump, load handling
b Servo valve, side shift right (Y6021)
29. Hydraulic oil pump, brake and steering
c Servo valve, open twistlock (Y6039)
30. Hydraulic oil filter, load handling
d Servo valve, lock twistlock (Y6040)
31. Hydraulic oil filter, cooling circuit
e Servo valve spreading out left (Y6018L)
32. Steering valve
f Servo valve spreading in left (Y6019L)
g Servo valve spreading out right (Y6018R)
34. Oil cooler
h Servo valve spreading in right (Y6019R)
35. Thermal bypass valve
16. Spreading cylinder left spreader beam
36. Fine filter

E:6 E Schematics – Common electrics
Common electrics
Circuit diagram, description
A circuit diagram is divided into circuit names (drawing numbers) and
consists of a set of numbered pages.
The circuits and their contents are governed by the following set of
rules:
• 20015.0001 circuit drawings-post designations K-standard.
• K-standard 1: norms, rules
• K-standard 2: cables, general physical
• K-standard 5: Designation and marking system, item designations
circuit drawings
The following is an explanation of symbols and texts in a circuit diagram:
Connectors
Connectors
Connectors in the wiring start with an X followed by a number and end
-X080f -X080m with f = female or m = male. If a connector is connected to a component
0301A 1 1 then the component number is inherited into the connector's number,
e.g. XB72002Rm which is the connector for Sensor, contact front right
017472
(B7202R).
Under the connector's number the pin is specified with numbers or
letters depending on the connector.
• X000-X199: In the cab.
• X200-X299: On the frame.
• X300-X399: On the boom.
• X400-: On the attachment.
• X37-: All grounding points start with X37, e.g. X37-201, which is a
grounding point on the frame.
X37-A, X37-B, X37-C and X37-D are grounding points in electronic
box, cab.
Zero references are in the control units.
Components
Components
+CHASSIS Components are described with component number (S220-2) and a
-S220-2 short descriptive text. Components (sensors, switches, etc.) are shown
P in standby mode i.e. de-energised mode or mechanical standby mode.
• S indicates the type of component, see Component designations,
1 1 2 1 page E:8.
013018
DECLUTCH • 220 is component number and indicates the function the

3,0MPa component has.
• -2 indicates that it is the second component of this type for the
specific diagram.
Cable marking
Cable marking
A 01012 0525 W 212D

All cables are either white (ground signal) or grey (other wiring) and
labelled with numbers.
Cable numbering is interpreted as follows:
A 01011 0524 W 212C
• 0525: the number on a cable can usually be traced to a pin in a
connector, in this example, connector X052 pin 5.
A 01010 0523 W 212B
• W212: cables that start with W and serial number cannot be
traced directly to a connector.
A 01016 0527 W 212E • A01012: cables that start with A are in the electronic box in the cab.
• W212D: cables that end with a capital letter are jointed in the
wiring from a main cable with the same number. Each joint will
013019
W 212A
have its own letter.

E Schematics – Common electrics E:7
References
References
0 An arrow symbol means that the circuit continues on another page in

the circuit diagram at the specified coordinates. Sometimes there are
1 also references for components that can then be part of a component
00816
/4 .0 _ 1 .B 1 5 1 whose other parts are on a different diagram. In some cases there is
013020
00816
/9 .1 0 _ 1 .A 2 also a help text where the cable connects.
Example: /11.5_1.D3 means page 11.5_1 coordinate D3.

Connection to control unit
Connection to control unit

Connections to control units are described as a table with two fields;
the upper one shows the type of connection, the lower one has a
-X 4 1 1
21 K 1 :2 1 A n a lo g In 0 -5 V +BO O M reference to the compilation of the control unit's connections. Together
/0 .0 _ 4 .D 5 -D 7 9 1 -1 with this there are descriptive texts that specify control unit and signal.
M E A S U R E P O IN T S C A L E 013021
For more information about the different connection types on the
control units, see section 11 Common electrics, group 11.5.5 Wiring.
Fuses
Fuse boxes always start with F5. Example: F58-3 means fuse box
3 with 8 fuses.
For most fuse boxes there is also a table and an explanation of the
circuits that the various fuses protect.

Component designations
The components in circuit diagrams have a prefix and number, the
prefix describes the type of component, the number which component.
Component list with component number, prefix and designation is
provided as an appendix after the circuit diagrams.
Prefix Description
A Control panel Drive-train/Wiper
B Converter from non-electric to electric signals or vice versa. Example: inductive sensor.
C Capacitor
D Binary element, delay unit, memory. Example: control unit.
E White light. Example: work lighting.
F Protective device. Example: fuse.
G Alternator, power supply device. Example: battery.
H Signal device. Example: horn, brake lights.
K Relay, contactor. Example: power relay ignition key lock.
M Engine. Example: electric motor.
P Measuring instrument, testing equipment. Example: hour meter.
Q Battery disconnector
R Resistor. Example: potentiometer.
S Electric switch for control circuit, selector. Example: switch.
V Diode
W Antenna
X Outlet/socket, connecting device. Example: connection terminal.
Y Electrically controlled mechanical device. Example: solenoid valve, hydraulic valve.
Circuit diagrams, compilation

Circuit diagrams are attached as an appendix in the following order.
Circuit diagram basic machine, drawing number A49226.0100. The
circuit contains pages for several machine models, those applying to
DCT 80-90 are listed here.
Sheet Designation
0.0-1 Cross-reference list
0.1-1 Truth table opt.
1.0-1 Circuit, drivetrain, engine
1.0-2D Circuit, Volvo TAD760VE engine
1.0-2E1 Circuit, Cummins QSB6.7 engine
1.0-2E2 Circuit, Cummins QSB6.7 engine
2.0-1 Circuit, drive-train, transmission
2.0-2D1 Circuit transmission Dana TE17FF

E Schematics – Common electrics E:9
Sheet Designation
4.0-1 Circuit, brake system
4.8-1 Circuit, brake oil cooling
7.0-1 Circuit, electric servo levers
7.0-2 Circuit, electric servo joystick
7.0-4 Circuit, accessory attachment
7.0-5 Circuit, accessory attachment
7.2-1 Circuit, lift/lower electric servo
7.2-6 Circuit, mast valves
7.7-1 Circuit, tilt electric servo
7.7-2 Circuit, tilt indication
7.9-1 Circuit, twistlock
8.2-1 Circuit, bypassing
9.0-1 Circuit, std. opt.
9.1-1 Circuit, optional equipment
9.1-2 Circuit, hour counter
9.3-1 Circuit, seat heating
9.3-2 Circuit, air suspension seat
9.4-1 Circuit, climate system
9.4-2 Circuit, climate system
9.4-3 Circuit, condenser chassis
9.5-1 Circuit, wipers
9.6-1 Circuit, work lights 20'-40'
9.6-2 Circuit, work lights, carriage
9.6-3 Circuit, work lights, mast
9.6-4 Circuit lighting
9.6-7 Circuit, direction indicators & hazard
9.6-8 Circuit, interior lighting
9.6-9 Circuit, work lights, option
9.6-10 Circuit, work lights, option
9.6-11 Circuit, entry lighting
9.6-12 Circuit, aux. lights, attachment
9.6-13 Circuit, work lights, option, hood lamp
9.6-14 Circuit, work lights, option carriage
9.7-1 Circuit, alarm, audible signals
9.7-2 Circuit, back-up alarm
9.7-3 Circuit, compressor horn
9.7-4 Circuit for horn, servo panel
9.8-1 Circuit, radio
9.8-2 Circuit, printer
9.9-1 Circuit, rearview mirror heating

Sheet Designation
9.9-2 Circuit, camera
9.10-1 Circuit, cab tilt/sliding cab
9.14–1 Circuit, central lubrication
10.4-1 Circuit, hydr. pump disengagement
10.6-1 Circuit, hydraulic oil cooling
11.5-1 Circuit, current
11.5-6 Circuit, emergency stop switch current
11.5-7 Circuit 24/12V
11.5-8 Circuit 24V socket
11.5-9 Circuit, option, ground power
11.5-10 Circuit, option, ground
11.5-11 Circuit, option, ground
11.6-1 Circuit CAN bus ground
Circuit diagram for side lift attachment, drawing number A50400.0100.
Sheet Designation
0.0_1 Cross-reference list
7.4_1 Side shift circuit
7.5_1 Spreading circuit
7.5_2 Circuit, spreading buzzer
7.5_3 Circuit, spreading sensors
7.8_1 Circuit, levelling
7.9_1 Circuit, open/lock
7.9_2 Circuit, open/lock sensors
7.9_3A Circuit, indicator lights
7.9_3B Circuit, indicator lights
7.9_4 Circuit, alignment sensors
7.9_5A Circuit, alignment sensors
7.9_5B Circuit, alignment sensors
9.6_1 Circuit, work lights, carriage/attachment
9.14_1 Circuit, central lubrication
11.5_1 Circuit, current
11.5_2 Circuit, current
11.6_1 Circuit, CAN bus

1 2 3 4 5 6 7 8
A A
Kretsar DCF70-
B B
DCE280-330-RoRo
C _________________________ C
D D
This document must not be copied without our

written permission and the contents thereof must
secuted.
not be imparted to a third party nor be used for any

unauthorized purpose. Contravention will be pro-
Wiring DCF70-
E E
DCE280-330-RoRo
stöd av gällande lag.
Denna ritning får ej utan vårt medgivande kopieras.

Den får ej heller delgivas annan eller annars obe-
hörigen användas. Överträdelse härav beivras med
F F
Benämning Produkt/Product Blad/Sheet

Ref. Nr Ändring Ändring nr Datum Sign. Datum/Date Huvudnr./Project no.
Ruta Sign.
No. Design change Change No. Date Ritad/Drawn KRETSAR,DCF370-,DCE300- DCF300-, DCE300- 0
Sq. RSO 081216 A47137.0100
Name
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Updated ultrasond 7.3_2 1021496 PLT 150810 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr
RSO 081216 Klass/Class
WIRING,DCF370-,DCE300- A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-D790-1
Pin Number Drawing Function Type Pin Number Drawing Function Type Pin Number Drawing Function Type
K1 1:1-1:6 /11.5_4.C5 Power Supply K6 6:1 /9.4_1.B1 LAMP INST. ILLUMINATION PWM 1.5A K9 9:1 /5.2_1.A2 SWITCHES ARM REST 24V reference
6:2 /9.6_2.B8 SW W-LIGHTS CARRIAGE Input 9:2 /5.2_1.C2 LAMP F/R ARM REST PWM 1.5A
K2 2:1 /9.5_1.C1 MOTOR FRONT WIPER 5A 6:3 /9.6_3.B8 SW WORK LIGHTS MAST Input 9:3 /5.2_1.C8 SW REVERSE ARM REST Input
2:2 /9.4_2.C1 MOTOR HEATING FAN PWM 6:4 /9.6_4.B8 SWITCH ROT. BEACON Input 9:4 /5.2_1.B8 SW FORWARD ARM REST Input
2:3 /9.4_2.E1 MOTOR RECIRCULATION 1.5 6:5 /9.6_4.A8 SWITCH MAIN LIGHT Input 9:5 /5.2_1.B8 SW ACT. MICRO STEERING Input
2:4 /9.5_1.D1 MOTOR REAR WIPER 5A 6:6 /9.3_1.B8 SWITCH SEAT HEATER Input
2:5 /9.6_4.E1 MOTOR ROT. BEACON 5A 6:7 /9.1_1.E8 SWITCH S2 OPT. Input 9:6 /5.2_1.D8 POT. MICRO STEERING 0V reference
2:6 /9.6_6.A1 REVERSING LIGHT LEFT 5A 6:8 /9.1_1.D8 SWITCH S3 OPT. Input 9:7 /5.2_1.D2 POT. MICRO STEERING Analog reference 5V
2:7 /9.6_6.B1 REVERSING LIGHT RIGHT 5A 9:8 /5.2_1.D8 POT. MICRO STEERING (P6) Analog Input
2:8 /9.4_2.D8 LOGIC SUPPLY HEAT FAN 6:9 /9.1_1.B8 SWITCH S4 OPT. Input 9:9 /5.2_1.E8 POT. MIC STEER/6TH LEV (P7)Analog Input
6:10 /9.6_1.A8 SW WORK LIGHTS MAST Input 9:10 /5.2_1.A8 SWITCH HORN ARM REST Input
B 6:11 /1.0_1.A8 POT. ACCELERATOR 1 Analog Input B
K4 4:1 /9.4_2.B1 MOTOR WATER VALVE 0.5A
4:2 /9.4_2.B1 MOTOR WATER VALVE 0.5A 6:12 /1.0_1.B8 POT. ACCELERATOR 2 Analog Input
4:3 /9.4_2.A1 MOTOR DRAUGHT VALVE 0.5A 6:13
4:4 /9.4_2.A1 MOTOR DRAUGHT VALVE 0.5A 6:14 /2.0_1.C8 PEDAL DECLUTCHING Input K10 10:1
4:5 /9.4_2.B1 POT. DRAUGHT/WAT. VALVE Analog reference 5V 6:15 10:2
4:6 /9.4_2.B8 POT. DRAUGHT/ WAT VALVE 0V reference 6:16 SEE K11:13 10:3 /7.0_4.B8 SENSOR ALIGNMENT Input
4:7 /9.4_2.B8 POT. DRAUGHT VALVE Analog Input 10:4 /9.4_2.C8 POT. WATER VALVE Analog Input
K7 7:1 /7.0_1.A8 POTENTIOM. EL. SERVO 0V reference 10:5 Input
4:8 /9.4_1.D8 SENSOR TEMP. INDOOR Reostat in 7:2 /7.0_1.A1 POTENTIOM. EL. SERVO Analog reference 5V 10:6 Input
4:9 /9.4_1.F8 SENSOR TEMP. AMBIENT Reostat in 7:3 /7.0_1.A8 POT. LIFT / LOWER (P1) Analog Input 10:7 /9.3_1.C2 RELAY SEAT HEATER 0.5A
4:10 /9.4_1.E8 SENSOR TEMP. FAN AIR Reostat in 7:4 /7.0_1.B8 POT. TILT (P2) Analog Input 10:8 /9.6_1.B1 CONTAINER LIGHT 40 0.5A
4:11 /9.4_1.E8 SENSOR DE-ICING SENSOR Reostat in 7:5 /7.0_1.C8 POT. SIDE SHIFTING (P3) Analog Input
4:12 /9.4_1.F1 SENSORS AIR-CONDITION 0V reference 7:6 /7.0_1.D8 POT. SPREADING (P4) Analog Input 10:9 /9.1_2.B1 HOUR MET/RELAY AIR SEAT 0.5A
4:13 /9.5_1.C8 MOTOR FRONT WIPER Input 7:7 /7.0_1.E8 POT. EXTRA (P5) Analog Input 10:10 /11.5_3.E1 RELAY K315-1 0.5A
4:14 /9.5_1.C1 MOTOR FRONT WIPER 24V reference 7:8 /9.6_1.D1 CONTAINER LIGHT 20 0.5A 10:11 /11.5_6.C1 RELAY K3009-1 0.5A
10:12 /11.5_6.B1 RELAY K3009-2,K3002,K3007 0.5A
C K5 5:1 /9.1_1.B1 SWITCHES LEFT PANEL 24V reference 7:9 /7.0_2.C1 IND. LOCKED LEVELLING 0.5A 10:13 /9.5_1.E1 MOTOR WASHER 3A C
5:2 7:10 /7.0_5.B1 RELAY ACTIVATE TW 0.5A 10:14 /9.5_1.E1 MOTOR ROOF WIPER 1.5A
5:3 /7.0_4.F2 OVERRIDE ALIGNMENT PWM (NPN) 7:11 /7.0_5.C1 RELAY ACTIVATE SPREAD 0.5A 10:15
5:4 /9.5_1.F8 MOTOR WASH REAR/ROOF PWM (NPN) 7:12 /7.0_2.B1 SWITCHES EL. SERVO Analog Reference 24V 10:16 /11.5_3.F1 RELAY K315-2 0.5A
5:5 /9.6_7.B8 SWITCH LAMP HAZARD PWM (PNP) 7:13 /7.5_1.B8 SWITCH SPREADING 20-40 Input
5:6 /9.6_7.A8 SWITCH HAZARD Input 7:14 /7.5_1.A8 SWITCH SPREADING 40-20 Input K11 11:1 /11.5_3.C8 SWITCH IGNITION Input
5:7 /9.4_1.B8 FAN SPEED Analog Input 7:15 /7.9_1.C8 SWITCH UNLOCK TW Input 11:2 /9.6_8.A8 INTERIOR LIGHT Input
7:16 /7.0_2.C8 SWITCH PISTOL Input 11:3 /9.6_8.B8 SWITCH BREAK CAB DOOR Input
5:8 /9.4_1.C8 TEMPERATURE Analog Input 11:4 /9.6_11.B8 SWITCH STEP IN LIGHT Input
5:9 /9.4_1.C8 DRAUGHT VALVE Analog Input K8 8:1 /7.8_1.E7 SWITCH LOCK LEVELLING Input 11:5
5:10 /9.4_1.D8 POT. FAN / TEMP / DEFROST 0V reference 8:2 /7.0_2.C8 SWITCH LOCK TILT Input 11:6 /9.6_8.D1 LAMP INTERIOR LIGHT 1.5A
5:11 /9.4_1.B1 POT. FAN / TEMP / D-VALVE Analog reference 5V 8:3 /8.2_1.B8 SWITCH OVERRIDE Input 11:7 See K13 REDUNDANT POWER Dig out
5:12 /1.0_1.A8 POT. ACCELERATOR 0V reference 8:4 /11.5_6.A8 SW. OPERATING POWER Input
5:13 /1.0_1.A1 POT. ACCELERATOR Analog reference 5V 8:5 /4.0_1.B8 SWITCH P-BRAKE OPEN Input 11:8 See K13 REDUNDANT POWER Dig out
5:14 /7.0_4.F8 OVERRIDE ALIGNMENT Input (K10:3) 8:6 /9.3_3.A8 SWITCH REV. SEAT C.W Input 11:9 See K13 REDUNDANT POWER Dig out
8:7 /9.3_3.B8 SWITCH REV. SEAT C.C.W Input 11:10 See K13 REDUNDANT POWER Dig out
D 8:8 /7.0_4.D8 LOCK TW / OHC UP Input 11:11 /9.7_1.B2 HORN 3A D
11:12 /9.7_1.D2 SWITCH SEAT 24V reference
8:9 /7.0_4.C8 UNLOCK TW / OHC DOWN Input

secuted.
11:13 /11.5_6.E8 FEEDBACK K2 Input

8:10 /7.5_1.C8 SWITCH 30-35 STOP Input 11:14 /9.7_1.D8 SWITCH SEAT Input
8:11 /7.5_3.B7 SWITCH AUT. 20-40 Input
8:12 /7.9_1.A8 SWITCH LOCK TW Input K12 12:1 /9.5_1.D1 MOTOR REAR WIPER 24V reference
8:13 /4.0_1.A8 SWITCH P-BRAKE LOCKED Input 12:2 /9.5_1.D8 MOTOR REAR WIPER Input
8:14 /9.1_1.A8 SWITCH S1 OPT. Input 12:3 /9.5_1.E1 MOTOR ROOF WIPER 24V reference
8:15 /9.3_3.B1 LIGHT SW. S169/S1010 PWM 1.5A 12:4 /9.5_1.E8 MOTOR ROOF WIPER Input
8:16 /7.9_1.C2 SWITCH ELSERVO PANEL 24V reference
K13 13:1-13:12 /11.6_1.D6 CAN-BUS
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Korsreferenslista DCF300-, DCE300- 0.0_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Crossreference list A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-D797-1
Pin Number Drawing Function Type

B B
Power /11.5_4.B5
CAN /11.6_1.E8
2:6 /4.8_1.A8 SENSOR BRAKE OIL TEMP. Temperature Input
2:11 /11.5_4.A5 Emergency stop Input
KDU contact K2
2:13 /10.6_1.A8 SENSOR HYDR. OIL TEMP. Temperature Input
2:15 /1.0_1.F8 SENSOR FUEL LEVEL Reostat In
2:16 /1.0_1.E1 D+ D+
C C
-D797-1
Pin Number Drawing Function Type Pin Number Drawing Function Type
1:1 /9.6_3.D1 LAMPS WORK LIGHT MAST 6A 1:21 /8.2_2.A7 SENSOR HYDR. SCALE LIFT Analog In 0-5V
1:2 /9.6_5.C1 SIDE POSITION LIGHT 1.5A 1:22 /8.2_2.D7 SENSOR HYDR. SCALE TILT Analog In 0-5V
1:3 /4.8_1.C1 RELAY COOLING FAN BRAKE OIL 1.5A 1:23 /7.7_2.D8 SENS.TILT ANGLE/FEEDBACK BRK FAN Analog In 0-5V
1:4 /7.2_1.C1 VALVE LIFT / LOWER 1.5A 1:24 /7.2_6.E8 SENSOR MAST POS/REGENERATING Analog In 0-5V
1:5 /7.7_1.C1 VALVE TILT 1.5A 1:25 /9.4_2.E1 COMPRESSOR AIR-CONDITION 1.5A
1:6 /8.2_2.C7 SENSOR HYDR. SCALE 0V Ref 1:26 /7.0_7.C8 SENSOR CAB TILT Dig In / 1.5A
1:7 /9.6_6.C1 BRAKE LIGHT LEFT 1.5A 1:27 /2.0_1.C8 SWITCH DECLUTCHING Analog In 0-5V
1:8 /8.2_2.A1 SENSOR HYDR. SCALE Analog Ref 5V 1:28 /9.6_5.B1 LAMP DIPPED LIGHT 6A
1:9 /9.6_6.C1 BRAKE LIGHT RIGHT 1.5A 1:29 /9.4_2.F1 COMPRESSOR AIR-CONDITION 1.5A
1:10 /9.7_2.B1 REVERSING ALARM 1.5A 1:30 /9.6_7.E1 LAMP DIRECTION LEFT 2.5A
D 1:11 /7.2_2.C7 MAST DOWN / REGENERATING LIFT Dig In / 1.5A 1:31 /9.6_7.D1 LAMP DIRECTION RIGHT 2.5A
D
1:12 /7.2_2.B7 CARRIAGE UP / REGENERATING LIFT Dig In / 1.5A 1:32 /1.0_1.F1 RELAY STARTING KEY 1.5A

secuted.

KDU contact K1
KDU contact K1
1:13 /4.0_1.D8 PRESSURE SWITCH ACCU. TANK Analog In 0-5V 1:33 /9.6_6.D1 REAR LIGHTS 1.5A
1:14 /10.6_1.B1 MOTOR COOLING FAN HYDR. OIL 10A 1:34 /4.0_1.E1 VALVE PARKING BRAKE 1.5A
1:15 /9.6_5.C1 HEAD LIGHT 6A 1:35 /10.4_1.D2 PUMP ATTACHMENT 1.5A
1:16 /7.2_1.C8 VALVE LIFT / BLOCK LIFT PWM 1:36 /8.2_3.C1 MAST POSITION 1.5A
1:17 /7.2_1.D8 VALVE LOWER / BLOCK LOWER PWM 1:37 /8.2_3.C8 MAST POSITION Dig In / 1.5A
1:18 /7.7_1.D8 VALVE TILT IN PWM 1:38 0V Ref
1:19 /7.7_1.C8 VALVE TILT OUT PWM 1:39 /10.4_1.C2 VALVE PUMP 2 1.5A
1:20 /9.6_5.E8 PRESSURE SWITCH BRAKE LIGHT Analog In 0-5V 1:40 /9.4_1.A8 PRESSURE SW. REFRIDGE Dig In / 1.5A
1:41 /4.0_1.C8 PRESSURE SWITCH P-BRAKE Analog In 0-5V
1:42 /9.0_1.C2 CENTRAL LUB. / WORK LIGHT OPT. 6A
E E

F F

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-D797-2
Power /11.5_5.D5
CAN /11.6_2C.E3
2:6 Temperature Input
2:11 /11.5_5.C4 Emergency stop Input
KDU contact K2
B B
2:15 Reostat In
2:16 D+
-D797-2
C C
1:1 /9.3_5.C1 HEAD LIGHT REAR 6A 1:21 /11.5_10.B8 OPT. Analog In 0-5V
1:2 /5.2_2.B1 VALVE MICRO STEERING RIGHT 1.5A 1:22 /11.5_10.B8 OPT. Analog In 0-5V
1:3 /5.2_2.C1 VALVE MICRO STEERING LEFT 1.5A 1:23 /11.5_10.C8 OPT. Analog In 0-5V
1:4 /7.10_1.B1 VALVE EXTRA FUNCT. OUT 1.5A 1:24 /11.5_9.C1 OPT. Analog In 0-5V
1:5 /7.10_1.C1 VALVE EXTRA FUNCT. IN 1.5A 1:25 /9.3_5.D1 LAMP REAR LIGHT FRONT 1.5A
1:6 /11.5_10.B1 OPT. 0V Ref 1:26 /11.5_11.D1 OPT. Dig In / 1.5A
1:7 /9.3_3.D1 SWITCHES SEAT POS. F/R 1.5A 1:27 Analog In 0-5V
1:8 /11.5_10.A1 OPT. Analog Ref 5V 1:28 /11.5_9.B1 OPT. 6A
1:9 /9.3_6.B1 VALVE STEERING FORWARD 1.5A 1:29 /9.3_7.A1 VALVE SEAT ROTATION C.W 1.5A
1:10 /9.3_6.C1 VALVE STEERING REVERSE 1.5A 1:30 /7.4_1.C1 VALVE SIDESHIFT RIGHT 2.5A
1:11 /11.5_11.B1 OPT. Dig In / 1.5A 1:31 /7.4_1.B1 VALVE SIDESHIFT LEFT 2.5A
1:12 /11.5_11.C1 OPT. Dig In / 1.5A 1:32 /7.5_1.E1 VALVE SPREADING IN 1.5A
KDU contact K1
KDU contact K1
1:13 /9.3_3.C8 SWITCH SEAT POS. F Analog In 0-5V 1:33 /7.5_1.E1 VALVE SPREADING OUT 1.5A
1:14 /11.5_9.A1 OPT. 10A 1:34 /9.3_7.B1 DAMPING TURNABLE SEAT 1.5A
1:15 /9.3_5.B1 LAMP DIPPED LIGHT REAR 6A 1:35 /9.3_7.C1 BRAKE TURNABLE SEAT 1.5A
D 1:16 /5.2_2.B8 VALVE MICRO STEERING PWM 1:36 /9.3_4.C2 LAMP BRAKE LIGHT FORWARD RIGHT 1.5A D
1:17 /7.10_1.B8 VALVE EXTRA FUNCT. PWM 1:37 /9.3_4.B2 LAMP BRAKE LIGHT FORWARD LEFT 1.5A
1:18 /7.4_1.B8 VALVE SIDESHIFT PWM 1:38 0V Ref

secuted.

1:19 /7.5_1.E8 VALVE SPREADING PWM 1:39 /9.3_7.B1 VALVE SEAT ROTATION C.C.W 1.5A
1:20 /9.3_3.D8 SWITCH SEAT POS. R Analog In 0-5V 1:40 /11.5_11.D1 OPT. Dig In / 1.5A
1:41 /11.5_10.A8 OPT. Analog In 0-5V
1:42 /11.5_9.D1 OPT. 6A
E E

F F

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-D791
Power /11.5_5.C5
CAN /11.6_2B.C3
B 2:6 Temperature Input B

2:11 /11.5_5.B4 Emergency stop Input
KDU contact K2
2:15 Reostat In
2:16 D+
-D791
C Pin Number Drawing Function Type Pin Number Drawing Function Type C
1:1 /9.6_2.C2 WORK LIGHT LEFT 6A 1:21 /7.10_2.B7 OPT. Analog In 0-5V
1:2 /7.3_1.B2 PROJECTING LEFT IN 1.5A 1:22 /7.9_2.D8 SENSOR UNLOCKED TW. LEFT Analog In 0-5V
1:3 /7.3_1.B2 PROJECTING LEFT OUT 1.5A 1:23 /7.9_2.E8 SENSOR LOCKED TW. LEFT Analog In 0-5V
1:4 /7.3_1.C2 PROJECTING RIGHT IN 1.5A 1:24 /7.9_2.B8 SENSOR LOCKED TW. RIGHT Analog In 0-5V
1:5 /7.3_1.D2 PROJECTING RIGHT OUT 1.5A 1:25 /7.9_1.C2 LAMP UNLOCKED TW 1.5A
1:6 /7.10_2.C7 OPT. 0V Ref 1:26 /7.9_2.C8 SENSOR ALIGNMENT REAR RIGHT Dig In / 1.5A
1:7 /7.9_1.E2 VALVE LOCK TWISTLOCK 1.5A 1:27 /7.9_2.E8 SENSOR ALIGNMENT REAR LEFT Analog In 0-5V
1:8 /7.10_2.B2 OPT. Analog Ref 5V 1:28 /7.5_3.D1 WARN. SIGNAL AUT. SPREADING 6A
1:9 /7.9_1.F2 VALVE UNLOCK TWISTLOCK 1.5A 1:29 /7.9_1.D2 LAMP LOCKED TW 1.5A
1:10 /7.9_2.C2 SENSORS ATTACHMENT 1.5A 1:30 /7.8_1.B2 VALVE LEVELLING LEFT 2.5A
1:11 /7.10_2.E7 SENSOR OPT. Dig In / 1.5A 1:31 /7.8_1.A2 VALVE LEVELLING RIGHT 2.5A
1:12 /7.5_2.D7 SENSOR DAMPING 20-40 Dig In / 1.5A 1:32 /7.4_2.B2 VALVE SIDESHIFT LEFT 1.5A
KDU contact K1
KDU contact K1
1:13 /7.9_2.D8 SENSOR ALIGNMENT FRONT LEFT Analog In 0-5V 1:33 /7.4_2.C2 VALVE SIDESHIFT RIGHT 1.5A
1:14 /9.14_1.D2 PUMP CENTRAL LUBRICATION 10A 1:34 /7.5_2.B2 VALVE SPREADING OUT 1.5A
D 1:15 /9.6_2.D2 WORK LIGHT RIGHT 6A 1:35 /7.5_2.C2 VALVE SPREADING IN 1.5A D
1:16 /7.3_1.B7 PROJECTING LEFT PWM 1:36 /7.10_2.C2 OPT. 1.5A
1:17 /7.3_1.C7 PROJECTING RIGHT PWM 1:37 /7.10_2.D2 OPT. 1.5A

secuted.

1:19 /7.5_2.B7 VALVE SPREADING PWM 1:39 /7.9_1.D2 LAMP ALIGNMENT 1.5A
1:20 /7.5_2.E7 SENSOR 30-35 STOP Analog In 0-5V 1:40 /7.9_2.A8 SENSOR ALIGNMENT FRONT RIGHT Dig In / 1.5A
1:41 /7.9_2.B8 SENSOR UNLOCKED TW. RIGHT Analog In 0-5V
1:42 /7.8_1.C2 VALVE UNLOCK LEVELLING 6A
E E

F F

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
S105-3 S105-1 M693
Choice: opt Choice: opt Central
mast fenders lubrication
Val: opt Val opt Central-
KDU stativ skärmar S199-3 S199-4 smörjning
D797-1 alt 1 X213

C D797-1 alt 2 X213 C
D797-1 alt 3 X213
D797-1 alt 4 X213
D797-1 + alt 5 X249 X240 X213
D797-2
D797-1 + alt 6 X249 X240 X213
D797-2
D797-1 + alt 7 X213 X249 X240
D D797-2 D
D797-1 + alt 8 X240/ X213

secuted.

D797-2 X249
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Sanningstabell opt DCF300-, DCE300- 0.1_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Truth table opt A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X005 -X040m -X040f -X066f -X066f -X040f -X040m -X005

Analog reference 5V K5:13 13 00513A 4 4 A0404 2 5V 0V 3 A0405 5 5 00512A 12 K5:12 0V reference
-D790-1 /9.3_3.D2 /9.3_3.E2 -D790-1
/0.0_1.D1 /0.0_1.D1
POT. ACCELERATOR POT. ACCELERATOR
-X038f -X038f
A 00513B 5 6 00512B A
-X690-1f -X006
-B690-1 BK 2 2 00611 11 K6:11 Analog Input
-D790-1
-X690-1f /0.0_1.B4
3
00513C 1 1 RD 1 2 WH 3 3 00512C
POT. ACCELERATOR 1
ACCELERATOR
-X016
24V D790-2/2:1 0161 1 K2:1 Input
/11.5_3.C7 -D790-2 -X066f -X040f -X040m -X006
/11.5_4.F4 D790-1/6:12 1 A0403 3 3 00612A 12 K6:12 Analog Input
/9.3_3.D6 -D790-1
SWITCH STARTER /0.0_1.B4
B POT. ACCELERATOR 2 B
-X016 -X038f
24V D790-2/2:2 0162 2 K2:2 Input 8 00612B
/11.5_3.C7 -D790-2
/11.5_4.F4
SWITCH PREHEAT /1.0_2B1.B1
/1.0_2C.C2
/1.0_2D.B2
-X210f /1.0_2F.C2
58-1/3:1 2101 1 58-1/3:1
/11.5_1.B5 /1.0_2G1.B1
/1.0_2B2.B7
/1.0_2D.B2
/1.0_2E2.B7
2102
/1.0_2F.C2
2 CHASSIS
/1.0_2G1.D6
/1.0_2A.B2
/1.0_2B1.B1
C /1.0_2C.C2 C
/1.0_2D.B2
/1.0_2E1.F1
CAN_J1939_+ 2033 30 3 /1.0_2F.B2
/11.6_1.C2 CAN_J1939_+
2034 /1.0_2G1.A1
/1.0_2A.B2
/1.0_2B1.B1
/1.0_2C.C2
/1.0_2D.B2
/1.0_2E1.F1
2034 30 /1.0_2F.B2
CAN_J1939_- 4 CAN_J1939_-
/11.6_1.C2 /1.0_2G1.A1
2033
-X210f /1.0_2A.E2
D 58-1/4:1 D
58-1/4:1 2105A 5 /1.0_2B1.B1
/11.5_1.C5 /1.0_2A.B2
/1.0_2B1.C1

secuted.

/1.0_2C.C2
/1.0_2D.B2
/1.0_2E1.C1
-X212 /1.0_2F.B2
D+ K2:16 16 21216 D+
-D797-1 /1.0_2G1.D1
/0.0_2.C4 6
D+ /1.0_1.E3
/1.0_2B2.B2
/1.0_2C.C2
/1.0_1.E6 2107A
/1.0_2D.B2
58-2/7:1 7 58-2/7:1
/11.5_1.C8 /1.0_2E2.B2
/1.0_2A.E2
/1.0_2B1.C1
E /1.0_2C.D2 E
/1.0_2D.C2
/1.0_2E1.C1
58-2/8:1 2108A 8 /1.0_2F.B2
/11.5_1.C8 58-2/8:1
/1.0_2G1.B1
/1.0_2A.C2
-X211 -X278f /1.0_2B1.D1
1.5A K1:32 32 21132 2 START
-D797-1 /1.0_2E1.E1
/0.0_2.D5
-B757
RELAY STARTING KEY -XB757 -XB757 -X212

2102 7572 2 2 1 1 21215 15 K2:15 Reostat In
-D797-1
U /0.0_2.C4
F SENSOR FUEL LEVEL F
FUEL LEVEL
-X37-211A
-X37-211 CHASSIS
Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets drivlina motor DCF300-, DCE300- 1.0_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring drivetrain engine A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
D5.2
-X279
2791 1
A A
-X279
2
-X279
-X37-212 #4153 8
-X279
9
-X279
-X210m 2103B 12
CAN_J1939_+ 3 2103A -X90017
/1.0_1.C6 -X279
2104B 13
/1.0_2A.F8
CAN_J1939_- 4 2104A -X90018
/1.0_1.D6 -X279
2108D 14
B -D794 B
D+ 6 2106 ENGINE
/1.0_1.D6
-X22
1 2108E
2 2798
3 2792
Diagnostics engine. 4 2104C
5 2799
6 2103C SWITCH CLOSES WHEN
C COOLANT LEVEL IS TOO LOW C
-K315 -B759
-X278m 2 2 1 1
START 2 2782A 85 86 2782B
/1.0_1.F6 COOLANT LEVEL
GY
W224
87A 30 #4152 -X37-212
87
-G660 BK
-M654 B+
STARTING KEY
30 31 W225 B- D+
M G
2
1
ALTERNATOR
D 50 W D
-X280m
STARTER

secuted.

1
2
-X280f
2105C
-X210m
58-1/4:1 5 2105B
/1.0_1.D6
6
E E
20
-K312
-X23f
2108D 2108F 86 85 2108G 8 3
2108E -X90016
58-2/8:1 8 2108B PREHEATER
/1.0_1.E6
/1.0_2A.B8
-E800
W6 30 87 W7 1 2

PREHEATER -D794
ENGINE
F D5.1 F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets motor TAD 722 DCF300-, DCE300- 1.0_2A
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring engine TAD722 A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XD794-1m
1/50
2/50
3/50
4/50
5/50
-X210m -XD794-1f 6/50
58-1/3:1 1 2101 -X90068 2101A 7 7/50
/1.0_1.C6
2101B 8 8/50
9/50
CAN_J1939_+ 3 30 2103 10/50
/1.0_1.C6
B 11/50 B
12/50
CAN_J1939_- 4 30 2104 13/50
/1.0_1.D6
14/50
15/50
58-1/4:1 5 2105 16/50
/1.0_1.D6
2101C 17 17/50
2105A 18 18/50
D+ 6 2106 -X90069 19/50
/1.0_1.D6
20/50
21/50
58-2/8:1 8 2108 22/50
/1.0_1.E6
C 23/50 C
24/50
25/50
26/50
-K360 27/50
-X278m 2105B 28 28/50
START 2 2782 85 86 W19F W19A 29 29/50
/1.0_1.F6
W19B 30 30/50
87 30 31/50
87A 32/50
33/50
STARTING SOLENOID 34/50
D 35/50 D
36/50

secuted.

37 37/50
36030
38 38/50
W19C 39 39/50
RD W19D 40 40/50
41/50
42/50
-G660 43/50
-M654 B+
44/50
30 31 I W19
B- 45/50
M G -X90070 46 46/50
50 W 47/50
E E
48/50
WH 49/50
W19E 50 50/50
W11
-D794 /1.0_2B2.D6

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets motor Cummins QSM11 DCF300-, DCE300- 1.0_2B1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring engine Cummins QSM11 A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
SWITCH CLOSES WHEN

B B
COOLANT LEVEL IS TOO LOW
-K322
/1.0_1.E6 -X210m -X759f -X759m -B759 -X759m -X759f -X210m

58-2/7:1 7 2107 86 85 86 85 2102A 2 2 BK 2 2 1 1 GY 1 1 2102 2 CHASSIS
/11.5_1.C8 /1.0_1.C6
/1.0_2B2.C3
-XD794-2f -XD794-2m
-K322
C W25 5 5/31
30 30 87 87 C
87A 87a
W26 6 6/31
/1.0_2B2.B3
COOLANT LEVEL
7/31
W25A 19 19/31
-D794 /1.0_2B1.F6
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets motor Cummins QSM11 DCF300-, DCE300- 1.0_2B2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring engine Cummins QSM11 A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X22
1 221
2 2798
3 2793
Diagnostics engine. 4
5 2797
6
B B
-X210m
58-1/3:1 1 2101
/1.0_1.C6
-X279f -X279m
CAN_J1939_+ 3 2103 30 2103 1 1/8
/1.0_1.C6
2104 2 2/8
CAN_J1939_- 4 2104 2793 3 3/8
C /1.0_1.D6 C
2101 4 4/8
D+ 6 2106
/1.0_1.D6
2795 5 5/8
/1.0_1.E6 2107 -X90082 2107
58-2/7:1 7 6 6/8
/11.5_1.C8
2797 7 7/8
58-2/8:1 8 2108A 2798 8 8/8
/1.0_1.E6
-D794
D D
Only 950 & 1250

secuted.

Volvos harness
-XG660-D+ W
E L E
1 15
65430 1
BS
DFM
-M654
-G660 -G660
B+ 30 31
M
D+ B-
G

50
ALTERNATOR STARTER
W
F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets motor 950,1240,1250 DCF300-, DCE300- 1.0_2C
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring engine 950,1240,1250 A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-G660
B+
2106 D+ B-
A G A
ALTERNATOR
W
-X210m
58-1/3:1 1 2101
/1.0_1.C6
CHASSIS 2 2102
/1.0_1.C6
-X279f -X279m
CAN_J1939_+ 3 2103 30 2103 1 1/8
/1.0_1.C6
2104 2 2/8
CAN_J1939_- 4 2104 2102 3 3/8
B /1.0_1.D6 B
2101 4 4/8
D+ 6 2106 2108 5 5/8
/1.0_1.D6
2107 6 6/8
/1.0_1.E6 2107
58-2/7:1 7 7/8
/11.5_1.C8
8/8
58-2/8:1 8 2108
/1.0_1.E6
-X22A -X22f -X22m

1 221 1 1/6
2 222 30 2 2/6
C C
3 223 225 3 3/6
Diagnostics engine. 4/6
5 225 30 5 5/6
222 6/6
-XK312Am -XK312Af
1 1/2
2 2/2
D D

secuted.

-K312 -D794
-XK312f -XK312f
1 86 85 2
Volvo harness
-XK312-30 30 87 -XK312-87 UH
PRE HEAT
-E800-1 -E800-2
E 1 2 1 2
-M654 E
Preheat cylinder Preheat cylinder
31 30 -XM654-30 31230
M
50
STARTER -E800-3 -E800-4
1 2 1 2
31287 -XE800

-E800-5 -E800-6
1 2 1 2
F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets motor TAD760 DCF300-, DCE300- 1.0_2D
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring engine TAD760 A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-D794
-F56
-XD794-3f -XD794-3m
7941 1 1/4
A A
7942 2 2/4
65430-2 B:1 30A 2:1 7943 3 3/4
2:2 7944 4 4/4
-XD794-2m
1/50
2/50
3/50
4/50
B 5/50 B
-F56 6/50
1 7/50
2 Power ECU D794
3 8/50
4 9/50
5 10/50
-X37-217
6
-X210m 11/50
D+ 6 2106 12/50
/1.0_1.D6
13/50
58-2/8:1 8 2108 14/50
/1.0_1.E6
15/50
16/50
C 17/50 C
18/50
19/50
ALTERNATOR P 20/50
B WH 21/50
L
G B- 22/50
B+ 23/50
-G660 24/50
25/50
-K312 26/50
-F51 -E800
65430-1 31230 30 87 31287 1 2 -XD794-2f 27/50
1 2
125A /1.0_2E1.E5 PREHEATER D794-28 28 28/50
/1.0_2E2.D7
D RELAY PREHEATER 29/50 D
30/50
-M654

secuted.

31/50
30 31 D794-32 79432 32 32/50
M /1.0_2E2.C2
RD 33/50
50 34/50
STARTER
35/50
36/50
-K360 37/50
36030 30 87 36087 38/50
/1.0_2E1.E3 2108 39 39/50
RELAY STARTER 31286 40 40/50
E 41/50 E
-K312 31285 42 42/50
86 85 43/50
-K360 /1.0_2E1.D5 44/50
-X278m
START 2 2782 86 85 W19 RELAY PREHEATER 45/50
/1.0_1.F6
/1.0_2E1.E3 30 46 46/50
RELAY STARTER 47 47/50
-X37-217 48/50
49/50

-X210m 50/50
CAN_J1939_+ 3 2103 30
F /1.0_1.C6 F
CAN_J1939_- 4 2104
/1.0_1.D6

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets motor QSB6,7 DCF300-, DCE300- 1.0_2E1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring engine QSB6,7 A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B SWITCH CLOSES WHEN B

COOLANT LEVEL IS TOO LOW
-K322
/1.0_1.E6 -X210m -X759f -B759 -X759f -X210m

58-2/7:1 7 2107 86 85 86 85 2102A 2 2 1 1 2102 2 CHASSIS
/11.5_1.C8 /1.0_1.C6
D794-32 79432 30 30 87 -XR820f -XR820m

/1.0_2E1.D7 -R820-10
87A 87a 322-87A A A 1 2
18,0kOHM
COOLANT LEVEL
C -R820-11 C
322-30 B B 1 2
560kOHM
C C
V
Coolant level OK = 0,5V-2,1V
Coolant level low = 4,5V-4,9V
79428 D794-28
/1.0_2E1.D7
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets motor QSB6,7 DCF300-, DCE300- 1.0_2E2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring engine QSB6,7 A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X283m -X281f -X281m

1/6 1 30 2831 1 1 30 2811
-X283f 2/6 2832 2812
2 2 2
3/6 3 2833 3 3 2813
-X280m
A 58-1/2:1 2801 1 -EATS 5/6 5 30 2835 5 5 30 2815 A
/11.5_1.B5
6/6 6 2836 6 6 2816
-X280m
37-200D13 2
6540-30B
2
3
5
6
1
-XG6600-B+
-X281Af
-X37-200D13
-G6600 B+
-XG6600f-D+ -XG6600m-D+
-X37200 #7679
1 1 D+ B-
2/6
3/6
5/6
6/6
1/6
G SWITCH CLOSES WHEN
ALTERNATOR COOLANT LEVEL IS TOO LOW
-X281Am
W
-X210m -X279f -X279m
CAN_J1939_+ 3 2103 30 1 1/8
/1.0_1.C6
B CAN_J1939_- 4 2104 2 2/8 -B7590
/1.0_1.D6 B
-X210m 3 3/8 1 1 2 2
D+ 6 2106 4 4/8
/1.0_1.D6
279A 5 5/8 -X7590f -X7590m
-XSP279
58-2/8:1 8 2108 6/8 1 1 GY
/1.0_1.E6
7 7/8 2 2 BK
8 8/8
-X210m
58-1/3:1 1 2101
/1.0_1.C6 -X210m -XSP2102
C CHASSIS 2 2102 2793 C
/1.0_1.C6
-X22m
1 279B
2 30 2798
3 2793
5 30 2797
Volvo Diagnostics -XK3120Am -XK3120Af

1 1/2
Electric Box Chassis 2 2/2
D D

secuted.

-K3120 -D7940
-XK3120f -XK3120f
1 86 85 2
-M6540 -XM6540-30B Volvo harness
6540-30B
-XM6540-30A -F9951 -XK3120-30 -XK3120-87
31 30 6540-30A 31230 30 87 UH
M 1 2
125A
50 PRE HEAT
STARTER
E E
-XE8000 -E8000-1
31287 1 2
Preheat

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets motor D7,D13 DCF70- 1.0_2F
Sq. RSO 100204 A47137.0100
Name
R
E³ DRAWING
Wiring engine D7,D13 A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X285f -X285m -X284f

2851 WH 4 1 1 2841 WH 4 1 1
A /1.0_2G1.C6 A
-X37-200D13 58-1/3:2 2853 GY 2.5 3 3 2843 GY 2.5 3 3
/11.5_1.B5 ASM
-X37200 58-1/2:2 2854 GY 4 4 4 2844 GY 4 4 4 -D7940
/11.5_1.B5
-X210m
CAN_J1939_+ 3 30 21003 GN 0.75
/1.0_1.C6 Volvo wiring
CAN_J1939_- 4 21004 YE 0.75 -X304m_BB -X304f
/1.0_1.D6
1 1
Volvo wiring
2 2 30402 GN 0.75
6 6
-X304m_BB -X304f
B 3 3 -X279f B
4 4 30404 YE 0.75 30 1
5 5 2
-X210m 3 To Volvo Wiring D11
58-1/3:1 1 21001 GY 1.5 4
/1.0_1.C6 /1.0_2G2.C7
58-2/8:1 8 21008 GY 0.75 5
/1.0_1.E6
-X305m_BB -X305f Volvo D8/D11
1 1 7
2 2 30502 GY 0.75 8 To Volvo Wiring D8
3 3 /1.0_2G1.A6
/1.0_2G3.C7
4 4
5 5 -D7940
C 6 6 C
-X22Af -X22Am -X22f -X22m

1 1 22001 WH 0.75 1 1 30503 GY 0.75
9937-201E05 BK 0.75
Diagnostic 3 3
connector 4 4 30 22004 GN 0.75 4 4 30 2204 GN 0.75 -X210m
interface 6 6 22006 YE 0.75 6 6 2206 YE 0.75 21002 WH 2.5 2 CHASSIS
/1.0_1.C6
#Chassis
/11.5_1.E6
D D
-G6600
B+

secuted.

-X210m -XG6600-D+
D+ 6 21006 GY 0.75 1 D+ B-
/1.0_1.D6 G
-X9937-203
W
-M6540
-XM6540-30-1 30 31 -XM6540-31-1
#16100 W4 RD 70 W5 BK 70
/11.5_1.F1 M /11.5_1.F2
50
E E
-Y6450
-X278m -X645f
1 27801 GY 1.5 1 1 2
/9.4_2.E3
Magnetic clutch, compressor(opt)

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets Motor Volvo D8-D11, Steg4 DCF70- 1.0_2G1
Sq. PLT 141028 A47137.0100
Name
R
E³ DRAWING
PLT Klass/Class
Wiring diagram Volvo D11, Stage4 A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
1 Start Battery (24V)

2 Main Switch
3 Starter motor
4 Alternator
5 Relay module
B B
6 Erergency stop
7 8-pin connector, engine, (XD7940)
8 16-pin connector, EATS
9 Dosing valve, EATS injection
10 Connection, circuit breakers FROM Kalmar interface
11 Circuit breakers
12 Sensor, NOX-sensor (Upstream)
13 Pre-heater relay /1.0_2G1.B7
C C
14 14-pin connector, injectors
15 Dump valve, turbocharger (WGT)
16 EGR valve, (LISK)
17 Switch, coolant level
18 Coolant temerature sensor
19 Throttle sensor
20 Fuel pressure sensor
D 21 Exhaust back pressure D
22 Oil pressure sensor

secuted.

23 Sensor, oil level/temperature
To Aftertreatment
24 Sensor, boost pressure/temperature
/1.3.D6
25 Electric fan
26 Sensor, air filter indicator
27 Sensor, camshaft signal
28 Sensor, crankshaft signal
E 29 Fuel injection E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets motor Volvo D11,Steg 4 DCF70- 1.0_2G2
Sq. PLT 141028 A47137.0100
Name
R
E³ DRAWING
PLT Klass/Class
Wiring diagram Volvo D11,Stage 4 A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
1 Start Battery (24V)

2 Main Switch
3 Starter motor
4 Alternator
5 Relay module
6 Erergency stop
B
7 8-pin connector, engine, (XD7940)
B
8 16-pin connector, EATS
9 Dosing valve, EATS injection
10 Connection, circuit breakers
From Kalmar interface
11 Circuit breakers
12 NOX-sensor
13 Pre-heater relay /1.0_2G1.C7
14 14-pin connector, injectors
C
15 Connection, VGT C
16 Connection, EGR
17 Switch, coolant level
18 Temperature, EGR
19 Coolant temerature sensor
20 Throttle sensor
21 Exhaust back pressure
22 Oil pressure sensor
D 23 Fuel pressure sensor D
24 Sensor, oil level/temp To ACM

secuted.

25 Sensor, boost pressure/temp
/1.3.D6
26 Sensor, differntial pressure, EBR
27 Sensor, rail pressure
28 Sensor, air filter indicator (pressure)
29 Sensor, camshaft signal
30 Electric fan
E 31 Sensor, crankshaft signal E
32 MPROP
33 PRV
34 Sensor, turbocharger rpm

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Kretsschema efterbehandling Volvo D11,S DCF70- 1.0_2G3
Sq. PLT 2015-05-08 A47137.0100
Name
R
E³ DRAWING
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr Klass/Class
Wiring diagram exhaustsystem Volvo D11, A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
1 Main connection for ACM unit

C 2 Hose heaters C
3 Muffler connector
4 Pump unit connector
5 Tank heating valve
6 16-pole EATS connector
7 LT sensor (AdBlue)
/1.0_2G2.D7
/1.0_2G3.D7
D D
From Volvo D8 D11

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Kretsschema efterbehandling Volvo D8 D1 DCF70- 1.3
Sq. PLT 141030 A47137.0100
Name
R
E³ DRAWING
Wiring diagram exhaustsystem Volvo D8-D A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X017
-S162 MULTI-SWITCH 12 K3:12 Input
-D790-2
/11.5_4.F4
/9.6_4.C4
GEAR SWITCH REVERSE
R R BK/WH/GN
-X017
24V reference K3:10 10 RD 15/1 N N
-D790-2
/11.5_4.F4
-X017
24V REF TO GEAR SWITCH F F BK/GN 11 K3:11 Input
-D790-2
/11.5_4.F4
GEAR /9.5_1.B4 GEAR SWITCH FORWARD
B B
-X038f -X038m -S220-1 -X038m -X038f -X006

790-1:5-1/24V 0811 0381A 1 1 BK 1 2 BN 2 2 0382A 00614 14 K6:14 Input
/9.1_1.C2 -D790-1
BU 3 /0.0_1.B4
DECLUTCHING PEDAL DECLUTCHING
-XS220-3f -XS220-3f
0381B 1 790-1:5-1/24V 790-1/6:14 2 0382B
C /9.3_3.F2 /9.3_3.F6 C
-S220-2
P
-X211
58-2/5:1 216-1B 1 2 21127 27 K1:27 Analog In 0-5V
/9.6_5.E2 -D797-1
58-2/5:1 216-1C /0.0_2.D5
/4.0_1.C2 DECLUTCHING
SWITCH DECLUTCHING
/2.0_2A1.B2
/2.0_2B1.A2
-X205m /2.0_2C1.B1
CAN_J1939_+ 30 2035 A CAN_J1939_+
D /11.6_1.C2 /2.0_2D1.B1 D
2036

secuted.

/2.0_2A1.B2
/2.0_2B1.A2
30 2036
/2.0_2C1.B1
CAN_J1939_- B CAN_J1939_-
/11.6_1.C2 /2.0_2D1.A1
2035
/2.0_2A1.C7
/2.0_2B1.C7
-X201f /2.0_2C1.C8
2011 1 CHASSIS
/2.0_2D1.C8
/2.0_2A1.C2
/2.0_2B1.C2
E /2.0_2C1.C1 E
58-1/5:1 2012 2 58-1/5:1
/11.5_1.C5 /2.0_2D1.C1
/2.0_2A1.C7
/2.0_2B1.C7
/2.0_2C1.C8
2013 3 CHASSIS
/2.0_2D1.C8
/2.0_2A1.C2
/2.0_2B1.C2
/2.0_2C1.C1

-X37-211B 58-2/6:1 2014 4 58-2/6:1
/11.5_1.B8 /2.0_2D1.D1
F -X37-211 #4551 F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets drivlina växellåda DCF300-, DCE300- 2.0_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring drive train gearbox A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-D793
CAN
-X205f -X252f
CAN_J1939_- B 252A2 A2 L2 ECU793
/2.0_1.D7 CAN L
CAN_J1939_+ A 252B2 B2 M2
/2.0_1.D7 CAN H
C
B B
251K3D 0V_ref
/2.0_2A2.E2
C C
-D793
-X201m -X251f -X251f -X201m
58-1/5:1 2 251A1 A1 A1
ECU793 A3 A3 251A3 1 CHASSIS
/2.0_1.E7 PPWR Power Supply GND /2.0_1.E7
-X252f -X252f
58-2/6:1 4 252F2 F2 S2 S3 F3 252F3B 252F3A 3 CHASSIS
/2.0_1.F7 SPWR VFSGND /2.0_1.E7
CHASSIS 252F3D
D /2.0_2A3.E7 D

secuted.

-D793
RS 232
E ECU793 -X252f -X261m E
N2 C2 252C2 A
RxD
P2 D2 252D2 B
TxD
C
251K3E 0V_ref
/2.0_2A2.E2

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets växellåda TE32 DCF300-, DCE300- 2.0_2A1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring gearbox TE32 A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X251f
RPM B3 B3 251B3
-D793
-XB752
-B752 1 1
A -X251f A
2 2 251C3 C3 C3 RPM
-D793
DRUM SPEED
-X251f
RPM D3 D3 251D3
-D793
-XB758
-B758 1 1 -X251f
2 2 251E3 E3 E3 RPM
-D793
OUTPUT SPEED
B B
-B758/766
-XB766 -X251f
T T 1 251H3 H3 H3 Analogue Input
-D793
- 2 251G3
+ 3 251F3 -X251f
G3 G3 RPM
-D793
ENGINE SPEED/GEARBOX TEMPERATURE
-X251f
F3 F3 RPM
-D793
-S221
C -XS221 C
251J3B
-X37-Gearbox
1 T 2
TEMP SWITCH COOLER IN

(CONVERTER OUT TEMP)
-X251f
251J3A J3 J3 Analogue Input
-D793
-X252f -R8 -R7
5V Analogue Ref M1 B1 252B1 1 2 251J3C 1 2
-D793
10KOhm 10KOhm
251K3B
-X252f
D RPM R2 E2 252E2 D
-D793
-X251f
K3 Signal GND

secuted.

-XB751 K3
-D793
-B751 1 1
2 2 251K3C
TURBINE SPEED
0V_ref 251K3D 251K3A
/2.0_2A1.B7
0V_ref 251K3E
/2.0_2A1.E7
E -B765
E
P PRESURE FEEDBACK SENSOR
-X251f -X253f -X253f
Rheostat Input A2 A2 251A2 11 15 251K3F
-D793
2K2
2K2

F F

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6069
-X251f -X253f -X253f -X251f
Analogue Output D1 D1 251D1 1 1 2 2 251E1 E1 E1 Analogue Output
-D793 -D793
VFS 2ND/4TH
-Y630
-X251f -X253f -X253f -X251f
Analogue Output B1 B1 251B1 3 1 2 4 251C1 C1 C1 Analogue Output
B -D793 -D793 B
VFS FWD
-Y6067
-X251f -X253f -X253f -X251f
Analogue Output H1 H1 251H1 5 1 2 6 251J1 J1 J1 Analogue Output
-D793 -D793
VFS 1ST/3RD
C C
-Y631
-X251f -X253f -X253f -X251f
Analogue Output F1 F1 251F1 7 1 2 8 251G1 G1 G1 Analogue Output
-D793 -D793
VFS REV
-Y6066
-X251f -X253f -X253f -X251f
Digital Output K1 K1 251K1 9 1 2 10 251K2 K2 K2 Digital Output
-D793 -D793
D D

secuted.
DRIVE

-Y6074
-X251f -X253f -X253f
Digital Output E2 E2 251E2 12 1 2 14 252F3D CHASSIS
-D793 /2.0_2A1.D2
2/4 SELECT
-Y6075
E -X251f -X253f E
Digital Output F2 F2 251F2 13 1 2
-D793
1/3 SELECT

F F

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-D793
CAN
-X205f -X252f
CAN_J1939_- B 30 252A2 30 A2 L2 ECU793
A /2.0_1.D7 CAN L A
CAN_J1939_+ A 252B2 B2 M2
/2.0_1.D7 CAN H
B B
-D793
C -X201m -X251f -X251f -X201m C
58-1/5:1 2 251A1 A1 A1
-X201m -X252f -X252f -X201m
58-2/6:1 4 252F2 F2 S2 S3 F3 252F3B 3 CHASSIS
/2.0_1.F7 SPWR VFSGND /2.0_1.E7
0V_ref 252F3C
/2.0_2B2.F7
252F3A
0V_ref 252F3D
/2.0_2B3.E8
D D
-D793

secuted.

RS 232
ECU793 -X252f -X261m
N2 C2 252C2 A
RxD
P2 D2 252D2 B
TxD
C
251K3D 0V_ref
/2.0_2B2.E1
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets växellåda TE17 DCF300-, DCE300- 2.0_2B1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X251f
RPM B3 B3 251B3
-D793
A -XB752f A
DRUM SPEED -B752 1 1 -X251f
2 2 251C3 C3 C3 RPM
-D793
DRUM SPEED
DRUM SPEED
-X251f
RPM D3 D3 251D3
-D793
-XB758f
OUTPUT SPEED -B758 1 1 -X251f
2 2 251E3 E3 E3 RPM
-D793
OUTPUT SPEED
OUTPUT SPEED
B B
-X251f
251H3 H3 H3 Analogue Input
-D793
GEARBOX TEMPERATURE
-B758/766
-XB766f
T T B -X251f
- C 251G3 G3 G3 RPM
-D793
+ A
ENGINE SPEED/GEARBOX TEMPERATURE
C ENGINE SPEED/GEARBOX TEMPERATURE C
-X251f
251F3 F3 F3 RPM
-D793
-S221
-XS221
2211 1 2 T 1 ENGINE SPEED
-X37-GND_GEARBOX
TEMPERATURE SWITCH COOLER IN/CONVERTER OUT
-X251f
251J3 J3 J3 Analogue Input
-D793
-X252f -R820-8 -R820-9
5V Analogue Ref M1 B1 252B1 1 2 1 2 251K3B TEMPERATURE SWITCH COOLER IN
D -D793 D
10KOhm 10KOhm
TEMPERATURE SWITCH COOLER IN

secuted.
0.6W 0.6W

-X252f
RPM R2 E2 252E2
-D793
-XB751f
TURBINE SPEED -B751 1 1 -X251f
2 2 251K3C 251K3A K3 K3 Signal GND
-D793
TURBINE SPEED
0V_ref 251K3D
/2.0_2B1.E7
E E
-B765
P PRESSURE FEEDBACK SENSOR

-X251f -X253f -X253f
Rheostat Input A2 A2 251A2 11 1 2 12 252F3C 0V_ref
-D793 /2.0_2B1.D2
2K2
PRESSURE FEEDBACK SENSOR

1 2
F 2K2
F

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A -Y630 A
-X251f -X253f -X253f -X251f
-D793 -D793
VFS FWD
-Y6067
-X251f -X253f -X253f -X251f
Analogue Output H1 H1 251H1 5 1 2 6 251J1 J1 J1 Analogue Output
B -D793 -D793 B
VFS 1ST/3RD
-Y1
-X251f -X253f -X253f -X251f
-D793 -D793
C C
VFS 2ND
-Y631
-X251f -X253f -X253f -X251f
-D793 -D793
VFS REV
D D

secuted.

-Y6066
-X251f -X253f -X253f -X251f
Digital Output K1 K1 251K1 9 1 2 10 251K2 K2 K2 Digital Output
-D793 -D793
DRIVE
E E
-Y6075
-X251f -X253f -X253f
Digital Output F2 F2 251F2 13 1 2 14 252F3D 0V_ref
-D793 /2.0_2B1.D2
1/3 SELECT

F F

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-D793
CAN
-X205f -X252f
CAN_J1939_- B 30 252A2 A2 L2 ECU793
/2.0_1.D7 CAN L
CAN_J1939_+ A 252B2 B2 M2
/2.0_1.D7 CAN H
B B
-D793
-X201m -X251f -X251f -X201m
58-1/5:1 ECU793
2 251A1A 251A1B A1 A1 A3 A3 251A3 1 CHASSIS
/2.0_1.E7 PPWR GND /2.0_1.E7
Power Supply
-X252f -X252f
251A1C F2 S2 S3 F3 252F3B 252F3A 3 CHASSIS
SPWR VFSGND /2.0_1.E7
CHASSIS 252F3C 252F3C

C /2.0_2C3.C7 C
CHASSIS
/2.0_2C3.D7
CHASSIS 252F3E 252F3E
/2.0_2C3.E7
-X201m -X252f
58-2/6:1 R2
4 252E2A 252E2B E2
/2.0_1.F7 -D793
PON
252E2C 252E2C F58-2/5:1
/2.0_2C3.E2
D D

secuted.

-D793
RS 232
ECU793 -X252f -X261m
N2 C2 30 252C2 A
RxD
P2 D2 252D2 B
TxD
C
251K3D X251:K3
E /2.0_2C2.D2 E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets Dana TE32FF DCF300-, DCE300- 2.0_2C1
Sq. TKB 090923 A47137.0100
Name
R
E³ DRAWING
TKB 090923 Klass/Class
Wiring Dana TE 32FF A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A -X251f A
RPM B3 B3 251B3
-D793
-XB752f1
DRUM SPEED, SS0 -B759 1 1 -X251f
2 2 251C3 C3 C3 RPM
-D793
DRUM SPEED
DRUM SPEED, SS0
-X251f
RPM D3 D3 251D3
-D793
-XB758f1
OUTPUT SPEED, SS1 -B760 1 1 -X251f
2 2 251E3 E3 E3 RPM
-D793
OUTPUT SPEED
B B
OUTPUT SPEED, SS1
252B1B 252B1B 5V
/2.0_2C3.C2
252B1C 252B1C 5V
/2.0_2C3.D2
-X252f -S2210
5V Analogue Ref M1 B1 252B1A 251J3B 1 T 2
-D793
TEMPERATURE SWITCH COOLER IN, ANI4 TEMPERATURE SWITCH COOLER IN -X251f

C C
-D793
252B1D 1 2 251J3C 1 2 TEMPERATURE SWITCH COOLER IN, ANI2

10KOhm 10KOhm
0.6W 0.6W
251K3B
-X251f
RPM G3 G3 251G3
-D793 -X251f
K3 K3 Signal GND
D -D793 D
TURBINE SPEED, SS3 -B7510 1

secuted.

2 251K3C SGND
TURBINE SPEED
251K3A
X251:K3 251K3D 251K3D

/2.0_2C1.E8
X251:K3 251K3H 251K3H
/2.0_2C3.C7
X251:K3 251K3E 251K3E
/2.0_2C3.D7
-X251f
RPM F3 F3 251F3
-D793
E E
ENGINE SPEED, SS2 -B7530 1
2 251K3F
ENGINE SPEED
-B7660
-X251f

Analogue Input H3 H3 251H3 1 T 2 251K3G
-D793
U
F SUMP TEMPERATURE, ANI1 SUMP TEMPERATURE F

Ruta Sign.
Sq. TKB 090923 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-Y6067
-X251f -X251f
Analogue Output D1 D1 251D1 1 2 251E1 E1 E1 Analogue Output
-D793 -D793
A A
1ST/3RD PROPORTIONAL SOLENOID, ANO1+ 1ST/3RD PROPORTIONAL SOLENOID, ANO1-
1ST/3RD PROPORTIONAL SOLENOID
-Y6069
-X251f -X251f
Analogue Output F1 F1 251F1 1 2 251G1 G1 G1 Analogue Output
-D793 -D793
2ND/4TH PROPORTIONAL SOLENOID, ANO2+ 2ND/4TH PROPORTIONAL SOLENOID, ANO2-

2ND/4TH PROPORTIONAL SOLENOID
-Y6300
B -X251f -X251f B
Analogue Output B1 B1 251B1 1 2 251C1 C1 C1 Analogue Output
-D793 -D793
FWD/REV PROPORTIONAL SOLENOID, ANO0+ FWD/REV PROPORTIONAL SOLENOID, ANO0-

FWD/REV PROPORTIONAL SOLENOID
-B6067
5V 252B1B B A 251K3H X251:K3
/2.0_2C2.C7 P /2.0_2C2.D2
C
U
-X251f
1ST/3RD PRESSURE SENSOR 251A2 A2 A2 Rheostat Input
-D793
C 1ST/3RD PRESSURE SENSOR, ANI0 C

-Y6075
-X251f
Digital Output F2 F2 251F2 1 2 252F3C CHASSIS
-D793 /2.0_2C1.C2
1ST/3RD SELECTOR, DO2

1ST/3RD SELECTOR
-B6069
5V 252B1C B A 251K3E X251:K3
/2.0_2C2.C7 P /2.0_2C2.E2
C
U
-X252f
2ND/4TH PRESSURE SENSOR 252F1 F1 S1 Analogue Input
-D793
D D
2ND/4TH PRESSURE SENSOR, ANI6
-Y6066F

secuted.

-X251f
Digital Output K1 K1 251K1 2 1 252F3D CHASSIS
-D793 /2.0_2C1.C2
FWD SELECTOR, DO0

FWD SELECTOR
-Y6066R
-X251f
Digital Output E2 E2 251E2 1 2 252F3E CHASSIS
-D793 /2.0_2C1.C2
E REV SELECTOR, D01 E

REV SELECTOR
-Y6074
-X251f
F58-2/5:1 252E2C 1 2 251K2 K2 K2 Digital Output
/2.0_2C1.D7 -D793
2ND/4TH SELECTOR, D03

2ND/4TH SELECTOR

F F

Ruta Sign.
Sq. TKB 090923 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-D793
CAN
-X205F -X252f
CAN_J1939_- B 252A2 30 A2 L2 ECU793
/2.0_1.D7 CAN L
CAN_J1939_+ A 252B2 B2 M2
/2.0_1.D7 CAN H
B B
-D793
-X201m -XSP201:2 -X252f -X252f -X201m
58-1/5:1 2 251A1A 251A1B A1 A1
-X252f -X252f -XSP201:3 -X201m
251A1C F2 S2 S3 F3 252F3B 252F3A 3 CHASSIS
SPWR VFSGND /2.0_1.E7
C C
CHASSIS 252F3C
/2.0_2D3.D7
CHASSIS 252F3D
/2.0_2D3.E7
CHASSIS 252F3E
/2.0_2D3.F7
-X201m -X252f
58-2/6:1 4 252E2 E2 R2
/2.0_1.F7 -D793
D PON D

secuted.

-D793
RS 232
ECU793 -X252f -X261m
N2 C2 30 252C2 A
RxD
P2 D2 252D2 B
TxD
E C E
251K3E 0V Analogue Ref

/2.0_2D2.D2

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets Dana TE17FF DCF300-, DCE300- 2.0_2D1
Sq. MLG 111021 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X251f
RPM B3 B3 251B3
-D793
-XB7520f
DRUM SPEED -B7520 1 1 -X251f
2 2 251C3 C3 C3 RPM
-D793
A DRUM SPEED A
DRUM SPEED
-X251f
RPM D3 D3 251D3
-D793
-XB7580f
OUTPUT SPEED -B7580 1 1 -X251f
2 2 251E3 E3 E3 RPM
-D793
OUTPUT SPEED
OUTPUT SPEED
B 252B1B 5V Analogue Ref

/2.0_2D3.C1 B
252B1C 5V Analogue Ref
/2.0_2D3.D1
-XS2210 -S2210
251J3B 1 1 T 2
-X252f -XSP252:B1 1
5V Analogue Ref M1 B1 252B1A TEMPERATURE SWITCH COOLER IN
-D793
5V Analogue Ref
-X251f
-D793
C TEMPERATURE SWITCH COOLER IN C

-R820-12 -R820-13
252B1D 1 2 251J3C 1 2 251K3B
10K Ohm 10KOhm

0,6W 0.6W
0V Analogue Ref 251KC

/2.0_2D3.C7
0V Analogue Ref 251K3D -X251f
/2.0_2D3.D7 1 -XSP251:K3
0V Analogue Ref 251K3E 251K3A K3 K3 Signal GND
/2.0_2D1.E6 -D793
0V Analogue Ref
D D
-X251f
RPM G3

secuted.

G3 251G3
-D793
TURBINE SPEED -XB7510f

-B7510 1 1
2 2 251K3F
TURBINE SPEED
-X251f
RPM F3 F3 251F3
-D793
ENGINE SPEED -XB7530f

-B7530 1 1
E E
2 2 251K3G
ENGINE SPEED
-B7660
-X251f -XB7660 -XB7660
Analogue Input H3 H3 251H3 1 1 T 2 2 251K3H
-D793
U
SUMP GEARBOX TEMPERATURE SUMP GEARBOX TEMPERATURE

F F

Ruta Sign.
Sq. MLG 111021 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-Y6067
-X251f -XY6067 -XY6067 -X251f
-D793 -D793
A A
1ST/3RD Proportional Solenoid + 1ST/3RD Proportional Solenoid -
1ST/3RD Proportional Solenoid
-Y6069
-X251f -XY6069 -XY6069 -X251f
-D793 -D793
2ND/4TH Proportional Solenoid + 2ND/4TH Proportional Solenoid -

2ND/4TH Proportional Solenoid
B B
-Y6096
-X251f -XY6096 -XY6096 -X251f
-D793 -D793
FWD/REV Proportional Solenoid + FWD/REV Proportional Solenoid -

FWD/REV Proportional Solenoid
0V Analogue Ref
/2.0_2D2.D2
-XB7651 -B7651 -XB7651
5V Analogue Ref 252B1B B B A A 251KC
/2.0_2D2.B7 P
C C C
U C
1ST/3RD Pressure Sensor -X251f
251A2 A2 A2 Rheostat Input
-D793
1ST/3RD Pressure Sensor
-Y6075
-X251f -XY6075 -XY6075
Digital Output F2 F2 251F2 1 1 2 2 252F3C CHASSIS
-D793 /2.0_2D1.C3
1ST/3RD Selector
1ST/3RD Selector
D D
0V Analogue Ref
/2.0_2D2.D2

secuted.

-XB7652 -B7652 -XB7652
5V Analogue Ref 252B1C B B A A 251K3D
/2.0_2D2.B7 P
C C
U
2ND/4TH Pressure Sensor
-X252f
252F1 F1 S1 Analogue Input
-D793
2ND/4TH Pressure Sensor
-Y6300
-X251f -XY6300 -XY6300
Digital Output K1 K1 251K1 2 2 1 1 252F3D CHASSIS
E -D793 /2.0_2D1.C3 E
FWD Selector
FWD Selector
-Y6310
-X251f -XY6310 -XY6310
Digital Output E2 E2 251E2 1 1 2 2 252F3E CHASSIS
-D793 /2.0_2D1.D3

REV Selector
F REV Selector F

Ruta Sign.
Sq. MLG 111021 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X008
+CAB 00813A 13 K8:13 Input
A -S107 -D790-1 A
/0.0_1.D4
24V D790-1/8:16 00816H 1
/7.5_3.B2 SWITCH P-BRAKE LOCKED
0
5 1
24V D790-1/8:16 00816J 5 10
/8.2_1.B2 1 7 0085
10 9 7 9
CHASSIS-37-D 0923F 00813B -X008
/7.5_3.B2 PARKING BRAKE
5 K8:5 Input
-D790-1
/0.0_1.D4
SWITCH P-BRAKE OPEN
B B
-S200
P
-X211
58-2/5:1 216-1C 1 2 21141 41 K1:41 Analog In 0-5V
/2.0_1.D2 -D797-1
/0.0_2.E5
PARKING BRAKE
PRESSURE SWITCH P-BRAKE
C C
-S204
P
-X211
216-1D 1 2 21113 13 K1:13 Analog In 0-5V
-D797-1
/0.0_2.D2
PRESSURE ACCUMULATORTANK
PRESSURE SWITCH ACCU. TANK
D D

secuted.

-Y642
E -X211 E
1.5A K1:34 34 21134 1 1 2 2 642 CHASSIS
-D797-1 /7.2_2.F5
/0.0_2.D5
VALVE PARKING BRAKE
PARKING BRAKE

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets bromssystem DCF300-, DCE300- 4.0_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring brake system A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-B772
-XB772f -XB772f -X212
2 2 T 1 1 2126 6 K2:6 Temperature Input
-D797-1
U /0.0_2.B4
BRAKE OIL TEMPERATURE SENSOR BRAKE OIL TEMP.
B B
7722
-K3774
-X211
1.5A K1:3 3 2113 86 85 86 85 W212G CHASSIS
C -D797-1 /11.5_3.D7 C
/0.0_2.D2
RELAY COOLING FAN BRAKE OIL
-M674
-XM674f -XM674m -XM674m -XM674f
58-1/6:1 377430 30 30 87 87 6741 1 1 1 2 2 2 6742
/11.5_1.C5 M
87A
COOLING FAN BRAKE OIL -X37-202B

COOLING FAN BRAKE OIL
-X37-202 #4617
D Feedback oil cooler brakes D

secuted.

-XM674Am -XM674Af -XM674Af -XM674Am
1 674A1A 674A1B 1 2 674A2 2
-X90101
-XB771m
674A1C C 24V D797-1/1:23
E /7.7_2.C5 E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets kyln. bromsl olja DCF300-, DCE300- 4.8_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring cooling brake oil A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
+CAB
-S149-2
1
0 -XS149-2m -XS149-2f -X009Af -X009Am -X009
-X009 -X009Am -X009Af -XS149-2f -XS149-2m 1 2 2 009910A 10 10 00910 10 K9:10 Input
A 24V reference K9:1 1 0091 1 1 0091A 1 1 5 -D790-1 A
-D790-1 /0.0_1.B6
/0.0_1.A6
HORN SWITCH HORN ARM REST
SWITCHES ARM REST
+CAB
-S113
1
0 -XS113m -XS113f -X009Af -X009Am -X009
-XS113f -XS113m 1 2 2 0095A 5 5 0095 5 K9:5 Input
0091B 1 1 5 -D790-1
/0.0_1.B6
SW ACT. MICRO STEERING
ACTIVATE LEVER / MICRO STEERING
B B
-X009Af -X009Am -X009
0094A 4 4 0094 4 K9:4 Input
1 = FORWARD -D790-1
+CAB /0.0_1.B6
-S160-2 0 = NEUTRAL SW FORWARD ARM REST
1 2 = REVERSE
0
2
1 1 -X009Af -X009Am -X009
0091C 3 3
7 7 0093A 3 3 0093 3 K9:3 Input
-D790-1
2 /0.0_1.B6
4
8 SW REVERSE ARM REST
-X009 -X009Am -X009Af -X009Af -X009Am
PWM 1.5A K9:2 2 0092 2 2 0092A 10 10 9 9 W11A 11 11 W11
-D790-1
/0.0_1.A6
FORWARD / REVERSE
LAMP F/R ARM REST
C C
-X825-Hm -X37-D X37-D

RD 1
-X825-Pm -R825-1 -X825-Pm

3
1 YE 1 2 GN 2
LEVER STEERING (P6)

-X825-Hm -X825-Hf -X009Af -X009Am -X009
WH 1 1 0098A 8 8 0098 8 K9:8 Analog Input
-D790-1
/0.0_1.B6
POT. MICRO STEERING (P6)
D D

secuted.

-X009 -X009Am -X009Af -X825-Pf -X825-Pm -R825-1 -X825-Pm -X825-Pf -X009Af -X009Am -X009
Analog reference 5V 3 0V reference
K9:7 7 0097 7 7 0097A 1 1 GN 1 2 BN 2 2 0096A 6 6 0096 6 K9:6
-D790-1 -D790-1
/0.0_1.B6 /0.0_1.B6
POT. MICRO STEERING MICRO STEERING (P6) POT. MICRO STEERING
-X825-Hm -X825-Hf -X009Af -X009Am -X009

-R825-2 YE 2 2 0099A 9 9 0099 9 K9:9 Analog Input
-D790-1
3 /0.0_1.B6
GY 1 2 BU
POT. MIC STEER/6TH LEV (P7)
MICRO STEERING (P7)

OR 6th FUNCTION
E E
-X018 -XB770f -XB770m
1.5A K8:1 1 0181 1 1
-D790-2
/11.5_4.F4
SENSOR STEERING WHEEL
BN
-B770 -XB770m -XB770f -X018
BK 2 2 0182 2 K8:2 Input
-D790-2
/11.5_4.F4
STEERING WHEEL ANGLE
BU SENSOR STEERING WHEEL

F -XB770m -XB770f -X018
3 3 0183 3 K8:3 0V ref F
-D790-2
SENSOR STEERING WHEEL

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets spak/miniratt styrning DCF300-, DCE300- 5.2_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring lever/micro wheel A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y636-3/699-1
-X221 -X244f -X244m -X244m -X244f -X221
1.5A K1:2 2 2212 10 10 24410 1 1 2 2 24412B -X90039 24412A 12 12 22116 16 K1:16 PWM
-D797-2 -D797-2
/0.0_3.C2 /0.0_3.D2
VALVE MICRO STEERING RIGHT VALVE MICRO STEERING
VALVE EXRA 6:TH FUNCTION OUT MICRO/LEVERSTEERING RIGHT VALVE EXTRA 6:TH FUNCTION
B B
EXRA 6:TH FUNCTION OUT
-Y636-4/699-2
-X221 -X244f -X244m
1.5A K1:3 3 2213 11 11 24411 1 1 2 2 24412C
-D797-2
/0.0_3.C2
VALVE MICRO STEERING LEFT
VALVE EXTRA 6:TH FUNCTION IN MICRO/LEVERSTEERING LEFT
EXTRA 6:TH FUNCTION IN
C C
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets spak/miniratt styrning DCF300-, DCE300- 5.2_2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring lever/micro wheel A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XR8071m -XR8071f -X090m -X090f -X007

-R8071 RD 0903 0073 Analog Input
3 3 3 3 3 K7:3
-D790-1
/0.0_1.C4
A POT. LIFT / LOWER (P1) A
-X007 -X090f -X090m -XR8071f -XR8071m -X090m -X090f -X007
Analog reference 5V 3 0V reference
K7:2 2 0072 2 2 0902A 1 1 GN 1 2 YE 2 2 0901A 1 1 0071 1 K7:1
-D790-1 -D790-1
/0.0_1.C4 /0.0_1.B4
POTENTIOM. EL. SERVO LIFT / LOWER (P1) POTENTIOM. EL. SERVO
0902B
0901B
-XR8072m -XR8072f -X090m -X090f -X007
3 3 4 4 4 K7:4
-D790-1
/0.0_1.C4
POT. TILT (P2)
B -XR8072f -XR8072m B
3
1 1 GN 1 2 YE 2 2
TILT (P2)
Placering spakar från vänster
Placement levers from left
0902C
0901C
P1
-XR8073m -XR8073f -X090m -X090f -X007
P2 3 3 5 5 5 K7:5
-D790-1
/0.0_1.C4
P3 POT. SIDE SHIFTING (P3)
-XR8073f -XR8073m
P4 3
1 1 GN 1 2 YE 2 2
C C
P7 opt. FCH
SIDE SHIFTING (P3)
P5
0902D
0901D
-XR8074m -XR8074f -X090m -X090f -X007
3 3 6 6 6 K7:6
-D790-1
/0.0_1.C4
POT. SPREADING (P4)
-XR8074f -XR8074m
3
1 1 GN 1 2 YE 2 2
D D
SPREADING (P4)
PROJECTION LEFT

secuted.

0902E
0901E
-XR8075-1m -XR8075-1f -X090m -X090f -X007

-R8075-1 RD 0907 0077 Analog Input
3 3 7 7 7 K7:7
-D790-1
/0.0_1.C4
POT. EXTRA (P5)
-XR8075-1f -XR8075-1m
3
1 1 GN 1 2 YE 2 2
EXTRA (P5)
E E
LEVELLING
0902F
0901F
-XR8075-2m -XR8075-2f -X090m -X090f -X009

-R8075-2 RD 0908 0099 Analog Input
3 3 8 8 9 K9:9
-D790-1
POT 7TH LEVER (P7)

-XR8075-2f -XR8075-2m
3

1 1 GN 1 2 YE 2 2
F EXTRA (P7) F
PROJECTION RIGHT

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets elservo spakar DCF300-, DCE300- 7.0_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring el. servo levers A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Lever 815
-X007 -X091f -X091m -X815f T1-1 -X815f -X091m -X091f -X007f
Analog Reference 24V K7:12 12 00712 8 8 0918 15 15 14 14 0913 3 3 00714 14 K7:14 Input
-D790-1 -D790-1
/0.0_1.C4
SWITCHES EL. SERVO SW. SPREAD IN
T1-2 -X091m -X091f -X007f
16 16 0914 4 4 00713 13 K7:13 Input
B -D790-1 B
SW. SPREAD OUT
T2 -X091m -X091f -X007f
20 20 0915 5 5 00715 15 K7:15 Input
-D790-1
SWITCH UNLOCK TW
T4 -X091m -X091f -X007
19 19 0916 6 6 00716 16 K7:16 Input
-D790-1
/0.0_1.C4
SWITCH PISTOL
T3-1 -X091m -X091f -X008
17 17 0919 9 9 0081 1 K8:1 Input
-X007 -X091f -X091m -D790-1
0.5A K7:9 9 0079 7 7 0917 7 7
-D790-1
/0.0_1.C4 SWITCH LOCK LEVELLING
IND. LOCKED LEVELLING
C T3-2 -X091m -X091f -X008 C
18 18 0912 2 2 0082 2 K8:2 Input
-D790-1
CHASSIS-37-D 0923H 5 /0.0_1.D4
/7.8_1.F7
SWITCH LOCK TILT
6 6
-X090m -X090f -X007f
P1 8 8 0903 3 3 0073 3 K7:3 Analog Input
-X007f -X090f -X090m -D790-1
Analog Reference 5V K7:2 2 0072 2 2 0902 9 9
-D790-1
POT. LIFT / LOWER (P1)
POTENTIOM. EL. SERVO
-X090m -X090f -X007f
P2 4 4 0904 4 4 0074 4 K7:4 Analog Input
-D790-1
POT. TILT (P2)
D -X090m -X090f -X007f D

P3 11 11 0905 5 5 0075 5 K7:5 Analog Input
-D790-1

secuted.

POT. (P3)
-X090m -X090f -X007f

P4 1 1 0906 6 6 0076 6 K7:6 Analog Input
-D790-1
-X007f -X090f -X090m
0V Reference K7:1 1 0071 1 1 0901 10 10 POT. (P4)
-D790-1
POTENTIOM. EL. SERVO
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets elservo joystick DCF300-, DCE300- 7.0_2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring el. servo joystick A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
2028 58-3/3:1
/7.0_5.D2
-X207m -X207f
2075 5 5 2025 Alignment
B /7.0_5.E2 B
-X207f -X207m -R820-3 -X207m -X207f -X070m -X070f -X010

1 1 1 2 2 2 0701 1 1 A0103 3 K10:3 Input
-D790-1
/0.0_1.B6
820 Ohm
SENSOR ALIGNMENT
-X207m -X207f
2076 6 6 2026 Unlock TW
C /7.0_5.E2 C
-R820-4 -X207m -X207f -X070m -X070f -X069f -X069m -X008

3 3 0702 2 2 A0692 2 2 0089 9 K8:9 Input
-D790-1
D790-1_8:9 /0.0_1.D4
820 Ohm
/7.9_4.A8 UNLOCK TW / OHC DOWN
-X207m -X207f
2077 7 7 2027 Lock TW
D /7.0_5.F2 D

secuted.

-R820-5 -X207m -X207f -X070m -X070f -X069f -X069m -X008
4 4 0703 3 3 A0693 3 3 0088 8 K8:8 Input
-D790-1
/0.0_1.D4
820 Ohm
D790-1_8:8 LOCK TW / OHC UP
/7.9_4.A8
E E
-X081f
0053B 3
-X005 -X040m -X040f -X040f -X040m -X005

PWM (NPN) K5:3 3 0053A 1 1 A0401 6 6 00514 14 K5:14 Input (K10:3)
-D790-1 -D790-1
/0.0_1.C1 /0.0_1.D1

OVERRIDE ALIGNMENT OVERRIDE ALIGNMENT
F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets tillbehörsaggregat DCF300-, DCE300- 7.0_4
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring toplift frame A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-K3005
-X007 -X069m -X069f
0.5A K7:10 10 00710 4 4 A0694A 86 85 A0694B
-D790-1
/0.0_1.C4
RELAY ACTIVATE TW -X070f -X070m -X202f -X202m -X208f -X208m -X208Am
A0707C 30 87 A0706 6 6 0706 1 1 BN_/_1 1 1 BN_/_1 1
VALVE TWISTLOCK
TWISTLOCK
58-4/5:2
/11.5_2.B6
B B
A0707B
-K3006
-X007 -X069m -X069f
0.5A K7:11 11 00711 5 5 A0695A 86 85 A0695B
-D790-1
/0.0_1.C4
RELAY ACTIVATE SPREAD -X070f -X070m -X202f -X202m -X208f -X208m -X208Am
30 87 A0707A 7 7 0707 2 2 RD_/_2 2 2 RD_/_2 2
VALVE SPREADING
SPREADING
-X37-A #3628
C C
-X202f -X202m -X208f -X208m -X208Am

CHASSIS 2023 3 3 OG_/_3 3 3 OG_/_3 3
/9.7_2.C7 CHASSIS
D -X202f -X202m -X208f -X208m -X208Am D

58-3/3:1 2024 4 4 YE_/_4 4 4 YE_/_4 4
/11.5_6.D7 24V

secuted.

58-3/3:1 2028 8 8 GY_/_8 13 13 4A
/7.0_4.A7
-X202f -X202m -X208f -X208m -X208Am

Alignment 2025 5 5 GN_/_5 5 5 GN_/_5 5
/7.0_4.B7 SENSOR ALIGNMENT
Se krets aggregat
See circuit attachment
E -X202f -X202m -X208f -X208m -X208Am E

Unlock TW 2026 6 6 BU_/_6 6 6 BU_/_6 6
/7.0_4.C7 SENSOR UNLOCK TWISTLOCK
-X202f -X202m -X208f -X208m -X208Am

Lock TW 2027 7 7 VT_/_7 7 7 VT_/_7 7
/7.0_4.D7 SENSOR LOCK TWISTLOCK

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets tillbehörsaggregat DCF300-, DCE300- 7.0_5
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring toplift frame A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
C C
-X302f -X302m -XB7211-1f -XB7211-1m
58-2/5:1 A A 302A A A
/7.2_6.E1
BN
-B7211-1 -XB7211-1m -XB7211-1f -X302m -X302f -X248m -X248f -X211
BK C C 302C C C 2484 4 4 21126 26 K1:26 Dig In / 1.5A
-D797-1
/0.0_2.D5
AUT. CAB TILT
BU SENSOR CAB TILT
B B 302B B B CHASSIS
/7.2_6.F7
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Wiring toplift frame DCF300-, DCE300- 7.0_7
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring lift height A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-Y6005
-X211 -XK3007 -K3007 -XK3007 -X235f -X235m -X235m -X235f -X211
1.5A K1:4 4 2114A 30 30 87 87 2114B 1 1 2351A -X90029 2351B 1 1 2 2 2352 2 2 21116 16 K1:16 PWM
-D797-1 -D797-1
/0.0_2.D2 87A /0.0_2.D2
VALVE LIFT / LOWER /11.5_6.B4 VALVE LIFT / BLOCK LIFT
LIFT
C C
-Y6004
-X235m -X235f -X211
2351C 1 1 2 2 2353 3 3 21117 17 K1:17 PWM
D -D797-1 D
/0.0_2.D2
VALVE LOWER / BLOCK LOWER

secuted.

LOWER
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets lyft/sänk elservo DCF300-, DCE300- 7.2_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring lift/lower el. servo A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
/7.2_3.B6 -X236Lf -X211

24V D797-1/1:12 C 21112 12 K1:12 Dig In / 1.5A
/7.2_6.B1 -D797-1
/0.0_2.D2
CARRIAGE UP / REGENERATING LIFT
B -X236Lf /7.2_3.C6 -X236Lf B

90012B A 58-2/5:2 CHASSIS B 237B
/7.2_3.B3 /7.2_6.B7
58-2/5:2 90012A -X90012

/11.5_1.B8
/7.2_3.D6 -X236Rf -X211

24V D797-1/1:11 C 21111 11 K1:11 Dig In / 1.5A
/7.2_6.D1 -D797-1
/0.0_2.D2
MAST DOWN / REGENERATING LIFT
C C
-X236Rf /7.2_3.D6 -X236Rf

90012C A 58-2/5:2 CHASSIS B 236B
/7.2_3.C2 /7.2_6.D7
CHASSIS 6012
/10.4_1.D5
D D

secuted.

CHASSIS 771B
/7.7_2.D7
CHASSIS 6062 -X90032 37209 CHASSIS

/10.4_1.C7 /11.5_1.D6
CHASSIS 2482
/7.2_6.E7
E E
CHASSIS 2132
/9.0_1.C7
CHASSIS 6039
/8.2_3.D7
-XY6040/6019f
2 6040
/7.2_4.C2

CHASSIS 642
F /4.0_1.E7 F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets frilyft sensorer DCF300-, DCE300- 7.2_2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring free lift sensors A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X236Lm
58-2/5:2 A RD -XB260 1
/7.2_2.B3
B B
BN
-B260 -X236Lm
BK -XB260 2 GY C 24V D797-1/1:12
/7.2_2.B5
SENSOR CARRIAGE UP
BU
-X236Lm
-XB260 3 BK B CHASSIS
/7.2_2.B5
C C
-X236Rm
A
/7.2_2.C3
BN
-B261 -X236Rm
BK C 24V D797-1/1:11
/7.2_2.C5
SENSOR MAST DOWN
D BU D

secuted.

-X236Rm
B CHASSIS
/7.2_2.C5
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets frilyft sensorer DCF300-, DCE300- 7.2_3
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring free lift sensors A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-XY6039/6018m -XY699Rf
1 699R1 1
/8.2_3.C3
2 699R2 2
/8.2_3.D6
C C
-XY6040/6019m -XY699Lf
1 699L1 1
/8.2_3.C6
2 699L2 2
/7.2_2.F5
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn krets frilyfts ventiler DCF70-100 7.2_4
Sq. MLG 130523 A47137.0100
Name
R
E³ DRAWING
MLG 130523 Klass/Class
Wiring free lift Valves A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6052
-X236Lm -X236Lm
24V D797-1/1:12 C 236C 1 1 2 2 236B B CHASSIS
B /7.2_2.B5 /7.2_2.B5 B
REGENERATING LEFT
C C
-Y6051
-X236Rm -X236Rm
24V D797-1/1:11 C 236C 1 1 2 2 236B B CHASSIS
/7.2_2.C5 /7.2_2.C5
REGENERATING RIGHT
D D

secuted.

-X248f -X248m
58-2/5:1 2481 1 1 2481 -X301f -X301m -XB7211-2f -XB7211-2m
/9.6_5.E2
A A 301A A A
-X303m_BB -X303f
1 1 BN
-B7211-2 -XB7211-2m -XB7211-2f -X301m -X301f -X248m -X248f -X211
2 2 3032 BK C C 301C C C 2483 3 3 21124 24 K1:24 Analog In 0-5V
E -D797-1 E
6 6 /0.0_2.D5
MAST POSITION/STOP REGENERATING
BU SENSOR MAST POS/REGENERATING
58-2/5:1 3036 B B 301B B B 2 2 2482 CHASSIS
/7.0_7.C2 /7.2_2.E5
-X303f -X303m_BB
2482 3 3
3034 4 4
3035 5 5

CHASSIS
F /7.0_7.D7 F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets ventiler stativ DCF300-, DCE300- 7.2_6
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring control valves mast A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6046-1
-X421 -XY6046-1 -XY6046-1 -X421
1.5A K1:2 2 4212 1 1 2 2 42116B 42116A 16 K1:16 PWM
-D791 -D791
/0.0_4.C2 -X90050 /0.0_4.D2
PROJECTING LEFT IN PROJECTING LEFT
PROJECTING LEFT IN
B B
-Y6046-2
-X421 -XY6046-2 -XY6046-2
1.5A K1:3 3 4213 1 1 2 2 42116C
-D791
/0.0_4.C2
PROJECTING LEFT OUT
PROJECTING LEFT OUT
C C
-Y6046-3
-X421 -XY6046-3 -XY6046-3 -X421
1.5A K1:4 4 4214 1 1 2 2 42117B 42117A 17 K1:17 PWM
-D791 -D791
/0.0_4.C2 -X90051 /0.0_4.D2
PROJECTING RIGHT IN PROJECTING RIGHT
PROJECTING RIGHT IN
-Y6046-4
D -X421 -XY6046-4 -XY6046-4 D
1.5A K1:5 5 4215 1 1 2 2 42117C
-D791
/0.0_4.C2

secuted.

PROJECTING RIGHT OUT
PROJECTING RIGHT OUT
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets aggregat gantry DCF300-, DCE300- 7.3_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring projection gantry A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
1 1
C C
-X409m -X409Af -X409Am -XB769-U
1 GY grey 0.75mm2 A A GY grey 0.75mm2 1 1
/7.10_2.A4
2
-X409m -XB769-U
2 RD red 0.75mm2 B B RD red 0.75mm2 3 3
/7.10_2.A6
-X409m -XB769-U
3 BU blue 0.75mm2 C C BU blue 0.75mm2 4 4
/7.10_2.B6
D D

secuted.

-B769
SENSOR, DAMPING ATTACHMENT
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Kretsschema Givare ultrasonic DCF 7.3_2
Sq. PLT 150629 A47137.0100
Name
R
E³ DRAWING
PLT 150629 Klass/Class
Wiring sensor Ultrasonic A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6020
-X221 -X244f -X244m -X244m -X244f -X221
2.5A K1:31 31 22131 1 1 2441 1 1 2 2 2443B -X90036 2443A 3 3 22118 18 K1:18 PWM
-D797-2 -D797-2
/0.0_3.D5 /0.0_3.D2
VALVE SIDESHIFT LEFT VALVE SIDESHIFT
B B
SIDESHIFT LEFT
-Y6021
-X221 -X244f -X244m
2.5A K1:30 30 22130 2 2 2442 1 1 2 2 2443C
-D797-2
/0.0_3.D5
VALVE SIDESHIFT RIGHT
SIDESHIFT RIGHT
C C
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets Sidoföring elservo DCF300-, DCE300- 7.4_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring Sideshift el. servo A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6020
-X421 -X421
1.5A K1:32 32 42132 1 1 2 2 42118B 42118A 18 K1:18 PWM
-D791 -D791
/0.0_4.D5 -X90052 /0.0_4.D2
SIDESHIFT LEFT
B B
-Y6021
-X421
1.5A K1:33 33 42133 1 1 2 2 42118C
-D791
/0.0_4.D5
SIDESHIFT RIGHT
C C
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets sidoföring gantry DCF300-, DCE300- 7.4_2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring sideshift gantry A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A 1 = 40'-20' A
0=0
2 = 20'-40' -X091m -X091f -X007
0913 3 3 00714 14 K7:14 Input
+CAB -D790-1
-S1012 /0.0_1.C4
1 SWITCH SPREADING 40-20
0
24V D790-1/8:16 0921C 2
/9.7_4.B2 1 1 -X091m -X091f -X007
24V D790-1/8:16 0921D 3 3
/7.8_1.E2 7 7 0914 4 4 00713 13 K7:13 Input
-D790-1
2 /0.0_1.C4
4
8 SWITCH SPREADING 20-40
CHASSIS-37-D 0923F 10 10 9 9
/7.9_1.B3
CHASSIS-37-D 0923G
B /7.8_1.F2 20-40 B
0922B D790-1/8:15
/7.8_1.E7
/9.3_3.B7 0922A
D790-1/8:15
/9.10_1.B7
C C
+CAB
-S1004
1 -X008
00810A 10 K8:10 Input
24V D790-1/8:16 00816D 0 -D790-1
/7.9_1.A2 5 1 /0.0_1.D4
24V D790-1/8:16 00816E 5 10
/9.1_1.A2 1 SWITCH 30-35 STOP
CHASSIS-37-D 0923B 10 9 7 9 00810B
/7.9_1.A2
CHASSIS-37-D 0923C
/9.1_1.A2 30-35 STOP
D D

secuted.

-Y6018
-X221 -X244f -X244m -X244m -X244f -X221
1.5A K1:33 33 22133 4 4 2444 1 1 2 2 2446B -X90037 2446A 6 6 22119 19 K1:19 PWM
-D797-2 -D797-2
/0.0_3.D5 /0.0_3.D2
VALVE SPREADING OUT VALVE SPREADING
SPREADING OUT
E E
-Y6019
-X221 -X244f -X244m
1.5A K1:32 32 22132 5 5 2445 1 1 2 2 2446C
-D797-2
/0.0_3.D5
VALVE SPREADING IN
SPREADING IN

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets 20-40, 30-35 stopp DCF300-, DCE300- 7.5_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring 20-40, 30-35 stop A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6018
-X421 -XY6018 -XY6018 -X421
1.5A K1:34 34 42134 1 1 2 2 42119B 42119A 19 K1:19 PWM
-D791 -D791
/0.0_4.D5 -X90053 /0.0_4.D2
B B
VALVE SPREADING OUT VALVE SPREADING
SPREADING OUT
-Y6019
-X421 -XY6019 -XY6019
1.5A K1:35 35 42135 1 1 2 2 42119C
-D791
/0.0_4.D5
VALVE SPREADING IN
C C
SPREADING IN
-XB769-1f -XB769-1m
24V D791-1/1:10 4041C A A
/7.9_2.F3
BN
-B769-1 -XB769-1m -XB769-1f -X404Am -X404Af -X421
BK C C 4047 7 7 42112 12 K1:12 Dig In / 1.5A
-D791
/0.0_4.D2
DAMPING 20-40
BU SENSOR DAMPING 20-40
D -XB769-1m -XB769-1f D
B B 4042C CHASSIS
/7.9_2.F4

secuted.

-XB777-1f -XB777-1m
24V D791-1/1:10 4041D A A
/7.9_2.F3
BN
-B777-1 -XB777-1m -XB777-1f -X404Am -X404Af -X421
BK C C 4048 8 8 42120 20 K1:20 Analog In 0-5V
-D791
/0.0_4.D2
30-35 STOP
BU SENSOR 30-35 STOP
-XB777-1m -XB777-1f
B B 4042D CHASSIS
E /7.9_2.F4 E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets spridning gantry DCF300-, DCE300- 7.5_2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring spreading gantry A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1012-2
/9.3_3.A2 1 -X008
24V D790-1/8:16 00816G 00811A 11 K8:11 Input
/9.10_1.A2 0 -D790-1
1 1 /0.0_1.D4
24V D790-1/8:16 00816H 5 5
/4.0_1.A2 SWITCH AUT. 20-40
CHASSIS-37-D 0923F 10 10 9 9 00811B
/4.0_1.B2
B /9.3_3.B2 AUT. 20-40 B
CHASSIS-37-D 0923E
/9.10_1.B2
C C
-X421 -XH9003f -XH9003m -H9003

6A K1:28 28 42128 1 1 RD +
-D791
/0.0_4.D5 2 2 BK -
D D
WARN. SIGNAL AUT. SPREADING
WARNING SIGNAL AUT. SPREADING

secuted.

W9003 CHASSIS
/9.6_2.F8
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets 20-40 opt. DCF300-, DCE300- 7.5_3
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring 20-40 opt A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-Y6010
-X211 -XK3002 -K3002 -XK3002 -X235f -X235m -X235m -X235f -X211
1.5A K1:5 5 2115A 30 30 87 87 2115B 4 4 2354A -X90030 2354B 1 1 2 2 2355 5 5 21119 19 K1:19 PWM
-D797-1 -D797-1
/0.0_2.D2 87A /0.0_2.E2
VALVE TILT /11.5_6.B4 VALVE TILT OUT
C C
TILT OUT
D D

secuted.

-Y6011
-X235m -X235f -X211
2354C 1 1 2 2 2356 6 6 21118 18 K1:18 PWM
-D797-1
/0.0_2.D2
VALVE TILT IN
TILT IN
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets tilt elservo DCF300-, DCE300- 7.7_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring tilt el. servo A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
24V D797-1/1:23
/4.8_1.E6
C C
-XB771f -XB771m
58-2/5:1 771A A A
/9.6_5.E2
BN
-B771 -XB771m -XB771f -X211
BK C C 21123 23 K1:23 Analog In 0-5V
-D797-1
/0.0_2.D5
SENSOR TILT ANGLE
BU SENS.TILT ANGLE/FEEDBACK BRK FAN
B B 771B CHASSIS
/7.2_2.D5
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets tiltindikering DCF300-, DCE300- 7.7_2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring tilt indicator A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-Y6035
-X421
2.5A K1:31 31 42131 1 1 2 2 6035 CHASSIS
A -D791 /7.9_1.E7 A
/0.0_4.D5
VALVE LEVELLING RIGHT
LEVELLING RIGHT
-Y6036
B -X421 B
2.5A K1:30 30 42130 1 1 2 2 6036 CHASSIS
-D791 /7.9_1.E7
/0.0_4.D5
VALVE LEVELLING LEFT
LEVELLING LEFT
C -Y637-1 C
-X421
6A K1:42 42 42142A -X90071 42142B 1 1 2 2 637-1 CHASSIS
-D791 /7.9_1.E7
/0.0_4.D5
VALVE UNLOCK LEVELLING
UNLOCK LEVELLING
D D
-Y637-2

secuted.

42142C 1 1 2 2 637-2 CHASSIS
/7.9_1.E7
UNLOCK LEVELLING
-S1037
E 1 -X091m -X091f -X008 E
0919A 9 9 0081 1 K8:1 Input
0 -D790-1
1 1 /0.0_1.D4
24V D790-1/8:16 0921D 5 5
/7.5_1.B2 7 SWITCH LOCK LEVELLING
2 2 0919B
6 6
8 8 0922B D790-1/8:15
/7.5_1.B7
CHASSIS-37-D 0923G 10 10 9 9
/7.5_1.B2
LOCK LEVELLING

0922C
F 0923H CHASSIS-37-D
F
/7.0_2.C2

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets skevning gantry DCF300-, DCE300- 7.8_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring levelling gantry A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
+CAB
-S1003
1
A 24V D790-1/8:16 00816D 0 A
/7.5_1.C2 2
1
00816C 3 3
7 7 00812B
2 2 -X008
4 4 00812A 12 K8:12 Input
8 -D790-1
/0.0_1.D4
CHASSIS-37-D 0923B 10 10 9 9 00812C
/7.5_1.D2 SWITCH LOCK TW
0923A
Twistlock
-X092f -X092m
0923 3 3 0923F
Vid hydr. servo
-S1002 When hyd. servo
-X093f
CHASSIS-37-D
2 0923J
B -X37-D CHASSIS-37-D /7.9_4.B8 -XS1002m-2 -XS1002m-1 B
CHASSIS-37-D 1 RD 2 1 BK 1
/7.5_1.B2
UNLOCK TW
24V D790-1/8:16 0921B
/9.7_4.B2
00816B
-S1002
1
0
2 -XS1002m-3 -XS1002f-3 0915A
-X008 -X092f -X092m -XS1002f-2 -XS1002m-2 3 -X091m -X091f -X007
24V reference K8:16 16 00816A 1 1 0921A 2 0915 5 5 00715 15 K7:15 Input
-D790-1 1 -D790-1
/0.0_1.E4 /0.0_1.C4
SWITCH ELSERVO PANEL SWITCH UNLOCK TW
UNLOCK TW
-X093f
24V D790-1/8:16
0921E 3
/7.9_4.A1
C C
-H562
-X421 -X405f -X405m -XH562-1 -XH562-2
1.5A K1:25 25 42125 1 1 4051 1 1 2 1
-D791
/0.0_4.C5
LAMP UNLOCKED TW UNLOCKED TW
-H564
-X421 -X405f -X405m -XH564-1 -XH564-2
1.5A K1:39 39 42139 2 2 4052 1 1 2 1 4054C
-D791
/0.0_4.D5
LAMP ALIGNMENT ALIGNMENT
D D
-H563
-X421 -X405f -X405m -XH563-1 -XH563-2
1.5A

secuted.

K1:29 29 42129 3 3 4053 1 1 2 1 4054B
-D791
/0.0_4.D5
LAMP LOCKED TW LOCKED TW
-X405m -X405f
4054A 4 4 4054 CHASSIS
/9.6_2.C8
6035 CHASSIS
/7.8_1.A7
-Y6040 6036
-X421 CHASSIS
/7.8_1.B7
1.5A K1:7 7 4217 1 1 2 2 6040
-D791
/0.0_4.D2 637-1 CHASSIS
E /7.8_1.C7 E
VALVE LOCK TWISTLOCK
LOCK TW 637-2 CHASSIS
/7.8_1.D7
-Y6039
-X421
1.5A K1:9 9 4219 1 1 2 2 6039 W402 CHASSIS
-D791 /11.5_5.B7

/0.0_4.D2 -X90060
VALVE UNLOCK TWISTLOCK
F UNLOCK TW F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets Twistlock DCF300-, DCE300- 7.9_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring twistlock A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X403Am -X403Af -X403Bf -X403Bm -XB7202Rf -XB7202Rm

1 1 4031 1 1 4031 -X90054 4031A A A -X403Bm -X403Bf -X403Af -X403Am -X421
A 4033 3 3 4033 3 3 42140 40 K1:40 Dig In / 1.5A A
BN -D791
-B7202R -XB7202Rm -XB7202Rf /0.0_4.D5
BK C C 4033
SENSOR ALIGNMENT FRONT RIGHT
B B 4032A 4032 2 2 4032 2 2 4032
ALIGNMENT FRONT RIGHT
BU -X90055
-XB7204Rf -XB7204Rm
4031B A A
BN
-B7204R -XB7204Rm -XB7204Rf -X403Bm -X403Bf -X403Af -X403Am -X421
BK C C 4034 4034 4 4 4034 4 4 42141 41 K1:41 Analog In 0-5V
-D791
B B 4032B /0.0_4.D5
UNLOCKED TWISTLOCK RIGHT
BU SENSOR UNLOCKED TW. RIGHT
-XB7205Rf -XB7205Rm
4031C A A
B B
BN
BK C C 4035 4035 5 5 4035 5 5 42124 24 K1:24 Analog In 0-5V
-D791
B B 4032C /0.0_4.C5
LOCKED TWISTLOCK RIGHT
BU SENSOR LOCKED TW. RIGHT
-XB7203Rf -XB7203Rm
4031D A A
BN
42110B BK C C 4036 4036 6 6 4036 6 6 42126 26 K1:26 Dig In / 1.5A
-D791
B B 4032D /0.0_4.C5
ALIGNMENT REAR RIGHT
BU SENSOR ALIGNMENT REAR RIGHT
-X421 42110C 24V D791-1/1:10

C /7.10_2.E2 C
1.5A K1:10 10 42110A -X90058 769B CHASSIS
-D791 /7.10_2.F7
/0.0_4.D2 42110D 24V D791-1/1:10 7211B CHASSIS
/7.10_2.A2 /7.10_2.A7
SENSORS ATTACHMENT CHASSIS W401 -X90059 4032
-X404Am -X404Af /11.5_5.B7
4041A 1 1 42110E 4042
-X404Bf -X404Bm -XB7202Lf -XB7202Lm

-X90083 4041B 1 1 4041 -X90056 4041A A A -X404Bm -X404Bf -X404Am -X404Af -X421
4043 3 3 4043 3 3 42113 13 K1:13 Analog In 0-5V
BN -D791
-B7202L -XB7202Lm -XB7202Lf /0.0_4.D2
BK C C
SENSOR ALIGNMENT FRONT LEFT
B B 4042A 4042 2 2 4042B 4042A 2 2 4042
ALIGNMENT FRONT LEFT
BU -X90057 -X90084
D -XB7204Lf -XB7204Lm D
4041B A A
BN

secuted.

-B7204L -XB7204Lm -XB7204Lf -X404Bm -X404Bf -X404Am -X404Af -X421
BK C C 4044 4044 4 4 4044 4 4 42122 22 K1:22 Analog In 0-5V
-D791
B B 4042B /0.0_4.C5
UNLOCKED TWISTLOCK LEFT
BU SENSOR UNLOCKED TW. LEFT
-XB7205Lf -XB7205Lm
4041C A A
BN
BK C C 4045 4045 5 5 4045 5 5 42123 23 K1:23 Analog In 0-5V
-D791
B B 4042C /0.0_4.C5
LOCKED TWISTLOCK LEFT
BU SENSOR LOCKED TW. LEFT
E -XB7203Lf -XB7203Lm E
4041D A A
BN
BK C C 4046 4046 6 6 4046 6 6 42127 27 K1:27 Analog In 0-5V
-D791
B B 4042D /0.0_4.D5
ALIGNMENT REAR LEFT
BU SENSOR ALIGNMENT REAR LEFT
4041C 24V D791-1/1:10 CHASSIS 4042C

/7.5_2.D1 /7.5_2.D6

4041D 24V D791-1/1:10 CHASSIS 4042D
F /7.5_2.D1 /7.5_2.E6 F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets givare gantry DCF300-, DCE300- 7.9_2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring sensors gantry A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X242m
58-2/4:1 7 YE_/_4
/11.5_10.B4
-X208Am -X208Af -X242m

1 1 BN_/_1 1 D797-2/1:41
A /11.5_10.A5 A
2 2
3 3 OG_/_3 8 CHASSIS
/11.5_10.D5
Strömbrytare S1008 klämma / lossa.
Kopplas in på XS1012. 4 4 YE_/_4
5 5
Switch S1008 clamping / releasing. 6 6 BU_/_6 3 D797-2/1:22
/11.5_10.B5
Connected to XS1012.
7 7 VT_/_7 4 D797-2/1:23
/11.5_10.C5
+CAB
-S1008
B 1 B
0
2
1
3
7
2
4
8 -K3768-1
10 9 86 86 85 85
CLAMPING RELEASING
30 30 87 87
87A
C C
-K3768-2
86 86 85 85
30 30 87 87
87A 87a
D D
-B768-1

secuted.

1
2
3
4
OPENS AT 150 BAR

CLOSES AT 135 BAR
-H5000-1
-B768-2
E 1 2
E
PRESSURE CYLINDER UNDER 125 BAR (RED) 1
2
3
4
-H5000-2
1 2
OPENS AT 150 BAR
PRESSURE CYLINDER OVER 125 BAR (GREEN) CLOSES AT 135 BAR

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets tång Avesta DCF300-, DCE300- 7.9_3
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring attachment Avesta A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A +CAB A
-S1031
1
0
2 -X070m
24V D790-1/8:16 -X093m 1 0703 3 D790-1_8:9
3 0933 3 /7.0_4.D5
/7.9_1.C7 7 0702 2 D790-1_8:8
/7.0_4.E5
2
4
8 -X093m
/9.3_3.B7 D790-1/8:15 -X093m CHASSIS-37-D
1 0931 10 9 0932 2
/9.10_1.B7 /7.9_1.B3
Over Height Up/Down
B B
-Y6070
-X409m -XB769-2m
CHASSIS
24V D791-1/1:36 7 4097 1 2 7692B 7692A B
/7.10_2.C4 /7.10_2.F6
-X90102
Over Height Up
C C
-Y6071
-X409m
24V D791-1/1:37 8 4098 1 2 7692C
/7.10_2.D4
Over Height Down
-X409m -X410f -X410m -X491f -X491m -XB7231Lf -XB7231Lm

24V D791-1/1:10 1 4091 1 1 2101 A A 491A A A
/7.10_2.A4
BN
D -B7231L -XB7231Lm -XB7231Lf -X491m -X491f D
BK C C 491C C C

secuted.

Over Height, Leg Upper Pos
BU
-XB7231Lm -XB7231Lf -X491m -X491f -X410m -X410f
B B 491B B B 2104 4 4 7692E
-XB7231Rm -XB7231Rf -X492m -X492f

A A 492A A A 7231
BN
E -B7231R -XB7231Rm -XB7231Rf -X492m -X492f -X410m -X410f -X409m E
BK C C 492C C C 2102 2 2 4093 3 D791-1/1:21
/7.10_2.B6
Over Height, Leg Upper Pos -XB7231Rm -XB7231Rf -X492m -X492f -X410m -X410f
BU B B 492B B B 2103 3 3 7692D

-H5001
-XB769-2m -X408f -X408m -X408m -X408f
24V D791-1/1:11 C 50011 1 1 50011 1 2 50012 2 2 7692F
F /7.10_2.E6 F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets Over Height DCF300-, DCE300- 7.9_4
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring Over Height A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-Y6022
-X221 -X244f -X244m -X244m -X244f -X221
1.5A K1:4 4 2214 7 7 2447 1 1 2 2 2449B -X90038 2449A 9 9 22117 17 K1:17 PWM
-D797-2 -D797-2
/0.0_3.C2 /0.0_3.D2
VALVE EXTRA FUNCT. OUT VALVE EXTRA FUNCT.
5TH FUNCTION OUT
C C
-Y6023
-X221 -X244f -X244m
1.5A K1:5 5 2215 8 8 2448 1 1 2 2 2449C
-D797-2
/0.0_3.C2
VALVE EXTRA FUNCT. IN
5TH FUNCTION IN
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets 5:e funkt. elservo DCF300-, DCE300- 7.10_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring 5th function el. servo A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X409f -X409f
24V D791-1/1:10 42110D 1 24V D791-1/1:10 1 2 7211B CHASSIS
/7.9_2.C4 /7.9_4.D1 /7.3_2.D3 /7.9_2.C7
/7.3_2.C3 1
-X409f -X421
D791-1/1:21 3 42121 21 K1:21 Analog In 0-5V
-X421 -X409f /7.9_4.E8 -D791
Analog Ref 5V K1:8 8 4218 5 1 /0.0_4.C5
B -D791 /7.3_2.D3 B
/0.0_4.D2 OPT.
OPT.
-X421 -X409f -X409f -X421

1.5A K1:36 36 42136 7 24V D791-1/1:36 4 4216 6 K1:6 0V Ref
-D791 /7.9_4.C1 -D791
/0.0_4.D5 /0.0_4.C2
OPT. OPT.
C C
-X421 -X409f
1.5A K1:37 37 42137 8 24V D791-1/1:37
-D791 /7.9_4.C1
/0.0_4.D5
OPT.
D D

secuted.

-XB769-2f -XB769-2f -X421
24V D791-1/1:10 42110C A 24V D791-1/1:11 C 42111 11 K1:11 Dig In / 1.5A
E /7.9_2.C4 /7.9_4.F1 -D791 E
/0.0_4.D2
SENSOR OPT.
-XB769-2f
CHASSIS B 769B CHASSIS
/7.9_4.C8 /7.9_2.C7

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets option gantry DCF300-, DCE300- 7.10_2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring option gantry A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
+CAB
B -S1005 B
1
0 -XS1005 -X008
-XS1005 1 1 0083 3 K8:3 Input
24V D790-1/8:16 00816J 5 5 -D790-1
/4.0_1.A2 /0.0_1.D4
24V D790-1/8:16 00816K
/11.5_6.A2 OVER RIDE SWITCH OVERRIDE
C C
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets förbikoppling DCF300-, DCE300- 8.2_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring override A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X211 -X768-1f -X768-1m -B768-1 -X768-1m -X768-1f

Analog Ref 5V K1:8 8 2118A -X90031 2118B A A 768-1 1 2 768-2 B B 2116B
-D797-1 P -X211
/0.0_2.D2 3 768-3 C C 21121 21 K1:21 Analog In 0-5V
U -D797-1
SENSOR HYDR. SCALE /0.0_2.C5
HYDRAULIC SCALE LIFT
SENSOR HYDR. SCALE LIFT
B B
C C
-B768-2 -X211
2118C 1 2 2116C 2116A 6 K1:6 0V Ref
P -D797-1
3 -X90064 /0.0_2.D2
U
SENSOR HYDR. SCALE
HYDRAULIC SCALE TILT
-X211
21122 22 K1:22 Analog In 0-5V
-D797-1
/0.0_2.C5
SENSOR HYDR. SCALE TILT
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets överlastsystem DCF300-, DCE300- 8.2_2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring overloading system A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
C -X211 -XY6039/6018f -XY6039/6018m -XB7211-3f -XB7211-3m /7.2_4.C2 C

1.5A K1:36 36 21136 1 1 GY A A
-D797-1
/0.0_2.D5
MAST POSITION BN
-B7211-3 -XB7211-3m -XB7211-3f -XY6040/6019m -XY6040/6019f -X211
BK C C RD 1 1 21137 37 K1:37 Dig In / 1.5A
-D797-1
/0.0_2.D5
/7.2_4.C2 MAST POSITION OLS
BU MAST POSITION
-XY6039/6018m -XY6039/6018f
B B BK 2 2 6039 CHASSIS
/7.2_2.E5
/7.2_4.C2
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets givare stativ OLS DCF300-, DCE300- 8.2_3
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring sensor mast OLS A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
08712
08713
A A
-D795-2
-X087f -X087f 0876
13 K1:13 CAN 2 K1:6 6
L+ + -X90093
12 K1:12 CAN K1:5 5 0875
L- -
8 K1:8 K1:4 -X90094
+ Shield
RS232
K1:11 K1:3 3 30
R+ TX
K1:10 CAN K1:2 2
R- RX
K1:7 K1:1 1
+ GND
9 K1:9 0V REF BUZZER K1:14

B B
KID
0878
0879
0871
0872
0592
0591
-X088f
25 0872
TX2
26 0873 -X059m
RX2 30 1 CAN+
30 08830 -X90091 0871 2
C GND CAN- C
0878 3
3 0883
+15
+15 0879 5
13 08813 GND
GND -X059f
14 0599
Batt+ 9 9 A0599
28 08828
-A911 TX1
0895
MIU 29 08829
RX1
D D

secuted.

2 30
4
3
5
6
7
8
9
1
-X089m
E E
-XF51-1 -F51-1 -XF51-1 -X070m -X070f

Batt + GY 1 2 0709 9 9 A0599
/11.5_1.D3 1 2
5A

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets RMI DCF300-, DCE300- 8.2_4
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring RMI A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-X211 -X213f /9.6_9.C2 /9.6_9.C7 -X213f

6A K1:42 42 21142 1 24V D797-1/1:42 CHASSIS 2 2132 CHASSIS
-D797-1 /9.14_1.B2 /9.14_1.C7 /7.2_2.E5
/0.0_2.E5
CENTRAL LUB. / WORK LIGHT OPT.
C C
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets std. opt. DCF300-, DCE300- 9.0_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring std. opt. A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
(1010-2)
+CAB
00816E
-S199-2
24V D790-1/8:16 -X008
/7.5_1.D2 1
00814A 14 K8:14 Input
A 0 -D790-1 A
/9.3_3.A2 1 1 /0.0_1.D4
24V D790-1/8:16 00816F 5 5
/9.10_1.A2 SWITCH S1 OPT.
10 10 9 9 00814B
CHASSIS-37-D 0923C
/7.5_1.D2
/9.3_3.A2 0923D
CHASSIS-37-D
/9.10_1.B2
(1019)
B B
+CAB
-S199-1
1 -X080m -X080f -X006
-X005 -X081f -X081m 0069A 9 9 0069 9 K6:9 Input
24V reference K5:1 1 0051 1 1 0811A 0 -D790-1
-D790-1 1 1 /0.0_1.B4
/0.0_1.C1 0811B 5 5
SWITCH S4 OPT.
SWITCHES LEFT PANEL
0812B 10 10 9 9 0069B
OPTION
790-1:5-1/24V 0811
/2.0_1.C2
C C
-X081m -X081f
0812A 2 2 W08 CHASSIS
/9.5_1.B8
CHASSIS 0812L
/9.1_2.B7
+CAB
-S199-3
D 1 -X080m -X080f -X006 D
0808A 8 8 0068 8 K6:8 Input
0811B 0 -D790-1
/0.0_1.B4

secuted.

1 1
0811C 5 5
SWITCH S3 OPT.
0812B 10 10 9 9 0808B
0812C
OPTION
E E
(123)
+CAB
-S199-4
1 -X080m -X080f -X006
0807A 7 7 0067 7 K6:7 Input
0811C 0 -D790-1
1 1 /0.0_1.B4
790-1:5-1/24V 0811D 5 5
/9.3_1.B2 SWITCH S2 OPT.
0812C 10 10 9 9 0807B

CHASSIS 0812D
/9.3_1.B2 OPTION
F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets extra utrustning DCF300-, DCE300- 9.1_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring option A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-P708 h
HOUR METER
+ -
1
2
B B
-X010 -X039f -X039m -X081f -X081m

0.5A K10:9 9 A0109A 1 1 0391 9 9 0819 0812L CHASSIS
-D790-1 /9.1_1.D2
/0.0_1.C6
HOUR MET/RELAY AIR SEAT
790-1/10:9 A0109B
/9.3_2.B2
C C
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets timräknare DCF300-, DCE300- 9.1_2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring hour meter A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X37-C -X37-C8
1 W330-2 WH 0.75
-K330-2
-XK330-2 -XK330-2
790-1/10:9 0109D GY 0.75 86 86 85 85
/9.3_2.A4
/9.2.B4
-X058m -X058-5f -XK330-2 -K330-2

B 0586 0586A GY 0.75 5 1 0585 GY 0.75 30 30 87 -XK330-2
/11.5_3.D5 B
87A 87a BK
-X058-8f /9.2.B4 WH
8 1 0588 GY 0.75 BN
-B1
BU
-XK1:13a-1
-XK1:13a-2
C A1 C
-XK1:12a-1
12a 13a 1 3 -K10
-K10
A2
12b 13b
2 4
-XK1:12b-1
-XK1:13b-1
2812A
-X2811f -X281m
28111 GY 0.75 1 1 2811
28112 28112 WH 0.75 2 2 2812
/9.5_1.E6
28113 28113 GY 0.75 3 3 2813
/11.5_3.D5
28114 28114 GY 0.75 4 4 2814
D /11.5_3.D6 D

secuted.

E Inside heater-box E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets startspärr DCF300-, DCE300- 9.2
Sq. RSO 140430 A47137.0100
Name
R
E³ DRAWING
Wiring interlock A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
When Isringhausen seat:
Switch S143 replaced by
jumper between 1 and 5.
Switch is placed on the seat.
+CAB
-S143
1 -X080m -X080f -X006
790-1:5-1/24V 0811E 0806A 6 6 0066 6 K6:6 Input
/9.6_4.A2 0 -D790-1
1 1 /0.0_1.B4
790-1:5-1/24V 0811D 5 5
/9.1_1.F2 SWITCH SEAT HEATER
CHASSIS 0812D 10 10 9 9 0806B
B /9.1_1.F2 B
CHASSIS 0812E SEAT HEATER
/9.6_4.A2
C C
-K383
-X010
0.5A K10:7 7 A0107 86 85 86 85 W05
-D790-1
/0.0_1.C6
RELAY SEAT HEATER SEAT HEATER
A0634B
-X37-B #354
58-4/6:1 30 30 87 87
/11.5_2.B6
87A
D D

secuted.

A0634
-X063f -X063m -XE803m -XE803f -E803 -XE803f -XE803m -X063m -X063f

4 4 0634 1 1 YE 1 2 BK 2 2 0633 3 3 W06
SEAT HEATER
-X37-D CHASSIS
CHASSIS 0633A
E /9.3_2.C7 E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets Stolsvärme DCF300-, DCE300- 9.3_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring seat heater A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XK330-2_86m -XK330-2_86f
1 0109C GY 0.75 1
790-1/10:9
/9.2.B2
-K358
790-1/10:9 A0109B 86 85 86 85 W07

/9.1_2.C2
58-4/8:1 A0635B 30 30 87 87
/11.5_2.B6
B 87A -X37-B #364 B
COMPRESSOR AIR SEAT
-X063m -X063f
0635 5 5 A0635
C -S268 C
-M670
P COMPRESSOR
-XM670m -XM670f AIR-SUSPENDED SEAT -XM670f -XM670m
1 1 RD 1 - + BK 2 2 0633A CHASSIS
M /9.3_1.E6
COMPRESSOR
AIR CUSHIONED SEAT
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets luftfjädrad stol DCF300-, DCE300- 9.3_2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring aircushioned seat A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1 = C.W
0=0
+CAB 2 = C.C.W -X008
-S169 0086 Input
6 K8:6
1 -D790-1
0 /0.0_1.D4
A 24V D790-1/8:16 00816F 2 A
/9.1_1.A2 1 1 SWITCH REV. SEAT C.W
24V D790-1/8:16 00816G 3 3
/7.5_3.B2 7 7 0087
2
4
8
CHASSIS-37-D 0923D 10 10 9 9 00815B -X008
/9.1_1.B2
CHASSIS-37-D 0923E 7 K8:7 Input
/7.5_3.B2 REVERSIBLE SEAT -D790-1
/0.0_1.D4
SWITCH REV. SEAT C.C.W
B B
-X008 -X092f -X092m

PWM 1.5A K8:15 15 00815A 2 2 0922A D790-1/8:15
-D790-1 /7.5_1.B2
/0.0_1.E4
-X093f
LIGHT SW. S169/S1010 D790-1/8:15
0922D 1
/7.9_4.B1
-XS720-Ff -XS720-Fm -S720-F -XS720-Fm -XS720-Ff -X245f -X245m -X243m -X243f -X221
1 1 BU BN 2 2 2453 3 3 2435 5 5 22113 13 K1:13 Analog In 0-5V
-D797-2
BK BK/WH /0.0_3.D2
SWITCH SEAT POS. F
C SEAT POS. FRONT C
2451B
-X221 -X243f -X243m -X245m -X245f -XS720-Rf -XS720-Rm -S720-R -XS720-Rm -XS720-Rf -X245f -X245m -X243m -X243f -X221
1.5A K1:7 7 2217 4 4 2434 1 1 2451A 1 1 BU BN 2 2 2454 4 4 2436 6 6 22120 20 K1:20 Analog In 0-5V
-D797-2 -D797-2
/0.0_3.C2 BK BK/WH /0.0_3.D2
SWITCHES SEAT POS. F/R SWITCH SEAT POS. R
SEAT POS. REAR
D D

secuted.

-X690-2f -X066m
-B690-2 BK 2 2 0661 1 D790-1/6:12
-X066m -X690-2f /1.0_1.B5
3
5V 2 0662 1 1 RD 1 2 WH 3 3
/1.0_1.A4
ACCELERATOR REAR
-X066m
0V 3 0663
/1.0_1.A6
E E
-XS220-3m -S220-3 -XS220-3m

790-1:5-1/24V 1 BK 1 2 BN 2 790-1/6:14
/2.0_1.C3 /2.0_1.C6
BU 3

DECLUTCHING REAR
F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets vändbar förarstol DCF300-, DCE300- 9.3_3
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring turnable drivers seat A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-H410L
B -X221 -X247f -X247m -X270f -X270m B
1.5A K1:37 37 22137 1 1 2471 3 3 3 1 1 2 CHASSIS
-D797-2 /9.6_7.E8
/0.0_3.D5
LAMP BRAKE LIGHT FORWARD LEFT BRAKE LIGHT FORWARD LEFT
-H410R
-X221 -X247f -X247m -X271f -X271m
1.5A K1:36 36 22136 2 2 2472 3 3 3 1 1 2 CHASSIS
-D797-2 /9.6_7.D8
/0.0_3.D5
C C
LAMP BRAKE LIGHT FORWARD RIGHT BRAKE LIGHT FORWARD RIGHT
D D

secuted.

E E

F F

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-E401R
-X221 -X243f -X243m -X275-2f -X275-2m -X273-2f -X273-2m
6A K1:15 15 22115 1 1 2431A 1 1 2431B -X90034 2431D 2 2 2A 1 2
-D797-2
/0.0_3.D2
B B
LAMP DIPPED LIGHT REAR DIPPED LIGHT REAR RIGHT
-E401L
-X272-2f -X272-2m
2431C 2 2 2A 1 2
DIPPED LIGHT REAR LEFT
-E402R-2
C -X221 -X243f -X243m -X275-2f -X275-2m -X273-2f -X273-2m C
6A K1:1 1 2211 2 2 2432A 2 2 2432B -X90033 2432D 1 1 1A 1 2 6A CHASSIS
-D797-2 /9.6_6.E7
/0.0_3.C2
HEAD LIGHT REAR HEAD LIGHT REAR RIGHT
-E402L-2
-X272-2f -X272-2m
2432C 1 1 1A 1 2 6A CHASSIS
/9.6_6.D7
HEAD LIGHT REAR LEFT
D D

secuted.
-H413R

-X221 -X243f -X243m -X271-2f -X271-2m
1.5A K1:25 25 22125 3 3 2433A -X90025 2433B 2 2 2A 1 2 CHASSIS
-D797-2 /9.6_7.D8
/0.0_3.C5
LAMP REAR LIGHT FRONT REAR LIGHT FRONT RIGHT
-H413L
-X270-2f -X270-2m
2433C 2 2 2A 1 2 CHASSIS
/9.6_7.E8
REAR LIGHT FRONT LEFT
E E

F F

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B -Y636-1 B
-X221 -X243f -X243m -XY636f -XY636m -XY636m -XY636f
1.5A K1:9 9 2219 10 10 24310 1 1 BN 1 1 2 2 BU 2 2 24312B
-D797-2
/0.0_3.D2
VALVE STEERING FORWARD
STEERING FORWARD
-Y636-2
-X221 -X243f -X243m -XY636f -XY636m -XY636m -XY636f -X243m -X243f
1.5A K1:10 10 22110 11 11 24311 3 3 BN 1 1 2 2 BU 4 4 24312C -X90040 24312A 12 12 W243
-D797-2
C /0.0_3.D2 C
VALVE STEERING REVERSE
STEERING REVERSE -X37-216 CHASSIS
D D

secuted.

CHASSIS 24312D
/9.3_7.C6
E E

F F

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X066f -X066m
58-4/6:2 A0664 4 4 BN
/11.5_2.B6
A A
-A798
-X221 -X243f -X243m -X246f -X246m -XA798-1m
1.5A K1:29 29 22129 8 8 2438 B B RD 5/10
-D797-2
/0.0_3.D5
VALVE SEAT ROTATION C.W
-XA798-2m
BN 6/10 1/1 -X066m -X066f
BU 5 5 A0665
-X221 -X243f -X243m -X246f -X246m

1.5A K1:39 39 22139 9 9 2439 C C BK 7/10 2/10
-D797-2
/0.0_3.D5
B B
VALVE SEAT ROTATION C.C.W -X37-E #5815
BU 8/10 3/10
-X221 -X243f -X243m -X246f -X246m

1.5A K1:34 34 22134 7 7 2437 A A 9/10 4/10
-D797-2
/0.0_3.D5
DAMPING TURNABLE SEAT
10/10
BU
BN
WH
C C
A
B
-X37-798
-XM675f
-XM675f
-Y676
-X221 -X243Bf -X243Bm -XY676f -XY676m -XY676m -XY676f
B
1.5A
A
K1:35 35 22135 1 1 243B1 1 1 GY BU 2 2 24312D CHASSIS

-D797-2 /9.3_6.D5
-XM675m
-XM675m
/0.0_3.D5
BRAKE TURNABLE SEAT
BU
BN
TURN SEAT BRAKE -M675

31 50
M
D TURN SEAT
D
MOTOR
YE/GN

secuted.

#5642
E E

F F

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-S246
P
-XS246-1 -XS246-2 -X211
58-2/5:1 246-1 1 1 2 1 21140 21140 40 K1:40 Dig In / 1.5A
A /9.6_5.E2 -D797-1 A
/0.0_2.E5
REFRIGERANT
PRESSURE SW. REFRIDGE
-S118
-X005 -X033f -X033m 1
Analog reference 5V K5:11 11 00511 5 5 0335 0
-D790-1 2
/0.0_1.D1 1 1 -X033m -X033f -X005
3 3 0331 1 1 0057 7 K5:7 Analog Input
POT. FAN / TEMP / D-VALVE 7 7 -D790-1
/0.0_1.C1
-R820-6 2
1 2 4 FAN SPEED
8 -X033m -X033f
8k Ohm 0337 9 9 10 10 0338 8 8 0338 0363 CHASSIS
/9.4_2.E7
B -X006 -X033f -X033m FAN SPEED B
PWM 1.5A K6:1 1 0061 7 7
-D790-1
/0.0_1.A4
LAMP INST. ILLUMINATION -S139 -X37-D CHASSIS
1
0335A 0
2
1 1 -X033m -X033f -X005
3 3 0333 3 3 0059 9 K5:9 Analog Input
0339A 7 7 -D790-1
/0.0_1.D1
2
4 DRAUGHT VALVE
8
0337A 9 9 10 10 0338A
DRAUGHT VALVE
C C
-S117
-X033m 1
9 0339 0
2
0335B 1 1 -X033m -X033f -X005
3 3 0332 2 2 0058 8 K5:8 Analog Input
0339B 7 7 -D790-1
/0.0_1.D1
2
4 TEMPERATURE
8
0337B 9 9 10 10 0338B
TEMPERATURE
-R820-7 -X005
1 2 4 4 00510 10 K5:10 0V reference
-D790-1
/0.0_1.D1
D 8k Ohm D
0,5W POT. FAN / TEMP / DEFROST

secuted.

-B775-1
-X035f -X035m -X775-1 -X775-1 -X035m -X035f -X004
9 9 WH 1 1 T 2 2 YE 7 7 0048 8 K4:8 Reostat in
-D790-1
WH U /0.0_1.C1
TEMP. INDOOR SENSOR TEMP. INDOOR
10kOhm
-B775-2
-X775-2 -X775-2 -X035m -X035f -X004
00412C
1 1 T 2 2 BU 8 8 00410 10 K4:10 Reostat in
-D790-1
U /0.0_1.C1
TEMP. FAN AIR SENSOR TEMP. FAN AIR
E 10kOhm at 25°C E
-B775-3
-X036f -X036m -X775-3 -X775-3 -X036m -X036f -X004
9 9 WH 1 1 T 2 2 YE 8 8 00411 11 K4:11 Reostat in
-D790-1
U /0.0_1.C1
DE-ICING SENSOR SENSOR DE-ICING SENSOR
10kOhm at 25°C
00412B
-B774
-X004 -X039m -X039f -X065f -X065m -X774 -X774 -X065m -X065f -X039f -X039m -X004

0V reference K4:12 12 00412A 7 7 A0397 1 1 0651 1 1 T 2 2 0652 2 2 A0399 9 9 0049 9 K4:9 Reostat in
-D790-1 -D790-1
/0.0_1.C1 U /0.0_1.C1
F SENSORS AIR-CONDITION TEMP. AMBIENT SENSOR TEMP. AMBIENT F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets klimatsystem DCF300-, DCE300- 9.4_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring climate control A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
24V/12V
-X004 -X035f -X035m -R6
0.5A K4:4 4 0044 2 2 BK 1 2
A -D790-1 A
/0.0_1.B1
2 x 47 Ohm
MOTOR DRAUGHT VALVE
-X004 -X035f -X035m -R5 -Y672 DRAUGHT VALVE
0.5A K4:3 3 0043 1 1 RD 1 2
-D790-1 5 M 6
/0.0_1.B1
MOTOR DRAUGHT VALVE
-X004 -X035f -X035m -X035m -X035f -X004
Analog reference 5V K4:5 5 0045A 4 4 GN BN 6 6 0046A 6 K4:6 0V reference
-D790-1 10 8 -D790-1
/0.0_1.B1 /0.0_1.B1
9
POT. DRAUGHT/WAT. VALVE POT. DRAUGHT/ WAT VALVE
-X035m -X035f -X004
OG 5 5 0047 7 K4:7 Analog Input
-D790-1
/0.0_1.B1
0045B
24V / 12V
POT. DRAUGHT VALVE
-X004 -X034f -X034m -R4
0.5A K4:2 2 0042 5 5 BK 1 2
B -D790-1 B
/0.0_1.B1
2 x 220 Ohm
MOTOR WATER VALVE WATER VALVE
0046B
-X004 -X034f -X034m -R3 -Y673
0.5A K4:1 1 0041 4 4 RD 1 2 5 6
-D790-1 M
/0.0_1.B1
MOTOR WATER VALVE
-X034f -X034m -X034m -X034f
7 7 GN 10 8 BN 9 9
9 -X034m -X034f -X039m -X039f -X010

OG 8 8 0398 8 8 A0104 4 K10:4 Analog Input
-D790-1
/0.0_1.B6
POT. WATER VALVE
-M657
C -X039f -X039m -X034f -X034m -X657f -X657m C
58-5/3:1 A0396 6 6 0396 1 1 OG 1 1 OG
/11.5_2.D6 1
-X002 -X062f -X062m -X034f -X034m -X657f -X657m
PWM K2:2 2 A0022 8 8 0628 2 2 BK 2 2 BK
-D790-1 31
/0.0_1.B1
MOTOR HEATING FAN HEATING FAN
-X002
58-5/3:2 A0028 A0028 8 K2:8
/11.5_2.D6 -D790-1
/0.0_1.B1
24/12v LOGIC SUPPLY HEAT FAN
D D
-X039f -X039m -X036f -X036m -R1

secuted.

58-5/4:1 A0395 5 5 0395 1 1 RD 1 2 -X612f -X612m -M612
/11.5_2.D6
82 Ohm RD 1 1 RD
+12V
BK 2 2 GY
GND M
BU BU 3 3 BU
Signal
-X002 -X062f -X062m -X036f -X036m
1.5 A0023 0629
MOTOR, RECIRCULATION
K2:3 3 9 9 2 2
-D790-1
/0.0_1.B1
MOTOR RECIRCULATION
E E
-X036m -X036f
-M645 BK 3 3 0363 CHASSIS
/9.4_1.B7
-X211 -X278f -X278m -X645
1.5A K1:25 25 21125A -X90013 21125B 1 1 2781 1 2
-D797-1
/0.0_2.D5 1
/1.0_2G1.F1
COMPRESSOR AIR-CONDITION
COMPRESSOR
-X211

1.5A K1:29 29 21129
-D797-1
/0.0_2.D5
F COMPRESSOR AIR-CONDITION F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets klimatsystem DCF300-, DCE300- 9.4_2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring climate control A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X8110f -X8110m
F58-1-7:1 F58-1-7-1 1 1/9
/11.5_1.C5
81102 2 2/9
B 3/9 B
4/9
5/9
6/9
7/9
-X8110f 8/9
37-200E 9 9/9
-XM645f
645f1
-A8100
1
Condensor
C C
-XSP645
=Con chassis
-X37-200E
-XM645m -X37-200
1 645m1
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets kondensor chassi DCF300-, DCE300- 9.4_3
Sq. RSO 091123 A47137.0100
Name
R
E³ DRAWING
Wiring condensor chassis A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-S162 MULTI-SWITCH
-X017 -X017
24V reference K3:5 5 RD 15 53C GY 4 K3:4 Input
A -D790-2 -D790-2 A
/11.5_4.F4 /11.5_4.F4
SWITCH MULTI-FUNCTION SWITCH FLUSHING
-X017
J1 GN 6 K3:6 Input
-D790-2
/11.5_4.F4
SWITCH WIPER FRONT
-X017
J2 BK 7 K3:7 Input
-D790-2
/11.5_4.F4
SWITCH WIPER FRONT
-X017
53 BU 8 K3:8 Input
-D790-2
/9.7_1.B1 /11.5_4.F4
SWITCH WIPER FRONT
WIPER /9.6_4.C5
B /2.0_1.B5 B
31
-XM650-1m -XM650-1f
(1) 4 4 W01 W08 CHASSIS
/9.1_1.D7
-M650-1 M
-X002 -X062f -X062m -XM650-1f -XM650-1m FRONT WIPER
5A K2:1 1 A0021 7 7 0627 2 2 (1)
-D790-1
-
/0.0_1.B1
53
-X37-D CHASSIS
53a
53b
31b
MOTOR FRONT WIPER
-X004 -XM650-1f -XM650-1m
24V reference K4:14 14 00414 1 1 YE
-D790-1
/0.0_1.C1
-XM650-1m -XM650-1f -X004
C MOTOR FRONT WIPER (1) 3 3 00413 13 K4:13 Input C
-D790-1
/0.0_1.C1
MOTOR FRONT WIPER
-M650-2
-X002 -X057f -X057m -XM650-2f -XM650-2m -XM650-2m -XM650-2f -X057m -X057f
5A K2:4 4 A0024 1 1 0571 1 1 YE 53 31 BN 2 2 0574 4 4
-D790-1 M
/0.0_1.B1
MOTOR REAR WIPER -
-X012 -X057f -X057m -XM650-2f -XM650-2m 31b -XM650-2m -XM650-2f -X057m -X057f -X012
24V reference K12:1 1 A0121 3 3 0573 4 4 BK/GN 53a BK 3 3 0572 2 2 A0122 2 K12:2 Input
-D790-1 -D790-1
/0.0_1.D6 REAR WIPER /0.0_1.D6
D MOTOR REAR WIPER MOTOR REAR WIPER D
A0574

secuted.

-M650-3
-X010 -X055f -X055m -XM650-3f -XM650-3m -XM650-3m -XM650-3f -X055m -X055f
1.5A K10:14 14 A01014 1 1 0551 1 1 YE 53 31 BN 2 2 0554 4 4 A0554 -X37-B #3667
-D790-1 M
/0.0_1.C6
MOTOR ROOF WIPER -
-X012 -X055f -X055m -XM650-3f -XM650-3m 31b -XM650-3m -XM650-3f -X055m -X055f -X012
24V reference K12:3 3 A0123 3 3 0553 4 4 BK/GN 53a BK 3 3 0552 2 2 A0124 4 K12:4 Input
-D790-1 -D790-1
/0.0_1.D6 ROOF WIPER /0.0_1.E6
MOTOR ROOF WIPER MOTOR ROOF WIPER
-X058f -X058m
E -X058m -X058f 2 0582 WH 0.75 2
-M651-1 E
1 0581 GY 0.75 1
WASHER FRONT
-X010 -X058f -X058m -XM651-1 -XM651-1 -X058m 28112 28112 WH 0.75 -X058f
/9.2.D2
3A K10:13 13 A01013 1 1 0581 1 - + 2 0582 2 2 A0582
-D790-1 M
/0.0_1.C6
MOTOR WASHER
-X37-B #3658
-X058f -X058m
-X058m -X058f 4 0584 GY 0.75 4
-M651-2
3 0583 GY 0.75 3

WASHER REAR & ROOF
-X058f -X058m -XM651-2 -XM651-2 -X058m -X058f -X040f -X040m -X005
F A01013A 3 3 0583 1 - + 2 0584 4 4 A0402 2 2 0054 4 K5:4 PWM (NPN) F
M -D790-1
/0.0_1.C1
MOTOR WASH REAR/ROOF

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets torkare DCF300-, DCE300- 9.5_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring wiper function A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-S105-1
1 -X080m -X080f -X006
00610A 1 1 00610 10 K6:10 Input
0 -D790-1
1 1 /0.0_1.B4
790-1:5-1/24V 0811I 5 5
/9.6_2.B2 SW WORK LIGHTS MAST
A A
CHASSIS 0812J 10 10 9 9 00610B
/9.6_2.B2
WORK LIGHTS 20-40
-K3017-1
-X010
0.5A K10:8 8 A0108 86 86 85 85 W02
-D790-1
/0.0_1.C6
CONTAINER LIGHT 40
58-4/7:2 A0545B 30 30 87 87
/11.5_2.B6
87A
B CONTAINER LIGHT 40 B
A0565
-X37-A #3616
A0563
-E406L-1
-X056f -X056m -XE406L-1f -XE406L-1m -XE406L-1m -XE406L-1f
3 3 0563 1 1 GY 1 1 2 2 BK 2 2 0567A
CONTAINER LIGHT 40
C C
-E406R-1
-X056f -X056m -XE406R-1f -XE406R-1m -XE406R-1m -XE406R-1f -X056m -X056f
5 5 0565 1 1 GY 1 1 2 2 BK 2 2 0567B 7 7 A0567
CONTAINER LIGHT 40 -X37-E #4695
-K3017-2
-X007 -X069m -X069f
0.5A K7:8 8 0078 1 1 A0691 86 86 85 85 W02A
-D790-1
D /0.0_1.C4 D
CONTAINER LIGHT 20

secuted.

58-4/7:2 A0545C 30 30 87 87
/11.5_2.B6
87A
CONTAINER LIGHT 20
A0564
A0562 -X37-C #3616
-E406L-2
-X056f -X056m -XE406L-2f -XE406L-2m -XE406L-2m -XE406L-2f
2 2 0562 1 1 GY 1 1 2 2 BK 2 2 0566A
E E
CONTAINER LIGHT 20
-E406R-2
-X056f -X056m -XE406R-2f -XE406R-2m -XE406R-2m -XE406R-2f -X056m -X056f
4 4 0564 1 1 GY 1 1 2 2 BK 2 2 0566B 6 6 A0566

F F
CONTAINER LIGHT 20 -X37-E #4693

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets arbetsljus 20-40 DCF300-, DCE300- 9.6_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring work lights 20-40 A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S105-2
1 -X080m -X080f -X006
790-1:5-1/24V 0811H 0062A 2 2 0062 2 K6:2 Input
/9.6_3.B2 0 -D790-1
1 1 /0.0_1.A4
790-1:5-1/24V 0811I 5 5
/9.6_1.A2 SW W-LIGHTS CARRIAGE
B B
CHASSIS 0812J 10 10 9 9 0062B
/9.6_1.A2
CHASSIS 0812I WORK LIGHTS CARRIAGE
/9.6_3.B2
24V D791-1/1:1 CHASSIS

/9.6_14.B2 /9.6_14.B7
C C
-E404L-3
-X421 -XE404L-3f -XE404L-3f
6A K1:1 1 4211 1 1 2 2 W4211 4054 CHASSIS
-D791 /7.9_1.E7
/0.0_4.C2
WORK LIGHT LEFT WORK LIGHT CARRIAGE LEFT
24V D791-1/1:15 CHASSIS

/9.6_14.E2 /9.6_14.E7
-E404R-3
-X421 -XE404R-3f -XE404R-3f
6A K1:15 15 42115 1 1 2 2 W42115 W400 CHASSIS
D -D791 /11.5_5.B7 D
/0.0_4.D2 -X90061
WORK LIGHT RIGHT

secuted.
WORK LIGHT CARRIAGE RIGHT

W42114 CHASSIS
/9.14_1.E7
E E
W9003 CHASSIS
/7.5_3.E7

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets arbetsljus vagn DCF300-, DCE300- 9.6_2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring work lights carriage A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B -S105-3 B
1 -X080m -X080f -X006
790-1:5-1/24V 0811G 0063A 3 3 0063 3 K6:3 Input
/9.6_4.B2 0 -D790-1
1 1 /0.0_1.B4
790-1:5-1/24V 0811H 5 5
/9.6_2.B2 SW WORK LIGHTS MAST
CHASSIS 0812I 10 10 9 9 0063B
/9.6_2.B2
CHASSIS 0812H WORK LIGHTS MAST
/9.6_4.B2
C C
D D
-E404R-1
-X211 -X204m -X204f -X2041f -X2041f -X204f -X204m
6A -X90019

secuted.

K1:1 1 2111A 2111B 1 1 2041 1 1 2 2 2043 3 3 W2043
-D797-1
/0.0_2.C2
LAMPS WORK LIGHT MAST WORK LIGHT MAST
-E404L-1
-X204m -X204f -X2042f -X2042f -X204f -X204m
2111C 2 2 2042 1 1 2 2 2044 4 4 W2044 W204
-X90078
WORK LIGHT MAST -X37-201A
E -X37-201 #4618 E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets arbetsljus stativ DCF300-, DCE300- 9.6_3
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring work lights mast A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-S100
1 -X080m -X080f -X006
0065A 5 5 0065 5 K6:5 Input
790-1:5-1/24V 0811E 0 -D790-1
/9.3_1.B2 1 1 /0.0_1.B4
5 5
SWITCH MAIN LIGHT
CHASSIS 0812E 10 10 9 9 0065B
A /9.3_1.B2 A
CHASSIS 0812F
/9.6_7.A2 MAIN LIGHT
0811F
-S110
1 -X080m -X080f -X006
0064A 4 4 0064 4 K6:4 Input
0 -D790-1
1 1 /0.0_1.B4
B 790-1:5-1/24V 0811G 5 5 B
/9.6_3.B2 SWITCH ROT. BEACON
CHASSIS 0812G 10 10 9 9 0064B
/9.6_7.B2
CHASSIS 0812H
/9.6_3.C2 ROT. BEACON
-S162 MULTI-SWITCH
56 56b
-X017
56a WH 9 K3:9 Input
C -D790-2 C
/11.5_4.F4
SWITCH MAIN / DIPPED BEAM
/2.0_1.A4
MAIN / DIPPED BEAM /9.5_1.B4
-K3775 Option extra beaconlight

-XK3775 -XK3775
85 86 85 86 K3775_85
D D
/9.6_4.E5

secuted.

-H828-2
-XK3775 -XK3775 -X054f -X054m -X428-3 -X428-4
585/8:2 K3775_30 30 30 87 87a K3775_87 9 9 054m 1 + - 1 37-B9
/11.5_2.E6 M
87A
0561
/9.6_4.D5 ROT. BEACON
1
-X37-B9
E -X002 -X056f -X056m E

5A A0025
-X37-C CHASSIS
K2:5 5 1 1
-D790-1
/0.0_1.B1
MOTOR ROT. BEACON
-H428
ROT. BEACON
-X054f -X054m -X428-1 -X428-2 -X054m -X054f
A0547 7 7 0547 1 + - 1 0548 8 8 A0548
M

F -X37-B #3666 F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets belysning DCF300-, DCE300- 9.6_4
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring lights A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
270:2 270:2 -E400L

A -X270f /9.6_13.A1 /9.6_13.A8 -X270m A
21128C 2 2 2 1 1 2
DIPPED LIGHT FRONT LEFT
271:2 271:2 -E400R

-X211 -X271f /9.6_13.C1 /9.6_13.C8 -X271m
6A K1:28 28 21128A -X90028 21128B 2 2 2 1 1 2
-D797-1
/0.0_2.D5
LAMP DIPPED LIGHT DIPPED LIGHT FRONT RIGHT
B B
-X270/271f X211:1 -X270/271m 270:1 -E402L-1

/9.6_13.E2 -X270f /9.6_13.A1 -X270m
21115C 1 1 21115D 1 1 1 1 1 2 1 6A
24V-K304-2-87
/9.6_13.F5
HEAD LIGHT FRONT LEFT
6B CHASSIS
/9.6_7.E8
-X270/271f -X270/271m 271:1 -E402R-1
-X211 -X271f /9.6_13.C1 -X271m
6A K1:15 15 21115A -X90027 21115B 2 2 21115E 1 1 1 1 1 2 1 6A
-D797-1
/0.0_2.D2 24V-K304-2-87
/9.6_13.F5
HEAD LIGHT HEAD LIGHT FRONT RIGHT
C C
270:5 270:5 -H416-1 -X270m 270:6 270:6 -X270f

-X211 -X270f /9.6_13.A1 /9.6_13.A8 -X270m /9.6_13.A8 /9.6_13.A1
1.5A K1:2 2 2112A -X90006 2112B 5 5 5 1 1 2 1 6C 6 6 6 2706
-D797-1
/0.0_2.C2 -X90047
SIDE POSITION LIGHT SIDE POSITION FRONT LEFT
6B CHASSIS
/9.6_7.D8
271:5 271:5 -H417-1 -X271m 271:6 271:6 -X271f

-X271f /9.6_13.D1 /9.6_13.D8 -X271m /9.6_13.D8 /9.6_13.D1
2112C 5 5 5 1 1 2 1 6C 6 6 6 2716
D D
-X90046
-X37-207A

secuted.
SIDE POSITION FRONT RIGHT

-X37-207 CHAS
2112D 2112
/9.6_6.D2
58-2/5:1 771A -S216

/7.7_2.C2
58-2/5:1 2481
/7.2_6.E1 P
58-2/5:1 246-1 -X211
/9.4_1.A2
58-2/5:1 216-246 -X90043 216-1A 1 2 21120 20 K1:20 Analog In 0-5V
/11.5_1.B8 -D797-1
58-2/5:1 216-1B /0.0_2.E2
E /2.0_1.C2 BRAKE LIGHTS E
PRESSURE SWITCH BRAKE LIGHT

F F

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-E405L
-X056f -X056m
A0543 9 9 0569A 1 1 2 1 0569B
REVERSING LIGHT REAR LEFT

A A
-E405L
-X002 -X054f -X054m -X054m -X054f
5A K2:6 6 A0026 3 3 0543 1 1 2 2 0544 4 4 A0544
-D790-1
/0.0_1.B1
REVERSING LIGHT LEFT REVERSING LIGHT REAR LEFT
-E405R
-X056f -X056m
A0545 8 8 0568A 1 1 2 1 0568B
REVERSING LIGHT REAR RIGHT
-E405R -X37-C
-X002 -X054f -X054m #4684 -X054m -X054f
5A K2:7 7 A0027 5 5 0545 1 1 2 2 0546 6 6 A0546
B -D790-1 B
/0.0_1.B1
REVERSING LIGHT RIGHT REVERSING LIGHT REAR RIGHT
-X37-A #3665
-H411L
-X211 -X275f -X275m -X272f -X272m
1.5A K1:7 7 2117 3 3 2753 3 3 3 1 2
-D797-1
/0.0_2.D2
BRAKE LIGHT LEFT BRAKE LIGHT REAR LEFT
C -H411R C
-X211 -X275f -X275m -X273f -X273m
1.5A K1:9 9 2119 4 4 2754 3 3 3 1 2
-D797-1
/0.0_2.D2
BRAKE LIGHT RIGHT BRAKE LIGHT REAR RIGHT
CHASSIS
-H412L /9.6_7.E8
-X211 -X275f -X275m -X272f -X272m
1.5A K1:33 33 21133 5 5 2755A -X90007 2755B 2 2 2 1 2 6B
-D797-1
/0.0_2.D5
6A CHASSIS
REAR LIGHTS REAR LIGHT LEFT /9.3_5.D7
D D

secuted.

-H416-2
-X275f -X275m -X272f -X272m -X272m -X272f -X275m -X275f
2112 2112D 6 6 2756A -X90024 2756B 5 5 5 1 2 6C 6 6 6 2726 8 8 2758
/9.6_5.D6
-X90049
SIDE POSITION REAR LEFT
CHASSIS
-H412R /9.6_7.D8
-X273f -X273m
2755C 2 2 2 1 2 6B
6A CHASSIS
E REAR LIGHT RIGHT /9.3_5.C7 E
-H417-2
-X273f -X273m -X273m -X273f -X275m -X275f
2756C 5 5 5 1 2 6C 6 6 6 2736 7 7 2757
-X90048
SIDE POSITION REAR RIGHT

-X37-204 CHASSIS
F F

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A -S109 A
1
0 -X081m -X081f -X005
-X039f -X039m -X081f -X081m 1 1 0816 6 6 0056 6 K5:6 Input
58-4/2:2 A0392 2 2 0392 7 7 0817 5 5 -D790-1
/11.5_2.A6 /0.0_1.C1
CHASSIS 0812F 10 10 9 9 0815 5 5 SWITCH HAZARD
/9.6_4.A2
CHASSIS 0812G Hazard
/9.6_4.B2 -X005
0055 5 K5:5 PWM (PNP)
-D790-1
/0.0_1.C1
SWITCH LAMP HAZARD
B B
-S161
R
0
L -X018
1 1 0189 9 K8:9 Input
-D790-2
0187B 2 2 3 /11.5_4.F4
SWITCH DIRECTION LIGHT RIGHT
-X018
1.5A K8:7 7 0187A 5 5 4
-D790-2 -X018
/11.5_4.F4 6 6 0188 8 K8:8 Input
C -D790-2 C
SWITCH DIRECTION LIGHT /11.5_4.F4
DIRECTION LIGHT SWITCH DIRECTION LIGHT LEFT
271:4 271:4 -H423 CHASSIS

-X211 -X271f /9.6_13.C1 /9.6_13.C8 -X271m /9.3_5.D7
2.5A K1:31 31 21131A -X90065 21131B 4 4 4 1 1 2 1 6B CHASSIS
-D797-1 /9.6_5.D7
/0.0_2.D5 CHASSIS
D /9.3_4.C7 D
LAMP DIRECTION RIGHT Direction Right Front

secuted.

-H427
-X275f -X275m -X273f -X273m
21131C 2 2 2752 4 4 4 1 1 2 CHASSIS
/9.6_6.E7
Direction Right Rear
270:4 270:4 -H422 CHASSIS

-X211 -X270f /9.6_13.A1 /9.6_13.A8 -X270m /9.3_4.B7
2.5A K1:30 30 21130A -X90003 21130B 4 4 4 1 1 2 1 6B CHASSIS
-D797-1 /9.6_5.C7
/0.0_2.D5 CHASSIS
E /9.3_5.E7 E
LAMP DIRECTION LEFT Direction Left Front
-H426
-X275f -X275m -X272f -X272m
21130C 1 1 2751 4 4 4 1 1 2 CHASSIS
/9.6_6.D7
Direction Left Rear

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets blinkers & hazard DCF300-, DCE300- 9.6_7
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring light director & hazard A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A0668 58-4/2:1
/9.6_11.B1
A A
-X060f -X060m -X060Af -X060Am -X018 -X018 -X060Am -X060Af -X060m -X060f -X011
58-4/2:1 A0607 7 7 0607 7 7 0607B 10 K8:10 K8:11 11 0609 9 9 0609 9 9 A0112 2 K11:2 Input
/11.5_2.A6 -D790-2 -D790-2 -D790-1
/0.0_1.C6
SWITCH INTERIOR LIGHT SWITCH INTERIOR LIGHT INTERIOR LIGHT
58-4/2:1 0607A
/11.5_3.C2
INTERIOR LIGHT SWITCH DISPLAY
B B
-X039f -X039m -X082f -X082m -S266-LE -X082m -X082f -X039m -X039f -X011
58-4/2:1 A0393 3 3 0393A 1 1 0393C 1 1 2 1 0394C 2 2 0394A 4 4 A0113 3 K11:3 Input
/11.5_2.A6 -D790-1
/0.0_1.C6
BRAKING CAB DOOR
SWITCH BREAK CAB DOOR
-S266-RI
0393B 1 1 2 1 0394B
C C
BRAKING CAB DOOR
-E434-1
-X011 -X054f -X054m -X054m -X054f
1.5A K11:6 6 A0116 1 1 0541 1 1 2 1 0542 2 2 A0542A
-D790-1
/0.0_1.D6
LAMP INTERIOR LIGHT INTERIOR LIGHT
D D

secuted.

-X066f -X066f
A0541 6 24V D790-1/11:6 CHASSIS 7 A0542B
/9.6_11.C1 /9.6_11.C7
E E
-E434-2
-X062f -X062m -XE434-2f -XE434-2m -XE434-2m -XE434-2f -X062m -X062f
58-5/6:1 A0624 4 4 0624 1 1 BK 1 2 1 2 BK 2 2 0625 5 5 A0625
/11.5_2.E6
MAP LIGHT

-X37-A #4783
F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets innerbelysning DCF300-, DCE300- 9.6_8
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring interior lights A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-E404R-4
-X213m -XE404R-4f -XE404R-4f -X213m
24V D797-1/1:42 1 2131A -X90062 2131B 1 1 2 2 2132B 2132A 2 CHASSIS
/9.0_1.C4 /9.0_1.C6
-X90063
WORK LIGHT OPT
C C
-E404L-4
-XE404L-4f -XE404L-4f
2131C 1 1 2 2 2132C
WORK LIGHT OPT

D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets arbetsljus option DCF300-, DCE300- 9.6_9
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring work lights option A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-E404R-2
-XE404R-2f -XE404R-2f
2491C 1 1 2 2 2492C
C C
WORK LIGHT OPT
-E404L-2
-X249m -XE404L-2f -XE404L-2f -X249m
D797-2/1:42 1 2491A -X90042 2491B 1 1 2 2 2492B 2492A 2 CHASSIS
/11.5_9.D3 /11.5_9.D6
-X90041
WORK LIGHT OPT
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets arbetsljus option DCF300-, DCE300- 9.6_10
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring work lights option A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X066f -X066m -X276f -X276m -XS141f -XS141m -S141 -XS141m -XS141f -X276m -X276f -X066m -X066f -X011
58-4/2:1 A0668 8 8 GY 1 1 GY 1 1 BN 1 2 BK 2 2 BK 2 2 BK 9 9 A0114 4 K11:4 Input
/9.6_8.A2 -D790-1
/0.0_1.D6
STEP LIGHT
SWITCH STEP IN LIGHT
B B
C C
-E433
-X066m -X276f -X276m -X276m -X276f -X066m
24V D790-1/11:6 6 RD 3 3 GY 1 1 2 1 BK 4 4 BU 7 CHASSIS
/9.6_8.D3 /9.6_8.D6
STEP LIGHT
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets instegsbelysning DCF300-, DCE300- 9.6_11
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring step in light A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-E404L-5
-XE404L-3m -XE404L-5f -XE404L-5f -XE404L-3m
Kopplas till kontakt för std belyning. 1 4211A -X90085 4211B 1 1 2 2 W4211B -X90087 W4211A 2
Kopplas till kontakt för std belyning.
B B
Connected to connector std work light. Connected to connector std work light.
WORK LIGHT CARRIAGE LEFT OPT
-XE404L-3f -XE404L-3f
4211C 1
Std belysning 2 W4211C
Std work light
C C
-E404R-5
-XE404R-3m -XE404R-5f -XE404R-5f -XE404R-3m
Kopplas till kontakt för std belyning. 1 42115A -X90086 42115B 1 1 2 2 W42115B -X90088 W42115A 2
Kopplas till kontakt för std belyning.
Connected to connector std work light. Connected to connector std work light.
WORK LIGHT CARRIAGE RIGHT OPT
D -XE404R-3f -XE404R-3f D
42115C 1
Std belysning 2 W42115C

secuted.

Std work light
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets extra bel. aggr DCF300-, DCE300- 9.6_12
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring work lights carriage opt A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X270Am
270:1 1 1 -X270Af
/9.6_5.B4
270:2 2 2 2 2 270:2
A /9.6_5.A3 /9.6_5.A5 A
3 3 3 3
270:4 4 4 4 4 270:4
/9.6_7.E4 /9.6_7.E5
270:5 5 5 5 5 270:5
/9.6_5.C3 /9.6_5.C5
270:6 6 6 6A 6 270:6
/9.6_5.C8 /9.6_5.C7
-E404-7L
1A 1 2 6B
B B
OPT. WORKING LIGHT FRONT LEFT
-E404-8L
1B 1 2 6C
OPT. WORKING LIGHT FRONT LEFT
C C
-X271Am
271:1 1 1 -X271Af
/9.6_5.C4
271:2 2 2 2 2 271:2
/9.6_5.B3 /9.6_5.B5
3 3 3 3
271:4 4 4 4 4 271:4
/9.6_7.D4 /9.6_7.D5
271:5 5 5 5 5 271:5
/9.6_5.D3 /9.6_5.D5
271:6 6 6 6A 6 271:6
/9.6_5.D8 /9.6_5.D7
D D
-E404-7R

secuted.

1A 1 2 6B
OPT. WORKING LIGHT FRONT RIGHT
-E404-8R
1B 1 2 6C
OPT. WORKING LIGHT FRONT RIGHT
E E
-K304-2
-X270/271m
X211:1 1 GY 86 86 85 85 W304-2-85
/9.6_5.B3
-X270/271f -X37-200R
58-1/8:1 W304-2-30A 30 30 87 87 BK 1 24V-K304-2-87
/11.5_1.C5 /9.6_5.B3
87A RD 2 24V-K304-2-87
/9.6_5.C3

WORK LIGHTS
F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets arbetsljus option lamphuv DCF300-, DCE300- 9.6_13
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring work lights option fenders A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-E404L1
-XE404m -XE404m
24V D791-1/1:1 1 4041A -XSP404-1 4041B 1 1 2 2 4042B -XSP404-2 4042A 2 CHASSIS
/9.6_2.C4 /9.6_2.C5
WORK LIGHT CARRIAGE LEFT
-E404L2
4041C 1 1 2 2 4042C
WORK LIGHT CARRIAGE EXTRA LEFT

C C
D D

secuted.

-E404R1
-XE404Rm -XE404Rm
24V D791-1/1:15 1 4041A -XSP404-1 4041B 1 1 2 2 4042B -XSP404-2 4042A 2 CHASSIS
/9.6_2.D4 /9.6_2.D5
WORK LIGHT CARRIAGE RIGHT
-E404R2
4041C 1 1 2 2 4042C
E E
WORK LIGHT CARRIAGE EXTRA RIGHT

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets arbetsljus option vagn DCF300-, DCE300- 9.6_14
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Updated ultrasond 7.3_2 1021496 PLT 150810 6
Wiring work lights option carriage A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S162 MULTI-SWITCH
/9.5_1.B4
-X017
H BN 2 K3:2 Input
-D790-2
/11.5_4.F4
SWITCH HORN
HORN
B B
-X011 -X062f -X062m -H850

3A K11:11 11 A01111A 1 1 0621 +
-D790-1
/0.0_1.D6 0622 -
HORN
Horn
0621 A01111B
/9.7_3.B2
0622A CHASSIS
/9.7_3.C7
-X062f -X062m
C 2 2 C
A0622
-X37-B CHASSIS
-X011 -X063f -X063m -X230f -X230m -S230 -X230m -X230f -X063m -X063f -X011
24V reference K11:12 12 A01112 1 1 0631 2 2 BU 2 1 RD 1 1 0632 2 2 A01114 14 K11:14 Input
D -D790-1 -D790-1 D
/0.0_1.D6 3 GY 3 /0.0_1.D6
SWITCH SEAT SWITCH SEAT

secuted.

SEAT SWITCH
-H853
-X018 -XH853f -XH853m -XH853m -XH853f

1.5A K8:4 4 0184 1 1 RD 1 2 BK 2 2 02014 790-2/1:14
-D790-2 /11.6_1.B2
/11.5_4.F4
BUZZER
BUZZER
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets larm, ljudsignaler DCF300-, DCE300- 9.7_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring alarm, buzzer and horn A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-X211 -X275f -X275m -XH965f -XH965m -H965

1.5A K1:10 10 21110 9 9 2759 1 1 RD +
-D797-1
/0.0_2.D2 10 10 27510 2 2 BK -
REVERSING ALARM
REVERSING ALARM
C C
37210 2023 CHASSIS

/7.0_5.D2
-X37-210 CHASSIS
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets backalarm DCF300-, DCE300- 9.7_2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring reversing alarm A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-K3016
0621 A01111B 86 85 86 85 W04

/9.7_1.C2
/9.7_3.C4
COMPRESSOR HORN
B -X37-B #1064 B
-H850-1
COMPRESSOR HORN
-K3016 -X062f -X062m
58-5/8:1 A0623A 30 30 87 87 A0623B 3 3 0623 1 - + 1 0622A CHASSIS
/11.5_2.E6 M /9.7_1.C7
87A
/9.7_3.B4
COMPRESSOR HORN
C C
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets kompressor horn DCF300-, DCE300- 9.7_3
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring compressor horn A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S149-3
1
24V D790-1/8:16 0921B 0 -X091m -X091f -X009
/7.9_1.B2 1 0911 1 1 00910 10 K9:10 Input
24V D790-1/8:16 0921C 2 -D790-1
B /7.5_1.B2 B
HORN SERVO PANEL OPT. HORN SERVO PANEL OPT.
C C
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets tuta servopanel DCF300-, DCE300- 9.7_4
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring horn servo panel A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X900Af -X900Bf
1/8 1/8
2/8 2/8 -H902R
-X900Bm
3/8 3/8 3 BK/WH +
-X055f -X055m -X900Am
58-4/5:1 A0555 5 5 0555 4 4/8 4/8 4 BK -
/11.5_2.B6
5/8 5/8 5 BK/WH
SPEAKER RIGHT
6/8 6/8 6 BK
-X055f -X055m -X900Am
58-4/3:2 A0559 9 9 0559 7 7/8 7/8
/11.5_2.B6
A0557 7 7 0557 8 8/8 8/8
B -H902L B
+
-
SPEAKER LEFT
-A900
C C
A0557
D D

secuted.

-X37-C #3668
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets radio DCF300-, DCE300- 9.8_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring radio A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
+12V RD 12V
/11.5_7.C6
CHASSIS BK
/11.5_7.C6
5V
-XA909-2f
-X182m -X182f -XA909-2m
KID_RX 1822 2 2 90922 TX
/11.6_1.A2
KID_TX 1823 3 3 90923 RX
/11.6_1.A2
KID_GND 1825 5 5 90925 GND

/11.6_1.A2
B -A909 B
Printer Ap863
-X183f
+12V 1 RD 1
/11.5_7.D6
KID_RX 2 OG 2 Power
/11.5_7.D6
KID_TX 3 BU 3 RxD
C /11.5_7.D6 TxD C
KID_GND 5 BK 5 GND
/11.5_7.D6
-A910
Printer Ap1310DC
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets skrivare DCF300-, DCE300- 9.8_2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring printer A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Strömbrytare 123, se sida 9.1_1

B B
/Switch 123, see page 9.1_1
-X241m -XE802Rf -XE802Rm -E802R-1 -XE802Rm -XE802Rf -X241m
24V D797-2/1:11 2 GY 1 1 BN 1 2 BU 2 2 BK 1 CHASSIS
/11.5_11.B3 /11.5_11.B6
-E802R-2
BN 1 2 BU
C C
-X241m -XE802Lf -XE802Lm -E802L-1 -XE802Lm -XE802Lf -X241m

24V D797-2/1:12 3 GY 1 1 BN 1 2 BU 2 2 BK 4 CHASSIS
/11.5_11.C3 /11.5_11.D6
-E802L-2
BN 1 2 BU
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets värme backspeglar DCF300-, DCE300- 9.9_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring heating mirrors A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
WHEN BOTH CAMERAS ARE USED CONNECT CORE GN TO X056:8 OR X054:5
B B
1
-A907
-X057f -X057m -X265f -X265m -XA907f

A0577 RD RD
-XA907m
58-5/4:2 7 7 1 1 1
/11.5_2.D6
-X265f -X265m -A908-1
GN 2 2 GN 3 -XCA2f -XCA2m -XA908-1f -XA908-1m
+24V on CORE GN WILL ALWAYS DISPLAY THE REAR CAMERA BK BK
3 3 4
C C
Front Camera
-A908-2
-XCA1f -XCA1m -XA908-2f -XA908-2m
D Rear Camera D

secuted.

Monitor
E E
-X057m -X057f
BK 9 9 A0579
-X37-E CHASSIS

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets kamera DCF300-, DCE300- 9.9_2
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring cameraWiring camera A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Strömställare val manuell/automatisk hyttippning se S199-2.

Switch choice manual/automatic cab tilt see S199-2. 1 = UP/RIGHT
0=0
A 2 = DOWN/LEFT -X008 A
-S1010 0086 Input
6 K8:6
24V D790-1/8:16 00816F 1 -D790-1
/9.1_1.A2 0
2
1 1 SWITCH CAB TILT UP/RIGHT
24V D790-1/8:16 00816G 3 3
/7.5_3.B2 7 7
2
4
8 -X008
CHASSIS-37-D 0923D 10 10 9 9 00815B 0087 7 K8:7 Input
/9.1_1.B2 -D790-1
CHASSIS-37-D 0923E
/7.5_3.B2 CAB TILT/SLIDING CAB
SWITCH CAB TILT DOWN/LEFT
-X008 -X092f -X092m

1.5A K10:14 15 00815A 2 2 0922A D790-1/8:15
-D790-1 /7.5_1.B2
B -X093f B
LIGHT SW. S169/S1010 D790-1/8:15
0922D 1
/7.9_4.B1
-Y6080
-X221 -X243f -X243m -X243m
1.5A K1:25 25 22125 3 3 GY 1 1 2 2 BK 12
-D797-2
Endast vid hyttkörning, ej hyttilt. ACT. SLIDING CAB

Only for sliding cab, not cab tilt.
C C
-Y6047
-X221 -X243f -X243m
1.5A K1:29 29 22129 8 8 2438 1 1 2 2 24312B
-D797-2
CAB TILT UP/RIGHT
-Y6048
-X221 -X243f -X243m -X243m -X243f
1.5A K1:39 39 22139 9 9 2439 1 1 2 2 24312C 24312A 12 12 W243
-D797-2
-X90067
D CAB TILT DOWN/LEFT -X37-216 #4053 D

secuted.

-X221 -X243f -X243m -XB769-1f -XB769-1m
1.5A K1:7 7 2217 4 4 2434A -X90066 2434B A A
-D797-2
BN
-B769-1 -XB769-1m -XB769-1f -X243m -X243f -X221
BK C C 2435 5 5 22113 13 K1:13 Input
-D797-2
CAB TILT UP
BU
B B 24312D
E E
-XB769-2f -XB769-2m
2434C A A
BN
-B769-2 -XB769-2m -XB769-2f -X243m -X243f -X221
BK C C 2436 6 6 22120 20 K1:20 Input
-D797-2
CAB TILT DOWN
Endast vid hyttilt, ej hyttkörning. BU
B B 24312E
Only for cab tilt, not sliding cab.

F F
Givare stativ för automatisk hyttilt se B7211-1.
Sensor mast when automatic cab tilt see B7211-1.
Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets hyttilt/hyttkörning DCF300-, DCE300- 9.10_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring cab tilt/sliding cab A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-M693-1
1
GREY
2
B -X213m -XM693-1 B
24V D797-1/1:42 1 1 15
/9.0_1.C4 M
31 BLACK
2
CENTRAL LUBRICATION
-X213m
2 CHASSIS
/9.0_1.C6
C C
-M693-2
1
D GREY D
2

secuted.

-X421 -XM693-2
10A K1:14 14 42114 1 15
-D791 M
/0.0_4.D2 BLACK
2 31
PUMP CENTRAL LUBRICATION
CENTRAL LUBRICATION
W42114 CHASSIS
E /9.6_2.E8 E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets centralsmörjning DCF300-, DCE300- 9.14_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring central lubrication A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-Y6062
-X211
1.5A K1:39 39 21139 1 1 2 2 6062 CHASSIS
-D797-1 /7.2_2.E5
/0.0_2.E5
VALVE PUMP 2
CUT SERVO HYDRAULICS
(EXTRA PUMP LIFT)EC
C C
-Y6062-2
-X211 -XY6012/6062 -XY6012/6062
1.5A K1:35 35 21135 1 1 2 2 6012 CHASSIS
D -D797-1 /7.2_2.D5 D
/0.0_2.D5
PUMP ATTACHMENT

secuted.

INTERR PUMP ATT
(ACT. PUMP ATT)EC
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets urkoppl. hydr pump DCF300-, DCE300- 10.4_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring interruption hydr. pump A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-B776
-XB776f -XB776f -X212
2 2 T 1 1 21213 13 K2:13 Temperature Input
-D797-1
U /0.0_2.C4
HYDRAULIC OIL TEMPERATURE SENSOR HYDR. OIL TEMP.
7762
B B
-M668
-X211 -XM668f -XM668m -XM668m -XM668f
10A K1:14 14 21114 1 1 1 2 2 2 6682
-D797-1 M
/0.0_2.D2
MOTOR COOLING FAN HYDR. OIL
COOLING FAN HYDRAULIC OIL
-X37-202A
-X37-202 #4602
C C
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets kyln. hydraul olja DCF300-, DCE300- 10.6_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring cooling hydraulic oil A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
0711 54-4
MAIN RELAY IGNITION /11.5_2.C1
/11.5_3.E4
87 30
A -K315-1 A
W208
21211 58-2/1:1
/11.5_4.A2
-F58-2 2121 58-2/1:1
1a 1b /11.5_4.B2
50A /11.5_1.B2 W213 A:1 30 A 1:1 2129 58-2/1:2
A:1 1:1 /11.5_4.B2
W214 A:2 A:2 1:2 1:2 21210 58-2/1:2
/11.5_4.B2
W226 B:1 5A
B:1 2:1
B:2 2:2 2221 58-2/3:1
/11.5_5.D2
C:1 25 A 3:1 2229 58-2/3:1
2a 2b C:1 3:1 /11.5_5.D2
-F58-1 C:2 C:2 3:2 3:2 22210 58-2/3:2
50A /11.5_5.D2
W223
B W209 A:1 30 A 1:1 0526 58-1/1:1 D:1 10 A 4:1 W237 58-2/4:1 B
A:1 1:1 /11.5_2.A2 D:1 4:1 /11.5_10.B2
A:2 A:2 1:2 D:2 4:2
B:1 30 A 2:1 2801 58-1/2:1 E:1 5A 5:1 216-246 58-2/5:1
B:1 2:1 /1.0_2F.A1 E:1 5:1 /9.6_5.E2
B:2 2:2 2:2 58-1/2:2 E:2 E:2 5:2 5:2 90012A 58-2/5:2
3a 3b /1.0_2G1.A2 /7.2_2.C2 /1.0_1.E3
50A W210 C:1 15 A 3:1 2101 58-1/3:1 F:1 5A 6:1 2014 58-2/6:1 /1.0_2B2.B2
C:1 3:1 /1.0_1.C3 F:1 6:1 /2.0_1.F2 /1.0_2C.C2
C:2 C:2 3:2 3:2 58-1/3:2 F:2 F:2 6:2
2105A
/1.0_2G1.A2 -K315-2
2107A
/1.0_2D.B2
D:1 10 A 4:1 58-1/4:1 G:1 5A 7:1 58-2/7:1
D:1 4:1 /1.0_1.D3 G:1 7:1 /1.0_2E2.B2
D:2 D:2 4:2 4:2 W221 30 87 W222 G:2 7:2
E:1 5A 5:1 2012 58-1/5:1 87A H:1 5A 8:1 2108A 58-2/8:1
4a 4b E:1 5:1 /2.0_1.E2 H:1 8:1 /1.0_1.E3
50A E:2 5:2 /11.5_3.F4 H:2 8:2
W228 377430
RELAY IGNITION
F:1 15A 6:1 58-1/6:1 /11.5_1.D6 +15
F:1 6:1 /4.8_1.C2
F:2 F:2 6:2
F2G1
C W214 G:1 25A 7:1 F58-1-7-1 F58-1-7:1 C
G:1 7:1 /9.4_3.B3 -F58-2
G:2 7:2 1 KDU CHASSIS
W304-2-30B H:1 15A 8:1 W304-2-30A 58-1/8:1 2 NOT USED
H:1 8:1 /9.6_13.F2 3 KDU OPT. CHASSIS
H:2 8:2
4 OPT.
/11.5_1.D3 +30 5 SWITCHES / SENSORS
6 TRANSMISSION
W207
W206
W211
7 ENGINE
1 CAB 8 ENGINE
2 EATS(volvo)
/11.5_1.C6
3 ENGINE
4 ENGINE
5 TRANSMISSION
6 OPT. COOLING FAN, BRAKES
54/3 7 OPT. Condensor outside
/11.5_6.D2
D 8 Opt. work lights D
/11.5_1.C3

secuted.

GY Batt + W212 CHASSIS
/8.2_4.F1 /11.5_3.E2
37209 CHASSIS
-S144 -G30-1 -G30-2 /7.2_2.E8
2 1 W3 + - W2 + - W1 9937-201E05 #Chassis
/1.0_2G1.D6
-X215-2A -X215-2B
12V, 140Ah 12V, 140Ah W219 BU CHASSIS
/11.5_5.B7
W5
W220 -X37-200D
W4
E -X37-100B E
-X37-200 CHASSIS
-X37-100 CHASSIS
-X092f -X092m
-X37-200A 0712 0712B 4 4 0924
-M654 -G660
B+ -X37-100C
-X37-100A -X37-200 CHASSIS 0712A
30 31 B- D+ -X37-100 CHASSIS -X37-100 CHASSIS
M /1.0_2G1.E6
G
#16100 -X37-200B
/1.0_2G1.E1 ALTERNATOR
Volvo D8 Stage4 W -X37-200B
Volvo D8 Stage4 50 -X37-200C

STARTER -X37-200 CHASSIS -X37-200 CHASSIS -X071-2 CHASSIS -X37-300 -X37-301
Inkoppling startmotor & generator
F se sida motor 1.0_2. F
Connection starter & alternator
see page engine 1.0_2.
Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets ström DCF300-, DCE300- 11.5_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring power A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A0595
A A
-F58-4
-X052m -X052f
0526 A0526 A0011
-X37-A #3671
58-1/1:1 6 6 A:1 10 A 1:1 58-4/1:1
/11.5_1.B5 A:1 1:1 /11.5_4.C2
AA2-B1 A:2 A:2 1:2 A0607 58-4/2:1
/9.6_8.A1
B:1 5A 2:1 A0393 58-4/2:1 -X059f
B:1 2:1 /9.6_8.B1
B:2 2:2 2:2 A0392 58-4/2:2 5
/9.6_7.A2
A0526A C:1 10 A 3:1 A0594 4
C:1 3:1
AC2-D1 C:2 C:2 3:2 3:2 A0559 58-4/3:2 3
/9.8_1.B2
D:1 10 A 4:1 A0672
D:1 4:1
D:2 4:2
10 A 5:1 A0555 58-4/5:1
E:1 5:1 /9.8_1.B2
AE2-F1 E:2 E:2 5:2 5:2 A0707C 58-4/5:2
/7.0_5.B1
F:1 25 A 6:1 A0634B 58-4/6:1 -X067f
B F:1 6:1 /9.3_1.D2 B
A0711B F:2 F:2 6:2 6:2 A0664 58-4/6:2 2
/9.3_7.A1 Dedicated for
15 A 7:1 A0545B 58-4/7:2 1
G:1 7:1 /9.6_1.B2
AG2-H1 G:2 G:2 7:2 7:2 A0545C 58-4/7:2 3 use of customer
/9.6_1.D2
H:1 15 A 8:1 A0635B 58-4/8:1 4
H:1 8:1 /9.3_2.B2
A0711D H:2 H:2 8:2
/11.5_2.C4 +30/+15 in Cab
-F58-4
-X071 1 KCU
54-4 0711 2 KCU STARTUP A0626A +12V
/11.5_1.A4 3 SERVICE
/11.5_7.C2
4 OPT. CUSTOMER
C 5 OPT. RADIO C
6 OPT. SEAT HEATER, TURNABLE SEAT.
7 OPT. CONTAINER LIGHT
A0673
8 OPT. AIR SEAT

/11.5_2.C4
-F58-5 A0012 58-5/1:1 -X37-B #3679

/11.5_4.C2
A0711A A:1 25 A 1:1 A0013 58-5/1:2
A:1 1:1 /11.5_4.C2
AA2-B1 A:2 A:2 1:2 1:2 A0014 58-5/1:2
/11.5_4.C2
B:1 10 A 2:1 A0615 58-5/2:1
B:1 2:1 /11.5_4.F2
B:2 2:2
A0711E C:1 15 A 3:1 A0396 58-5/3:1
D C:1 3:1 /9.4_2.C2 D
AC2-D1 C:2 C:2 3:2 3:2 A0028 58-5/3:2
/9.4_2.D2

secuted.

D:1 5A 4:1 A0395 58-5/4:1
D:1 4:1 /9.4_2.D2
AD2-E1 D:2 D:2 4:2 4:2 A0577 58-5/4:2
/9.9_2.C1
E:1 10 A 5:1 A0593
E:1 5:1
E:2 5:2 5:2 A0671
A0711C F:1 5A 6:1 A0624 58-5/6:1
F:1 6:1 /9.6_8.E1
AF2-G1 F:2 F:2 6:2
901 -X901.1f /11.5_7.A2
G:1 10 A 7:1 58-5/7:1
G:1 7:1 /11.5_8.C3
AG2-H1 G:2 G:2 7:2
H:1 10 A 8:1 A0623A 58-5/8:1
H:1 8:1 /9.7_3.C2
H:2 8:2 8:2 K3775_30 585/8:2
/9.6_4.D4
E /11.5_2.F4 +15 in Cab E
-F58-5
1 KCU
2 KIT
3 ECC, FAN
4 ECC, RECIRCULATION
5 SERVICE / CUSTOMER
6 OPT. MAP LIGHT
7 OPT. CONVERTER 12V
8 OPT. COMP. HORN

/11.5_2.E4
F F

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
P 1
B -S150 B
STARTER SWITCH 3
58
30
50
15
19
17
8-19
3-17
1-30
7-50a
5-15/54
0161 24V D790-2/2:1
/1.0_1.B1
0162A
58-4/2:1 0607A
/9.6_8.B1
0162 24V D790-2/2:2
/1.0_1.B1
C C
-X060Am -X060Af -X060m -X060f -X011

0608 8 8 0608 8 8 1 K11:1 Input
-D790-1
/0.0_1.C6
-X058f -X058m
6 GY 0.75 0586B 6 SWITCH IGNITION
0586 0.75 GY 0586A

-X058m /9.2.B1 -X058f
6 6 A0586
-X058f -X058m
D Cable 0586 is sometimes replace and pin 58:6 and 58:7 is 7 28113 28114 7 D
used for some optional interlock function instead. 28113 0.75 GY 0.75 GY 28114

secuted.

-X058m /9.2.D2 /9.2.D2 -X058f
0586 7 7 A0111
W212G CHASSIS
/4.8_1.C4
W212C CHASSIS
/11.5_6.C2
W212D CHASSIS
/11.5_6.C2
W212E CHASSIS
CHASSIS W212 -X90044 /11.5_6.D2
/11.5_1.D6 W212F CHASSIS
/11.5_6.D2
E -K315-1 E
-X010 -X052f -X052m
0.5A K10:10 10 A01010 3 3 0523 2 86 85 1 W212A
-D790-1
/0.0_1.C6 /11.5_1.A2
RELAY K315-1 MAIN RELAY IGNITION
-K315-2
-X010 -X052f -X052m
0.5A K10:16 16 A01016 7 7 0527 86 86 85 85 W212B
-D790-1
/0.0_1.C6 /11.5_1.C5

RELAY K315-2 RELAY IGNITION
F F

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A -X212 A
58-2/1:1 21211 11 K2:11 Input
/11.5_1.A8 -D797-1
/0.0_2.B4
Emergency stop
-X212 -D797-1
58-2/1:1 2121 1 K2:1
/11.5_1.A8 Main power
-X212 Power supply/Ground -X212
58-2/1:2 2129 9 K2:9 Main power Ground K2:12 12 21212
/11.5_1.B8
/11.5_1.B8
/0.0_2.B4
B B
-X37-203A
-X37-203 #4591
-X001 -D790-1
58-4/1:1 A0011 1 K1:1
C /11.5_2.A6 24V Battery C
-X001 -X001
58-5/1:1 A0012 2 K1:2 K1:5 5 A0015
/11.5_2.D6 24V Ignition Ground
58-5/1:2 A0013 3 K1:3 K1:6 6 A0016
/11.5_2.D6 24V Ignition Ground
58-5/1:2 A0014 4 K1:4
/11.5_2.D6 24V Ignition
/0.0_1.A1
Power Supply
-X37-A #4785
D D

secuted.

-D790-2
F
E -D790-2 -D790-2 E
/11.6_1.B3
Keyb.
Keybord
Ind.
Ind. Cluster
-X061f -X061m -X061Am -X061Af -X015 -X015 -X061Af -X061Am -X061m -X061f
58-5/2:1 A0615 5 5 0615 5 5 0615 1 K4:1 K4:5 5 0616 6 6 0616 6 6 A0616
/11.5_2.D6 + -

F F
-X37-A #4779

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X422
42211 11 K2:11 Input
-D791
/0.0_4.B4
Emergency stop
-X400-2D W400 CHASSIS

B /9.6_2.D8 B
-X400-1A -X400-1B -X422 -D791 -X400-2C W401 CHASSIS
58-3/1:1 RD 4221 1 K2:1 /7.9_2.C5
/11.5_6.D7 Main power W402 CHASSIS
-X422 /7.9_1.F7
Power supply/Ground
-X400-1C 4229 9 K2:9 K2:12 12 42212 -X400-2B
Main power Ground -X400-2A
42210 10 K2:10 Main power Ground K2:14 14 42214 BU CHASSIS
/11.5_1.E7
/0.0_4.B4
C C
-X222
58-3/5:1 22211 11 K2:11 Input
/11.5_6.E7 -D797-2
/0.0_3.B4
Emergency stop
-X222 -D797-2
58-2/3:1 2221 1 K2:1
/11.5_1.B8 Main power
D Power supply/Ground -X222 D
/11.5_1.B8

secuted.

/11.5_1.B8
/0.0_3.B4
-X37-208 #4300
E E

F F

Ruta Sign.
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-S250
-X008
24V D790-1/8:16 00816K 1 2 0084 4 K8:4 Input
/8.2_1.B2 -D790-1
/0.0_1.D4
OPERATING SWITCH SW. OPERATING POWER
A A
-K3002
-XK3002 -XK3002
0525C 86 85 86 85
/7.7_1.C3
TILT IN / OUT
-K3007
-XK3007 -XK3007
0525B 86 85 86 85
B /7.2_1.C3
B
LIFT / LOWER
-K3009-2
-X010 -X052f -X052m
0.5A K10:12 12 A01012 5 5 0525 -X90045 0525A 2 86 85 1
-D790-1
/0.0_1.C6 /11.5_6.D3
RELAY K3009-2,K3002,K3007 RELAY OPERATING SWITCH
-K3009-1
-X010 -X052f -X052m
0.5A K10:11 11 A01011 4 4 0524 2 86 85 1
-D790-1
/0.0_1.C6 /11.5_6.D2
C RELAY K3009-1 RELAY OPERATING SWITCH C
CHASSIS W212C
/11.5_3.D7
CHASSIS W212D
/11.5_3.E7
CHASSIS W212E
/11.5_3.E7
CHASSIS W212F
/11.5_3.E7
-X215-1A
RELAY OPERATING SWITCH RELAY OPERATING SWITCH 1681 RD 58-3/1:1
/11.5_6.C4 /11.5_6.C4 -F58-3 /11.5_5.B2
D D
54/3 W211 W215 W216A A:1 1:1 W227 -X168 -X215-1B
25 A
/11.5_1.D3 30 87 30 87 A:1 1:1

secuted.

A:2 A:2 1:2
-K3009-1 -K3009-2
B:1 5A
B:1 2:1
B:2 2:2
W216B 5A 3:1 2024 58-3/3:1
C:1 3:1 /7.0_5.D2
C:2 C:2 3:2
D:1 5A
D:1 4:1
D:2 4:2
E:1 5A 5:1 22211 58-3/5:1
E:1 5:1 /11.5_5.C2
E:2 5:2
F:1 6:1
E F:2 6:2 E
G:1 7:1
G:2 7:2 -X051m -X051f -X011
W218 5A 8:1 0511 1 1 A01113 13 K11:13 Input
H:1 8:1 -D790-1
H:2 8:2 /0.0_1.D6
/11.5_6.F5 +15E FEEDBACK K2
-F58-3
1 KDU ATTACHMENT
2 NOT USED
3 FORK ATTACHMENT

4 NOT USED
5 KDU OPT. CHASSIS
F 6 NOT USED F
7 NOT USED
8 FEEDBACK K3009-1
/11.5_6.E4

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets ström manöverbrytare DCF300-, DCE300- 11.5_6
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring power operating switch A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X901.3f W14B
24V COM
-X901.2f W14A
GND
-X901.4f
A 58-5/7:1
/11.5_2.E7 12V A
24V 12V
-A901 -X37-C #3034
-X055f -X055m -X905f -X37-C #3036

A0558 8 8 0558 2
A0556 6 6 0556 1 Com. Radio 12V
B OPTION ADAPTER B
-X062f -X062m -XE804f -XE804m -XE804Af

A0626 6 6 0626 1 1 804A1B 1
Cig. 12V
2 2 804A2B 2
+12V A0626A
/11.5_2.C8 -XA909-1f
804A1A 1 +12V
/9.8_2.A2
804A2A 2 CHASSIS
/9.8_2.A2
C C
OPTION ADAPTER
-XE804m -XE804Af
1 804A1B 1
Cig. 12V
2 804A2B 2
1825B
-X183m
-X020 804A1A 1 +12V
/9.8_2.C4
KID_RX 2 1822 30 3 KID_TX
D /11.6_1.A2 /9.8_2.C4 D
KID_TX 3 1823 2 KID_RX
/11.6_1.A2 /9.8_2.C4

secuted.

KID_GND 1 1825A 1825 5 KID_GND
/11.6_1.B2 /9.8_2.C4
-XSP020
W03
E E

F F
-X37-D +12V

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets 24/12V DCF300-, DCE300- 11.5_7
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring 24/12V A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-X901.1m -X901.2m -X901.2f

58-5/7:1 W14A
/11.5_2.E7
-X901.3f
W14B -X37-C #3684
C C
-X072f
BK 2
GY 1 24V
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets 24V uttag DCF300-, DCE300- 11.5_8
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring 24V contact A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X221 -X240f
10A K1:14 14 22114 1
-D797-2
/0.0_3.D2
OPT.
-X240f
4 W235D CHASSIS
B /11.5_11.A8 B
-X221 -X240f
6A K1:28 28 22128 2
-D797-2
/0.0_3.D5
OPT.
C -X221 -X240f C
Analog In 0-5V K1:24 24 22124 3
-D797-2
/0.0_3.C5
OPT.
D D

secuted.

-X221 -X249f -X249f
6A K1:42 42 22142 1 D797-2/1:42 CHASSIS 2 W235F CHASSIS
-D797-2 /9.6_10.D2 /9.6_10.D7 /11.5_11.B8
/0.0_3.D5
OPT.
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets option grund kraft DCF300-, DCE300- 11.5_9
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring option base power A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X221 -X242f -X242f -X221

Analog Ref 5V K1:8 8 2218 5 D797-2/1:41 1 22141 41 K1:41 Analog In 0-5V
-D797-2 /7.9_3.A7 -D797-2
/0.0_3.D2 /0.0_3.D5
OPT. OPT.
-X221 -X242f -X242f -X221

0V Ref K1:6 6 2216 6 2 22121 21 K1:21 Analog In 0-5V
-D797-2 -D797-2
/0.0_3.C2 /0.0_3.C5
OPT. OPT.
B B
-X242f -X242f -X221

58-2/4:1 W237 7 58-2/4:1 D797-2/1:22 3 22122 22 K1:22 Analog In 0-5V
/11.5_1.B8 /7.9_3.A2 /7.9_3.B7 -D797-2
/0.0_3.C5
OPT.
-X242f -X221
D797-2/1:23 4 22123 23 K1:23 Analog In 0-5V
C /7.9_3.B7 -D797-2 C
/0.0_3.C5
OPT.
-X242f
CHASSIS 8 W235E CHASSIS
/7.9_3.A7 /11.5_11.A8
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets option grund DCF300-, DCE300- 11.5_10
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring option base A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
W235D CHASSIS
/11.5_9.B7
W235E CHASSIS
/11.5_10.D7
W235F CHASSIS
/11.5_9.D7
B B
-X221 -X241f -X241f
Dig In / 1.5A K1:11 11 22111 2 24V D797-2/1:11 CHASSIS 1 W235B -X90035 W235A
-D797-2 /9.9_1.B2 /9.9_1.B7
/0.0_3.D2
OPT.
CHASSIS -X37-215
-X221 -X241f
Dig In / 1.5A K1:12 12 22112 3 24V D797-2/1:12
-D797-2 /9.9_1.D2
/0.0_3.D2
C C
OPT.
-X221 -X241f -X241f

Dig In / 1.5A K1:26 26 22126 6 CHASSIS 4 W235C
-D797-2 /9.9_1.D7
/0.0_3.C5
OPT.
D D

secuted.

-X221 -X241f
Dig In / 1.5A K1:40 40 22140 5
-D797-2
/0.0_3.D5
OPT.
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets option grund DCF300-, DCE300- 11.5_11
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring option base A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-R820-2 -D795
1 2 -X020 -X020 -X060Am -X060Af -X060m -X060f -X051f -X051m
6 K1:6 CAN 2 K1:13 13 30 0605 5 5 30 0605 5 5 A0512A 30 2 2
+ L+
K1:5 CAN K1:12 0606 0606 A0513A
WH
GY
5 12 6 6 6 6 3 3
- L-
KID_TX K1:4 K1:8 8 0604 4 4 0604 4 4
A /11.5_7.D5 Shield + A
GY
-X020 RS232
KID_TX 30 1823 3 K1:3 K1:11 11 30 0601A 1 1 30 0601 1 1
/9.8_2.B2 TX R+
KID_RX K1:2 CAN K1:10 0602A 0602
WH
1822 2 RX R- 10 2 2 2 2
/9.8_2.B2
KID_RX K1:1 K1:7 7 0603 3 3 0603 3 3
/11.5_7.D5 GND +
KID_GND 1825
GY
1 -X020 -X061Af -X061Am -X061m -X061f
/9.8_2.B2
KID_GND 14 K1:14 BUZZER 0V REF K1:9 9 0613 3 3 0613 3 3
/11.5_7.D5
WH
KID
790-2/1:14 02014
/9.7_1.E7
0152
0156
4
2
6
5
3
1
-X203m
A0513B
A0512B
-D790-2
A0613
30
30
4
2
6
5
3
B /11.5_4.E4 B
-X203f
-X015 -X015
2 K4:2 K4:7 7 0601B
+ + -X37-A #4778
6 K4:6 CAN CAN K4:8 8 0602B
- -
2034
0521 30 -X059f
30
2 30 30 0513
0522 K4:3 Shield Shield K4:4 1 0512
2033
30
-X052m -X052f
1 1 30 A0481B -X048 1 30 A0131
2033 CAN_J1939_+
/1.0_1.C3 A B
2036
2034 -X052m -X052f
30
CAN_J1939_-
/1.0_1.D3 2 2 30 A0482B -X048 2 30 A0132
C C
2035 CAN_J1939_+ A B A0135 30
2035
/2.0_1.D2
A0134
30
2036 CAN_J1939_- -X049m
/2.0_1.D2 A 30 A0481A
-R820-1
B A0482A 1 2
-X013 KCU -X013 -X050

1 K13:1 TX
K13:10 10 A01310 3
+
2 K13:2 CAN J1939 RS232 K13:11 11 A01311 2
- RX
No extra KDU => connect X209Af and 209Am K13:3 K13:12 12 A01312 5
Shield Ground
-X013
/11.6_2A.C7 4 K13:4
L+
/11.6_2B.B7 -X209Am 5 K13:5 CAN
CAN+ 4 0514 L-
D /11.6_2C.B7 K13:6 D
Shield
-X051m -X051f -X013 -D790-1

secuted.

/11.6_2A.C7 30 4 4 30 A0137 7 K13:7 /0.0_1.E6
/11.6_2B.B7 R+
CAN- 3 0515 5 5 A0138 8 K13:8 CAN
/11.6_2C.B7 R-
K13:9
Shield
RED+2 2 0519A -X011
/11.6_2C.B7 A0117
CAN-BUS
6 6 7 K11:7
Power 1
8 8 A0118A 8 K11:8
Power 1
/11.6_2A.C7 7 7 A0119 9 K11:9
/11.6_2B.B7 Power 2
RED+1 1 0518A 9 9 A01110A 10 K11:10
/11.6_2C.B7 Power 2
A0118B
E E
A01110B -X212
0513 5
R-
0512 4 K2:5 CAN
-X209Af R+
K2:4 CAN-BUS
RED+1 1 0518B 0517 0517 8
/11.6_2C.E7 +
K2:8
/11.6_2A.D7 0516 0516 7
+ /0.0_2.B4
/11.6_2B.C7 0519B 30 2123 K2:7
RED+2 2 3 -D797-1
/11.6_2C.E7 L-
2122 2 K2:3 CAN
L+
/11.6_2A.D7 K2:2

/11.6_2B.C7 2123
CAN- 3
/11.6_2C.F7
F F
/11.6_2A.D7
/11.6_2B.C7 2122
CAN+ 4
/11.6_2C.E7
Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets CANBUS grund DCF300-, DCE300- 11.6_1
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring CANBUS base A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-X209Bf
30 4 CAN+
/11.6_1.D2
3 CAN-
/11.6_1.D2
1 RED+1
C
Opt. chassi /11.6_1.E2 C
-X222
K2:2 2 2222
L+
CAN K2:3 3 2223
-D797-2 L-
K2:7 7 2227
+
-X209Bm
K2:8 8 2228 2 RED+2
CAN-BUS + /11.6_1.F2
K2:4 4 2224 30 4 CAN+
R+ /11.6_1.F2
CAN K2:5 5 2225 3 CAN-
R- /11.6_1.F2
CAN Shield
K2:6
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets CANBUS KDU opt. DCF300-, DCE300- 11.6_2A
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring CANBUS KDU opt. chassi A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B -X209Cf B
4 CAN+
/11.6_1.D2
3 CAN-
/11.6_1.D2
1 RED+1
/11.6_1.E2
Opt. attachment
-X422 -X401Am -X401Af
K2:2 2 4222 30 A A GN 30
L+
CAN K2:3 3 4223 B B YE
C -D791 L- C
K2:7 7 4227 C C GY
/0.0_4.B4 +
-X401Bf -X401Bm -X209Cm
K2:8 8 4228 C C OG 2 RED+2
+ /11.6_1.F2
CAN-BUS K2:4 4 4224 30 A A BN 30 4 CAN+
R+ /11.6_1.F2
CAN K2:5 5 4225 B B WH 3 CAN-
R- /11.6_1.F2
D D

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets CANBUS KDU opt. DCF300-, DCE300- 11.6_2B
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring CANBUS KDU opt. attachment A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Opt. attachment BU
-X422 -X401Am -X401Af -X209Cf

K2:2 2 30 1 4222 A A GN 30 4 CAN+
L+ /11.6_1.D2
CAN K2:3 3 2 4223 B B YE 3 CAN-
-D791 L- /11.6_1.D2
K2:7 7 3 4227 C C GY 1 RED+1
+ /11.6_1.E2
-X401Bf -X401Bm 2 RED+2
/11.6_1.E2
K2:8 8 3 4228 C C
+
CAN-BUS K2:4 4 30 1 4224 A A
R+
B CAN K2:5 5 2 4225 B B B
R-
VT
BN
WH
OG
2092
C C
30
2091
D D
4
2
2
3
1
1

secuted.

-X209Cm
-X214m
1
1
4
2
2
3
-X214f
-X209Bf
2142
Opt. chassis
-X222
K2:2 2222 30
2141
E 2 E
L+
CAN K2:3 3 2223
-D797-2 L- -X209Bm
K2:7 7 2227 1 RED+1
/0.0_3.B4 + /11.6_1.E2
K2:8 8 2228 2 RED+2

+ /11.6_1.F2
CAN-BUS K2:4 4 2224 30 4 CAN+
R+ /11.6_1.F2
CAN K2:5 5 2225 3 CAN-
R- /11.6_1.F2

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Krets CANBUS KDU opt. DCF300-, DCE300- 11.6_2C
Sq. RSO 081216 A47137.0100
Name
R
E³ DRAWING
Wiring CANBUS KDU opt. chassi + attach A49226.0100 45
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-D791-1
1:1 /9.6_1.B1 WORK LIGHT LEFT 6A 1:21 /7.9_4.D8 SENSOR DETECT RIGHT UPPER Analog In 0-5V
1:2 /7.5_1.A2 VALVE SPREADING LEFT IN 1.5A 1:22 /7.9_2.A8 SENSOR UNLOCKED LEFT Analog In 0-5V
1:3 /7.5_1.A2 VALVE SPREADING LEFT OUT 1.5A 1:23 /7.9_2.D8 SENSOR LOCKED LEFT (LOWER) Analog In 0-5V
1:4 /7.5_1.D2 VALVE SPREADING RIGHT IN 1.5A 1:24 /7.9_2.D8 SENSOR LOCKED RIGHT (LOWER) Analog In 0-5V
C 1:5 /7.5_1.D2 VALVE SPREADING RIGHT OUT 1.5A 1:25 /11.5_2.B2 LAMP UNLOCKED 1.5A
C
1:6 0V Ref 1:26 /7.9_4.E8 SENSOR ALIGNMENT RIGHT (LOWER) Dig In / 1.5A
1:7 /7.9_1.B1 VALVE LOCK CONTAINER 1.5A 1:27 /7.9_4.C8 SENSOR ALIGNMENT LEFT (LOWER) Analog In 0-5V
1:8 Analog Ref 5V 1:28 /7.5_2.B2 SUMMER AUT. SPREADING 6A
1:9 /7.9_1.C1 VALVE UNLOCK CONTAINER 1.5A 1:29 /11.5_2.E2 LAMP LOCKED 1.5A
1:10 /11.5_2.A2 SUPPLY SENSORS 1.5A 1:30 /7.8_1.B2 VALVE LEVELLING LEFT 2.5A
1:11 /11.5_2.D2 SENSOR ALIGNMENT UPPER LEFT Dig In / 1.5A 1:31 /7.8_1.C2 VALVE LEVELLING RIGHT 2.5A
1:12 /7.5_3.B8 SENSOR DAMPING LEFT Dig In / 1.5A 1:32 /7.4_1.B1 VALVE SIDESHIFT LEFT 1.5A
KDU contact K1
KDU contact K1
1:13 /7.9_4.B8 SENSOR DETECT LEFT UPPER Analog In 0-5V 1:33 /7.4_1.C1 VALVE SIDESHIFT RIGHT 1.5A
1:14 /9.14_1.B2 CENTRAL LUBRICATION 10A 1:34 /11.5_2.B2 LAMP ALIGNMENT (UPPER) 1.5A
1:15 /9.6_1.B1 WORK LIGHT RIGHT 6A 1:35 1.5A
1:16 /7.5_1.A7 SPREADING LEFT PWM 1:36 /11.5_2.D2 SENSOR ALIGNMENT UPPER RIGHT Dig In / 1.5A
1:17 /7.5_1.D7 SPREADING RIGHT PWM 1:37 /7.5_3.E8 SENSOR 30-35 STOP RIGHT Dig In / 1.5A
1:19 /7.8_1.B7 VALVE LEVELLING PWM 1:39 /11.5_2.C2 LAMP ALIGNMENT (LOWER) 1.5A
1:20 /7.5_3.B8 SENSOR 30-35 STOP LEFT Analog In 0-5V 1:40 /7.5_3.D8 SENSOR DAMPING RIGHT Dig In / 1.5A
D 1:41 /7.9_2.C8 SENSOR UNLOCKED RIGHT Analog In 0-5V
D
1:42 6A

secuted.

E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn KRETSSCHEMA,AGGREGAT,DCF90/100-45E DCF80-100-45E 0.0_1
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
CJS 050916 Klass/Class
WIRING DIAGRAM,ATTACHMENT,DCF90/100-45E A50400.0100 07
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-X403-2f -X403-2m
1 403-21 -XSP403-2-1 403-21A 1
2 403-22 -XSP403-2-2 403-22A 2
3 403-23 403-23 3
4 403-24 403-24 4
5 403-25 5
6 403-26 403-26 6
7 403-27 403-27 7
C C
8 403-28 403-28 8
-X236L-2f
A A 403-21B
D D

secuted.

BN
-B260 -X236L-2f
BK C C 403-25
SENSOR CARRIAGE UP
BU
-X236L-2f
B B 403-22B
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn Kretsschema för sensor vagn uppe (FFKT) DCF80-100-45E 7.2_3
Sq. CJS 2012-02-06 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
Wiring for sensor carrige up (FFKT) A50400.0100 07
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6020
-X421 -X421
1.5A K1:32 32 42132 1 1 2 2 18 K1:18 PWM
B -D791-1 -D791-1 B
/0.0_1.C5 -XSP23 /0.0_1.D3
SIDESHIFT LEFT
-Y6021
-X421
1.5A K1:33 33 42133 1 1 2 2 42118C
-D791-1
/0.0_1.D5
C C
SIDESHIFT RIGHT
D D

secuted.

E E

F F

Ruta Sign.
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-Y6019L
-X421 -X421
1.5A K1:2 2 4212 1 1 2 2 16 K1:16 PWM
-D791-1 -D791-1
/0.0_1.C3 -XSP10 /0.0_1.D3
VALVE SPREADING LEFT IN SPREADING LEFT
A A
SPREADING LEFT IN
-Y6018L
-X421
1.5A K1:3 3 4213 1 1 2 2 42116C
-D791-1
/0.0_1.C3
VALVE SPREADING LEFT OUT
SPREADING LEFT OUT
B B
C C
-Y6019R
-X421 -X421
1.5A K1:4 4 4214 1 1 2 2 17 K1:17 PWM
-D791-1 -D791-1
/0.0_1.C3 -XSP11 /0.0_1.D3
VALVE SPREADING RIGHT IN SPREADING RIGHT
SPREADING RIGHT IN
D -Y6018R D
-X421
1.5A

secuted.

K1:5 5 4215 1 1 2 2 42117C
-D791-1
/0.0_1.C3
VALVE SPREADING RIGHT OUT
SPREADING RIGHT OUT
E E

F F

Ruta Sign.
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-X421 -XH9003f -H9003
6A K1:28 28 42128 1 +
-D791-1
/0.0_1.C5 2 -
SUMMER AUT. SPREADING
WARNING SIGNAL AUT. SPREADING
W9003 CHASSIS
C /11.5_2.C8 C
D D

secuted.

E E

F F

Ruta Sign.
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X425f -X425m -XB769Lf -XB769Lm

D791-1:10-24V 42110D 1 1 -XSP13 A A
/11.5_2.A5
BN
-B769L -XB769Lm -XB769Lf -X425m -X425f -X421
BK C C 4253 3 3 42112 12 K1:12 Dig In / 1.5A
-D791-1
/0.0_1.C3
DAMPING 20/40 LEFT
BU SENSOR DAMPING LEFT
B B
-XB777Lf -XB777Lm
4251C A A
B B
BN
BK C C 4254 4 4 42120 20 K1:20 Analog In 0-5V
-D791-1
/0.0_1.D3
30-35 STOP LEFT
BU SENSOR 30-35 STOP LEFT
B B 4252B
-X425m -X425f
-XSP15 2 2 4252 CHASSIS
/11.5_2.E8
C C
-X426m -X426f -XB769Rf -XB769Rm

D791-1:10-24V 42110E 1 1 -XSP14 A A
/11.5_2.A5
BN
-B769R -XB769Rm -XB769Rf -X426f -X426m -X421
BK C C 4263 3 3 42140 40 K1:40 Dig In / 1.5A
-D791-1
/0.0_1.D5
D DAMPING 20/40 RIGHT D
BU SENSOR DAMPING RIGHT

secuted.

B B
-XB777Rf -XB777Rm
4261C A A
BN
BK C C 4264 4 4 42137 37 K1:37 Dig In / 1.5A
-D791-1
/0.0_1.D5
30-35 STOP RIGHT
BU SENSOR 30-35 STOP RIGHT
B B 4262B
-X426f -X426m
-XSP16 2 2 4262 CHASSIS
E /11.5_2.E8 E

F F

Ruta Sign.
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6036/-Y6084
-X421 -X421
2.5A K1:30 30 42130 1 1 2 2 19 K1:19 PWM
-D791-1 -D791-1
/0.0_1.C5 -XSP17 /0.0_1.D3
VALVE LEVELLING LEFT VALVE LEVELLING
LEVELLING LEFT, C.W, Bottom support out
B B
1
-Y6035/-Y6083
-X421
2.5A K1:31 31 42131 1 1 2 2 42119C
-D791-1
/0.0_1.C5
VALVE LEVELLING RIGHT
LEVELLING RIGHT, C.C.W, Bottom support in
C C
1
D D

secuted.

E E

F F

Ruta Sign.
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6040
-X421
1.5A K1:7 7 4217 1 1 2 2 W6040 CHASSIS
-D791-1 /11.5_2.C8
/0.0_1.C3
B B
VALVE LOCK CONTAINER
LOCK CONTAINER
-Y6039
-X421
1.5A K1:9 9 4219 1 1 2 2 W6039 CHASSIS
-D791-1 /11.5_2.D8
/0.0_1.C3
VALVE UNLOCK CONTAINER
C C
UNLOCK CONTAINER
D D

secuted.

E E

F F

Ruta Sign.
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XB7203LUf /7.9_5A.A3
4041F A D791-1:10-24V
/7.9_5B.A3
4041E D791-1:10-24V
/7.9_5B.B1
-X404f -X404m -XB7204Lf -XB7204Lm
A D791-1:10-24V 42110B 1 1 -XSP2 A A A
/11.5_2.A5
BN
BK C C 4043 3 3 42122 22 K1:22 Analog In 0-5V
-D791-1
/0.0_1.C5
UNLOCKED LEFT
BU SENSOR UNLOCKED LEFT
-X404m -X404f
B B 2 2 4042 CHASSIS
/11.5_2.D8
-XSP4
4042H CHASSIS
-XB7203RUf /9.6_1.E8
/7.9_5A.B3 4042G CHASSIS
4031F A D791-1:10-24V /9.6_1.E8
/7.9_5B.C3
4031E D791-1:10-24V -XB7203LUf /7.9_5A.B5
B /7.9_5B.C1 4042F B CHASSIS B
/7.9_5B.A5
-X403m -X403f -XB7204Rf -XB7204Rm 4042E CHASSIS
/7.9_5B.B7
D791-1:10-24V 42110C 1 1 -XSP3 A A
/11.5_2.A5
BN
BK C C 4033 3 3 42141 41 K1:41 Analog In 0-5V
-D791-1
/0.0_1.D5
UNLOCKED RIGHT
BU SENSOR UNLOCKED RIGHT
-X403f -X403m
B B 2 2 4032 CHASSIS
/11.5_2.E8
-XSP5
4032H CHASSIS
4041C
/9.6_1.D8
4032G CHASSIS
C /9.6_1.D8 C
-XB7203RUf /7.9_5A.C5
4032F B CHASSIS
-XB7205LLf -XB7205LLm /7.9_5B.C5
4032E CHASSIS
A A /7.9_5B.D7
BN
4031C
-B7205LL -XB7205LLm -XB7205LLf -X404m -X404f -X421
BK C C 4044 4 4 42123 23 K1:23 Analog In 0-5V
-D791-1
/0.0_1.C5
LOCKED LEFT
BU SENSOR LOCKED LEFT (LOWER)
B B 4042C
-XB7205RLf -XB7205RLm
D A A D
BN

secuted.

-B7205RL -XB7205RLm -XB7205RLf -X403f -X403m -X421
BK C C 4034 4 4 42124 24 K1:24 Analog In 0-5V
-D791-1
/0.0_1.C5
LOCKED RIGHT
BU SENSOR LOCKED RIGHT (LOWER)
4031D
4041D
B B 4032C
-XB7205LUf XSP2-24V
A /7.9_5B.E4
4042D
4032D
E E
XSP4-CHASSI -XB7205LUf
/7.9_5B.E5 B
-XB7205RUf XSP3-24V
A /7.9_5B.E4

F F
XSP5-CHASSI -XB7205RUf
/7.9_5B.F5 B

Ruta Sign.
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-H562
-X415m
D791-1:25-24V 1 4151 1 1 2 1 4154B
/11.5_2.B5
UNLOCKED (RED)
B B
-H564L
-X415m -XSP1 -X415m
D791-1:39-24V 2 4152 1 1 2 1 4154C 4154A 4 CHASSIS
/11.5_2.C5 /11.5_2.D8
ALIGNMENT (YELLOW)
C C
-H563
-X415m
D791-1:29-24V 3 4153 1 1 2 1 4154D
/11.5_2.E5
LOCKED (GREEN)
D D

secuted.

E E

F F
TWISTLOCK
Ruta Sign.
No. Design change Change No. Date Ritad/Drawn KRETSSCHEMA,indikeringslampor,std DCF80-90-45E 7.9_3A
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
WIRING DIAGRAM,Indicationlamps,std A50400.0100 07
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-H562L
-X415m
D791-1:25-24V 1 4151 1 1 2 1 4154B
/11.5_2.B5
UNLOCKED (RED)
B B
-H564UL
-X415m
D791-1:34-24V 5 4155 1 1 2 1 4154E
/11.5_2.B5
ALIGNMENT UPPER (YELLOW)
-XSP1 -X415m
4154A 4 CHASSIS
C /11.5_2.D8 C
-H564LL
-X415m
D791-1:39-24V 2 4152 1 1 2 1 4154C
/11.5_2.C5
ALIGNMENT LOWER (YELLOW)
D D

secuted.

-H563L
-X415m
D791-1:29-24V 3 4153 1 1 2 1 4154D
/11.5_2.E5
LOCKED (GREEN)
E E

F F
FLAPS
Ruta Sign.
No. Design change Change No. Date Ritad/Drawn KRETSSCHEMA,indikeringslampor DCF100-45E 7.9_3B
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
WIRING DIAGRAM,Indicationlamps,hook,std A50400.0100 07
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-H562
-X415m -XSP2 -XH562 -XH562
D791-1:25-24V 1 4151 BN 1 3 BU
/11.5_2.B5
B B
UNLOCKED (RED)
-H564L
-X415m -XSP3 -XH564 -XH564 -XSP1 -X415m CHASSIS
D791-1:39-24V 2 4152 BN 1 3 BU 4154 4
C /11.5_2.C5 C
ALIGNMENT (YELLOW)
D D
-H563
-X415m -XSP4 -XH563 -XH563

secuted.

D791-1:29-24V 3 4153 BN 1 3 BU
/11.5_2.E5
LOCKED (GREEN)
E E

F F

Ruta Sign.
No. Design change Change No. Date Ritad/Drawn KRETSSCHEMA,indikeringslampor,Led DCF80-100-45E 7.9_3C
Sq. MLG 121130 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
WIRING DIAGRAM,Indicationlamps,Led A50400.0100 07
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-H562L
-X415m -XSP2 -XH562L -XH562L
D791-1:25-24V 1 4151 BU 1 3 BN
/11.5_2.B5
UNLOCKED (RED)
B B
-H564UL
-X415m -XSP5 -XH564UL -XH564UL
D791-1:34-24V 5 4155 BU 1 3 BN
/11.5_2.B5
ALIGNMENT UPPER (YELLOW)
-XSP1 -X415m
4154 4 CHASSIS
C C
-H564LL
-X415m -XSP3 -XH564LL -XH564LL
D791-1:39-24V 2 4152 BU 1 3 BN
/11.5_2.C5
ALIGNMENT LOWER (YELLOW)
D D

secuted.

-H563L
-X415m -XSP4 -XH563L -XH563L
D791-1:29-24V 3 4153 BU 1 3 BN
LOCKED (GREEN)
E E

F F
FLAPS
Ruta Sign.
No. Design change Change No. Date Ritad/Drawn KRETSSCHEMA,indikeringslampor,Led,krok DCF80-100-45E 7.9_3D
Sq. MLG 121130 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
WIRING DIAGRAM,Indicationlamps,Led,hook A50400.0100 07
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X404f -X421
D791-1:13-24V 6 42113 13 K1:13 Analog In 0-5V
/7.9_5B.A7 -D791-1
/0.0_1.D3
SENSOR DETECT LEFT UPPER
B B
/7.9_5A.B7 -X404f -X421

D791-1:27-24V 7 42127 27 K1:27 Analog In 0-5V
/7.9_5B.B7 -D791-1
/0.0_1.C5
SENSOR ALIGNMENT LEFT (LOWER)
C C
-X403m -X421
D791-1:21-24V 6 42121 21 K1:21 Analog In 0-5V
/7.9_5B.C7 -D791-1
/0.0_1.C5
SENSOR DETECT RIGHT UPPER
D D

secuted.

/7.9_5A.C7 -X403m -X421
D791-1:26-24V 7 42126 26 K1:26 Dig In / 1.5A
/7.9_5B.D7 -D791-1
/0.0_1.C5
SENSOR ALIGNMENT RIGHT (LOWER)
E E

F F

Ruta Sign.
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XB7203Lm 1
D791-1:10-24V A
/7.9_2.A6
BN
-B7203L -XB7203Lm -XB7203LL -X404m
BK C C 4047 7 D791-1:27-24V
/7.9_4.C3
ALIGNMENT LEFT
BU
B CHASSIS
/7.9_2.B7
B B
-XB7203Rm 1
D791-1:10-24V A
/7.9_2.B4
BN
-B7203R -XB7203Rm -XB7203RL -X403f
BK C C 4037 7 D791-1:26-24V
/7.9_4.E3
ALIGNMENT RIGHT
BU
B CHASSIS
/7.9_2.C7
C C
D D

secuted.

E E

F F
TWISTLOCK
Ruta Sign.
No. Design change Change No. Date Ritad/Drawn KRETSSCHEMA,AGGREGAT,DCF90/100-45E DCF80-100-45E 7.9_5A
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XB7203LUm
A D791-1:10-24V A
/7.9_2.A6 A
BN
-B7203LU -XB7203LUm -XB7203LUf -X404m
BK C C 4046 6 D791-1:13-24V
/7.9_4.B3
DETECT LEFT UPPER
BU B CHASSIS
/7.9_2.B7
-XB7203LLf -XB7203LLm
D791-1:10-24V 4041E A A
/7.9_2.A6
BN
-B7203LL -XB7203LLm -XB7203LLf -X404m
BK C C 4047 7 D791-1:27-24V
/7.9_4.C3
ALIGNMENT LEFT LOWER
BU B B 4042E CHASSIS
/7.9_2.B7
B B
-XB7203RUm
D791-1:10-24V A
/7.9_2.B4
BN
-B7203RU -XB7203RUm -XB7203RUf -X403f
BK C C 4036 6 D791-1:21-24V
/7.9_4.D3
C DETECT RIGHT UPPER C
BU B CHASSIS
/7.9_2.C7
-XB7203RLf -XB7203RLm
D791-1:10-24V 4031E A A
/7.9_2.B4
BN
-B7203RL -XB7203RLm -XB7203RLf -X403f
BK C C 4037 7 D791-1:26-24V
/7.9_4.E3
ALIGNMENT RIGHT LOWER
BU B B 4032E CHASSIS
/7.9_2.C7
D D

secuted.

-XB7205LUm
XSP2-24V A 1
/7.9_2.E3
BN
-B7203LU-2 -XB7205LUm
BK C D791-1:11-24V
/11.5_2.D5
ALIGNMENT UPPER LEFT
BU
-XB7205LUm
E B XSP4-CHASSI
/7.9_2.E5 E
-XB7205RUm
XSP3-24V A 1
/7.9_2.E3
BN
-B7203RU-2 -XB7205RUm
BK C D791-1:36-24V
/11.5_2.D5
ALIGNMENT UPPER RIGHT
BU
-XB7205RUm
B XSP5-CHASSI
/7.9_2.F6

FLAPS
F F
HOOK
FLAPS
Ruta Sign.
No. Design change Change No. Date Ritad/Drawn KRETSSCHEMA,AGGREGAT,DCF90/100-45E DCF80-100-45E 7.9_5B
Sq. RSO 080917 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-E404L
-X421 -XE404Lf -XE404Lf
6A K1:1 1 -XSP8 1 1 2 2 W404L CHASSIS
-D791-1 /11.5_2.B8
/0.0_1.C3
WORK LIGHT LEFT OPT WORK LIGHT CARRIAGE LEFT (TW)
B B
-E404R
-X421 -XE404Rf -XE404Rf
6A K1:15 15 -XSP9 1 1 2 2 W404R CHASSIS
-D791-1 /11.5_2.B8
/0.0_1.D3
WORK LIGHT RIGHT OPT WORK LIGHT CARRIAGE RIGHT (TW)
-X403m -X403f
42115C 8 8 4038A
4211C
C C
std TW
-E404UL -E404UR
-X404f -X404m -XE404ULf -XE404ULf -XE404URf -XE404URf
8 8 -XSP6 1 1 2 2 -XSP7 1 1 2 2 4032H CHASSIS
/7.9_2.C7
WORK LIGHT ATTACHMENT UPPER LEFT WORK LIGHT ATTACHMENT UPPER RIGHT
4048C
1 1
-E404LL -E404LR
D -X404LLf -X404LLm -XE404LL -XE404LL -X404LLf -X404LRf -X404LRm -XE404Lr -XE404Lr -X404LRm -X404LRf D
1 1 404LL-11 1 2 2 404LL-2 2 4038C 1 1 404LR-1 1 1 2 2 404LR-2 2 4032G CHASSIS
/7.9_2.C7

secuted.
2 2

-X404LLm
WORK LIGHT ATTACHMENT LOWER LEFT WORK LIGHT ATTACHMENT LOWER RIGHT
std FLAPS
4042H CHASSIS
/7.9_2.B7
4042G CHASSIS
E /7.9_2.B7 E

F F

Ruta Sign.
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-M693
1
B B
GREY
2
-X421 -XM693f
10A K1:14 14 42114 1 15
-D791-1 M
/0.0_1.D3 BLACK
2 31
CENTRAL LUBRICATION
CENTRAL LUBRICATION
C C
W693 CHASSIS
/11.5_2.C8
D D

secuted.

E E

F F

Ruta Sign.
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X422
42211 11 K2:11 Emergency stop
-D791-1
B B
EMERGENCY STOP
-X400-1A -X400-1B -X422 -D791-1

See wiring chassi 4221 1 K2:1
Main power
-X400-1C Power supply/Ground -X422
4229 9 K2:9 Main power Ground K2:12 12 W400-2B1 CHASSIS
/11.5_2.A8
42210 10 K2:10 Main power Ground K2:14 14 W400-2B2 CHASSIS
/11.5_2.A8
C C
D D

secuted.

E E

F F

Ruta Sign.
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
42110B D791-1:10-24V
/7.9_2.A1
42110C D791-1:10-24V
/7.9_2.B1
42110D D791-1:10-24V W400-2B1 CHASSIS
/7.5_3.A1 /11.5_1.C7
42110E D791-1:10-24V
/7.5_3.D1 W400-2B2 CHASSIS
A /11.5_1.C7 A
-X421 -X400-2B
1.5A K1:10 10 -XSP12 D791-1:10-24V
-D791-1
/0.0_1.C3 -X400-2D -X400-2A
See wiring chassi
SUPPLY SENSORS
-X400-2C
/7.9_3A.A2
/7.9_3B.B1
-X421 -X415f /7.9_3C.B2
1.5A K1:25 25 42125 1 D791-1:25-24V
-D791-1 /7.9_3D.B1
/0.0_1.C5
LAMP UNLOCKED
B B
-X421 -X415f W404L CHASSIS

/7.9_3B.C1 /9.6_1.B7
1.5A K1:34 34 42134 5 D791-1:34-24V
-D791-1 /7.9_3D.C1 W404R CHASSIS
/0.0_1.D5 /9.6_1.B8
LAMP ALIGNMENT (UPPER) -XSP20 CHASSIS
/7.5_2.C7
/7.9_3A.C2
/7.9_3B.D1
-X421 -X415f /7.9_3C.C1
1.5A K1:39 39 42139 2 D791-1:39-24V
-D791-1 /7.9_3D.D1
/0.0_1.D5
C C
LAMP ALIGNMENT (LOWER)
W693 CHASSIS
1 /9.14_1.D7
-XSP21 CHASSIS
-X421 -X403m -X403f -XB7205RUf /7.9_1.B7
Dig In / 1.5A K1:36 36 42136 5 5 4035 C D791-1:36-24V
-D791-1 /7.9_5B.E5 W6039 CHASSIS
/0.0_1.D5 /7.9_1.C7
SENSOR ALIGNMENT UPPER RIGHT (1) CHASSIS
(0) CHASSIS
1
D -X421 -X404f -X404m -XB7205LUf D
Dig In / 1.5A K1:11 11 42111 5 5 4045 C D791-1:11-24V
-D791-1 /7.9_5B.E5
/0.0_1.C3

secuted.

-X415f /7.9_3A.C7
SENSOR ALIGNMENT UPPER LEFT 4154 4 CHASSIS
/7.9_3B.C8
4042 CHASSIS
/7.9_2.B7
-XSP22 CHASSIS
/7.9_3A.D2 /7.9_2.C7
-X421 -X415f /7.9_3B.E1 4252 CHASSIS
1.5A K1:29 29 42129 3 D791-1:29-24V /7.5_3.C7
-D791-1 /7.9_3C.D1
/0.0_1.C5 4262 CHASSIS
/7.5_3.E7
LAMP LOCKED
E E

F F

Ruta Sign.
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-X422 -X401Am
K2:2 2 4222 30 A
L+
CAN K2:3 3 4223 B
-D791-1 L-
K2:7 7 4227 C
+
C -X401Bf C
K2:8 8 4228 C
+
CAN-BUS K2:4 4 4224 30 A
R+
CAN K2:5 5 4225 B
R-
See wiring chassi
D D

secuted.

E E

F F

Ruta Sign.
Sq. CJS 050916 A51185.0100
Name
R
E³ DRAWING
1 In p. 7.8_1 W Y6035 and Y6036 130583 MLG 130404 6
1 2 3 4 5 6 7 8
E Schema – Komponentförteckning / E Schematics – List of Components 1
NUMBER SVENSKA ENGLISH
A 32 Kretskort elcentral Printed circuit board, Junction box
A 685 Reglerenhet termostat AC Control unit, termostat AC
A 779 Reglersystem återladdning (EC) Control system, recharging (EC)
A 782 Logik interface 2 drivmotorer Logic (interface) two main motors (EC)
A 783 Logik interface gaspådrag Logic (interface) throttle
A 784 Logik interface bromsregl Logic (interface) brake control
A 785 Logik interface styrsystem Logic (interface) control system
A 786 Servoförstärkare styrsystem Servo amplifier steering system
A 799 Logik allm (option) Logic, general (option)
A 806 Aggregat klimatanläggning Aggregate, air conditioner
A 810 Kondensor AC, fläkt Condensor AC, fan
A 827 Växellåda Gearbox
A 900 Radio/bandspelare Radio/tape recorder
A 905 Kommunikationsradio Communication radio
A 907 Monitor Monitor
A 908 Kamera Camera
A 909 Skrivare Printer
A 911 Dataterminal Dataterminal
A 912 Alkolås Interlock device
A 940 Logik batterivakt Logic switch , battery watch
A 950 Logik transistortändning Logic transistor ignition
A 955 Logik övervarvningsskydd (LPG) Logic overspeed protection (LPG)
A 960 Logik rev-spärr/aut-vxl Logic unit, reversing interlock/automatic
gear changing
A 961 Motor/kupevärmare Engine- and cab heater
B 649 Termostat klimatannläggning Thermostat, air condition
B 690 Fartreglage (EC) Speed control (EC)
B 697 Elbroms Electric brake
B 751 Givare varvtal turbin Transmitter, speed turbin
B 752 Givare varvtal inre växellåda Transmitter, speed internal gear chain
B 753 Varvtalsgivare motor Transmitter, engine revolution
B 754 Givare lufttryck Transmitter, air pressure
B 755 Givare hydraulfilter indikering Transmitter, hydraulics filter indication
B 756 Temperatur kylvätska motor Transmitter, engine coolant temperature
B 757 Bränslenivågivare Transmitter, fuel level
B 758 Varvtalsgivare v-låda Transmitter, gear box revolution
B 759 Nivåindikator kylvätska Transmitter, coolant level
B 760 Givare rev-spärr/aut-vxl trans Transmitter, reversing interlock / automatic
gear change system (on gearbox output
shaft)
B 761 Givare rev-spärr/aut-vxl motor Transmitter, reversing interlock / automatic
gear changing system (engine speed)
B 762 Givare temp,spolkrets bromsar Transmitter, brake flushing circuit

B 763 Givare nivå hydraulolja Transmitter, hydraulic fluid level
B 764 Givare servotryck växellåda Transmitter, gear box servo pressure
B 765 Givare oljetryck v-låda Transmitter, oil pressure gear box
B 766 Givare oljetemp. v-låda Transmitter, oil temperature gear box
B 767 Givare oljetryck motor Transmitter, oil pressure engine
B 768 Givare oljetryck hydraulik Transmitter, hydraulic pressure
B 769 Givare ändläge Transmitter, end position
B 770 Givare rattutslag Transmitter, steering wheel angle
B 771 Givare vinkel Transmitter, angle
B 772 Givare temp bromsolja Transmitter, temperature brake fluid
Verkstadmanual / Workshop Manual – DCF 80–-100 VDCF01.03SE/GB
B 773 Givare närvaro Transmitter, presence
B 774 Givare utomhustemp Transmitter, ambient temperature
B 775 Givare temp klimatanläggning Transmitter, temperature air condition
B 776 Givare temp hydraulolja Transmitter, hydraulic temperature
B 777 Givare läge Transmitter, position
B 778 Givare drivbrytning Transmitter, drive break
B 789 Givare allmän Transmitter, common
B 902 Högtalare Loud speaker
B 7224 Givare, mätläge våg Sensor, measurepoint scale
B 7225 Givare, rotationsstopp Sensor, rotation stop
B 7226 Givare, tryck lyftcylinder Sensor, pressure lift cylinder
B 7227 Givare, tryck klämma Sensor, pressure clamp
B 7228 Givare lyfthöjd analog Sensor lift height analogue
B 7229 Givare tiltvinkel analog Sensor tilt angle analogue
B 7230 Givare ultraljud last position Sensor, ultrasonic load position
B 7231 Givare, Over Height, Ben uppe Sensor, Over Height, Leg upper position
B 7232 Givare,IR Last position Givare,IR Load position
B 7233 Givare lambda sond Sensor lambda sond
B 7234 Givare vatten i bränsle Transmitter water in fuel
B 7235 Givare temp avgaser Sensor exhaust temperature
B 7236 Givare tryck avgaser Sensor exhaust pressure
C 821 KONDENSATOR CAPACITOR
D 740 FleetManager kontrollenhet FleetManager control unit
D 742 FleetManager kortläsare FleetManager card device
D 743 FleetManager accelerations givare FleetManager acceleration sensor
D 744 Galvaniskt isolerad CAN brygga Galvanic insulated CAN bridge
D 780 Reglersystem drivmotor Control system traction motor
D 781 Reglersystem pumpmotor Control system pump motor
D 790 Elektronisk kontrollenhet ECU, hytt Electronic Control Unit ECU, cab
D 791 Elektronisk kontrollenhet aggregat Electronic Control Unit, attachment
D 792 Elektronisk kontrollenhet styrning Electronic Control Unit, steering system
D 793 Elektronisk kontrollenhet växellåda Electronic Control Unit, gearbox
D 794 Elektronisk kontrollenhet motor Electronic Control Unit, engine
D 796 Elektronisk kontrollenhet, lasthantering Electronic Control Unit, Loadhandling
D 797 Elektronisk kontrollenhet, ram Electronic Control Unit, frame
D 798 Elektronisk kontrollenhet, stolvändning Electronic Control Unit, seat rotation
D 2000 Elektronisk kontrollenhet, proportionalventil Electronic control unit, propotional valve
D 9001 Åkerströms fjärrkontroll Åkerströms Remote Control

E 400 G-lampa vä fram Light bulb, roading light left hand front
E 400 G-lampa hö fram Light bulb, roading light right hand rear
E 401 G-lampa vä bak Light bulb, roading light left hand front
E 401 G-lampa hö bak Light bulb, roading light right hand rear
E 402 G-lampa fjärrljus Light bulb, distance light
E 403 G-lampa lastljus Light bulb, mast light
E 404 G-lampa arbetsljus Light bulb, working light
E 405 G-lampa backljus Light bulb, rear light
E 406 G-lampa cont belysning vänster Container light left-hand
E 406 G-lampa cont belysning höger Container light right-hand
E 408 G-lampa park ljus vä fram Light bulb, parking light, left-hand forward
E 408 G-lampa park ljus hö fram Light bulb, parking light, right-hand forward
E 429 G-lampa cigarettändare belysning Light bulb, cigarett lighter illumination

E 431 G-lampa instrument belysning Light bulb, instrument illumination
E 432 G-lampa handsfack belysning Light bulb, glove pocket light
E 433 G-lampa instegs belysning Light bulb, step-in lighting
E 434 G-lampa innerbelysning Light bulb, interior lighting
E 435 G-lampa låsbelysning Light bulb, reading lighting
E 436 G-lampa identifikationsljus Light bulb, identification light
E 437 G-lampa identifikationsljus/takskylt Light bulb, identification light/roof sign
E 438 G-lampa motorrumsbelysning Light bulb, engine compartment light
E 439 Nummerskyltsbelysning Light license plate
E 440 G-lampa värmereglage belysning Light bulb, heating control light
E 456 G-lampa backljus blackout IR vänster Light bulb, rear light blackout IR left-hand
E 456 G-lampa backljus blackout IR höger Light bulb, rear light blackout IR right-hand
E 458 G-lampa fram blackout vänster Light bulb, roading light blackout left-hand
E 458 G-lampa fram blackout höger Light bulb, roading light blackout right-hand
E 459 G-lampa fram blackout IR vänster Light bulb, roading light blackout IR left-
hand
E 459 G-lampa fram blackout IR höger Light bulb, roading light blackout IR right-
hand
E 460 G-lampa arb.belysning hytt blackout IR vä Light bulb, working light cab blackout IR left
E 460 G-lampa arb.belysning hytt blackout IR hö Light bulb, working light cab blackout IR
right
E 461 G-lampa arb.bel. bom 20' blackout IR vä Light bulb, working light boom20' b.out IR
left
E 461 G-lampa arb.bel. bom 20' blackout IR hö Light bulb, working light boom20' b.out IR
right
E 462 G-lampa arb.bel. bom 40' blackout IR vä Light bulb, working light boom40' b.out IR
left
E 462 G-lampa arb.bel. bom 40' blackout IR hö Light bulb, working light boom40' b.out IR
right
E 464 G-lampa cont belysning IR vänster Light bulb,Container light IR left-hand
E 464 G-lampa cont belysning IR höger Light bulb,Container light IR right-hand
E 669 Värmare kupe/ motor diesel Heater compartment/engine diesel
E 802 Eluppvärmd backspegel Electrical heated observation mirror
E 803 Eluppvärmd stol Electrical heated seat
E 804 Cigarettändare Cigarett lighter
E 805 Elvärme hytt Electrical heating cab
E 808 Eluppvärmd lufttorkare Electrical heater air dryer
E 835 Tändstift Ignition plug
E 888 Lufttork, kompressor Air Dryer, Compressor
E 962 Logik slitageind kol elmotor Logic indication of wear, brush electrical
motor
E 4370 Sökljus Search light
E 8092 Eluppvärmd ruta Electrical heated window
F 51 Säkringshållare 1-polig Fuse holder, 1-pole
F 62 Batterihandske 2-polig Battery connector, 2-pole
F 64 Batterihandske 4-polig Battery connector, 4-pole
G 30 Batteri Battery
G 658 Generator (extra) Alternator extra
G 659 Generator utan laddregulator Alternator without loading regulator
G 660 Generator med laddregulator Alternator with loading regulator
G 662 Laddregulator Loading regulator
H 410 G-lampa broms ljus vä fram Light bulb, brake light, left-hand forward
H 410 G-lampa broms ljus hö fram Light bulb, brake light, right-hand forward
H 411 G-lampa broms ljus vä bak Light bulb, brake light, left-hand rear
H 411 G-lampa broms ljus hö bak Light bulb, brake light, right-hand rear
H 412 G-lampa bak ljus vä bak Light bulb, rear light, left-hand rear
H 412 G-lampa bak ljus hö bak Light bulb, rear light right-hand rear
H 413 G-lampa bak ljus vä fram (VBFS) Light bulb, rear light, left-hand forward
(VBFS)
H 413 G-lampa bak ljus hö fram (VBFS) Light bulb, rear light,right-hand forward
(VBFS)
H 416 G-lampa sidomarkering vä fram Light bulb, side position light, left-hand
forward
H 416 G-lampa sidomarkering vä bak Light bulb, side position light, left-hand rear
H 417 G-lampa sidomarkering hö fram Light bulb, side position light, right -hand
forward
H 417 G-lampa sidomarkering hö bak Light bulb, side position light, right-hand
rear
H 420 G-lampa positionsljus vänster Light bulb, position light, left-hand
H 421 G-lampa positionsljus höger Light bulb, position light, right-hand
H 422 G-lampa körvisare vä fram Light bulb, direction indicator left-hand
forward
H 423 G-lampa körvisare hö fram Light bulb, direction indicator right-hand
forwrd
H 426 G-lampa körvisare vä bak Light bulb, direction indicator left-hand rear
H 427 G-lampa körvisare hö bak Light bulb, direction indicator right-hand

rear
H 428 G-lampa roterande varningsljus Light bulb, flashing beacon lamp
H 445 G-lampa körvisare vä (extra) Light bulb, extra direction indicator left
H 446 G-lampa körvisare hö (extra) Light bulb, extra direction indicator right
H 451 G-lampa dimbakljus vänster Light bulb, fog light rear left
H 452 G-lampa dimbakljus höger Light bulb, fog light rear right
H 453 G-lampa bromsljus/körvisare vänster Light bulb, brake light/dir. indicator left-hand
H 453 G-lampa bromsljus/körvisare höger Light bulb, brake light/dir. indicator right-
hand
H 454 G-lampa bromsljus blackout vänster Light bulb, brake light blackout left-hand
H 454 G-lampa bromsljus blackout höger Light bulb, brake light blackout right-hand
H 457 G-lampa positionsljus blackout vänster Light bulb, position light blackout left-hand
H 457 G-lampa positionsljus blackout höger Light bulb, position light blackout right-hand
H 463 G-lampa bak ljus vänster bak, blackout Light bulb, rear light left-hand rear, blackout
H 463 G-lampa bak ljus höger bak, blackout Light bulb, rear light right-hand rear,
blackout
H 465 G-lampa röd saxagregat ute Light-bulb, red extender exended
H 466 G-lampa orange vertikalhålning på Light bulb, orange vertical hold on
H 467 G-lampa grön klämtryck OK Light bulb, green clamp pressure OK
H 468 G-Lampa Röd Maxlast Light bulb,Red Overload
H 500 Kont lampa körvisare Indicating lamp, direction indicator
H 501 Kont lampa körvisare (extra) Indicating lamp, direction indicator extra
H 503 Varn lampa oljetryck motor Warning lamp, oil pressure engine
H 504 Kont lampa helljus Indicating lamp, main beam
H 505 Varn lampa laddning Warning lamp, loading
H 506 Varn lampa laddning (extra) Warning lamp, loading extra
H 507 Varn lampa färdbroms Warning lamp, brake
H 508 Varn lampa parkerings broms Warning lamp, parking brake
H 509 Varn lampa nivå kylvatten Warning lamp, coolant level
H 510 Kont lampa diff spärr Indicating lamp, diff. interlock
H 512 Varn lampa temp momentförst Warning lamp, temperature converter
H 514 Kont lampa överväxel Indicating lamp, overdrive clutch
H 519 Kont lampa halvljus Indicating lamp, dipped lights
H 524 Kont lampa luftfilter Indicating lamp, air filter
H 525 Kont lampa UNIKAT Indicating lamp, UNIKAT
H 528 Kont lampa förvärmning Indicating lamp, preheating
H 530 Kont lampa framhjuls styrning Indicating lamp, forward wheel steering
H 531 Kont lampa 4-hjuls styrning Indicating lamp, 4-wheel steering
H 532 Kont lampa crab styrning Indicating lamp, crab steering
H 533 Kont lampa hyd.pump Indicating lamp, emergency hyd. pump
H 547 Varn lampa centralvarning Warning lamp, central warning
H 549 Varn lampa oljetryck v-låda Warning lamp, oil pressure gear box
H 550 Varn lampa hyttlåsning Warning lamp, cab lock
H 551 Varn lampa temp v-låda Warning lamp, temperature gear box
H 552 Varn lampa bromstryck Warning lamp, brake pressure
H 554 Varn lampa temp spolkrets bromsar Warning lamp, temp. cooling system
brakes
H 555 Varn lampa temp kylvatten mot Warning lamp, temperature coolant engine
H 556 Varn lampa låsning vändskiva Warning lamp, interlocking of turntable

H 560 Varn lampa temp drivmotor el Warning lamp, temperature, drive motor
H 561 Varn lampa temp pumpmotor el Warning lamp, temperature, pump motor
H 562 Varn lampa öppen twistlock Warning lamp, unlocked twist lock
H 563 Varn lampa låst twistlock Warning lamp, locked twist lock
H 564 Varn lampa anliggning Warning lamp, alignement
H 565 Varn lampa temp motor el Warning lamp ,temperature motor
H 569 Kont lampa elvärme Indicating lamp, electric heater
H 569 Kont lampa elvärme Indicating lamp, electric heater
H 570 Varn lampa överkoppling säkerhetssystem Warning lamp, by-pass safety system
H 571 Kont lampa bränslenivå Indicating lamp, fuel level

H 572 Varningslampa lyfthöjd Warning lamp lifting height
H 573 Kontroll lampa motor information Indicator lamp engine information
H 574 Kontroll lampa stödben nere Indicator lamp support jacks down
H 575 Kontroll lampa stödben ur arb.läge Indicator lamp support jacks out of working
pos
H 576 Kontroll lampa anliggning främre ben Indicator lamp, alignment front legs
H 577 Kontroll lampa anliggning bakre ben Indicator lamp, alignment rear legs
H 578 Kontroll lampa klämläge främre ben Indicator lamp, clamp position front legs
H 579 Kontroll lampa klämläge bakre ben Indicator lamp, clamp position rear legs
H 580 Kontroll lampa främre ben uppe Indicator lamp, front legs upper position
H 581 Kontroll lampa främre ben nere Indicator lamp, front legs lower position
H 582 Varningslampa överlast Warning lamp overload
H 583 Kontroll lampa anliggning ett ben Indicator lamp, alignment one leg
H 584 Kontroll lampa anliggning alla ben Indicator lamp, alignment all legs
H 599 Kont lampa option Indicating lamp, option
H 850 Signalhorn Horn
H 853 Summer Buzzer
H 965 Backvarnare Reversing alarm
H 5000 Kont lampa tryck lyfttång Indicating lamp, pressure lift tong
H 5001 Varn lampa, Over Height ben uppe Warn. Lamp, Over Height leg upper pos
H 9003 Varningssignal aut. rörelse Warning alarm aut. movement
K 300 Relä hel/halvljus Relay, main/dipped beam
K 301 Relä dimljus Relay, fog light
K 302 Relä fjärrljus Relay, distance light
K 303 Relä lastljus Relay, mast light
K 304 Relä arbetsljus Relay, working light
K 305 Relä backljus Relay, reversing light
K 306 Relä helljus Relay, main beam
K 307 Relä halvljus Relay, dipped beam
K 308 Relä bromsljus Relay, brake light
K 309 Relä parkeringsbroms Relay, parking light
K 310 Relä körvisare vä Relay, direction indicator left
K 311 Relä körvisare hö Relay, direction indicator right
K 312 Relä startelement Relay,element preheater
K 313 Relä vändbar förarstol Relay, rotating driver´s seat (VBFS)
K 314 Relä parkeringsbroms Relay, parking brake
K 315 Relä tändningslås Relay, ignition key
K 316 Relä torkare Relay, wiper
K 317 Relä strålkastartorkare Relay, roading lights wiper
K 318 Relä AT-regulator Relay, AT-regulator
K 319 Relä varningsblinkers Relay, hazard blinkers
K 320 Relä elektrisk stopp Relay, electical stop
K 321 Relä intervalltorkare Relay, intermittent wiper
K 322 Relä kylvätskenivå Relay, coolant level
K 323 Relä blinkers Relay, blinkers
K 324 Relä rangespärr Relay, range interlock
K 325 Relä blinkande bromsljus (back) Relay, flashing brake lights (reversing)
K 326 Relä blinkande bromsljus (runt) Relay, flashing hazard brake lights
K 327 Relä växel neutral Relay, gear neutral
K 328 Relä växelskifte Relay, gear shift
K 329 Relä växel hög/låg Relay, high/low gear
K 330 Relä startspärr Relay, start interlock
K 331 Relä drivning fram Relay, forward driving
K 332 Relä drivning bak Relay, reversing driving
K 333 Tidrelä förvärmning Time relay, automatically preheating
K 334 Relä frikoppling/drivbrytning Relay, free wheel/drive disconnection
K 335 Relä växelventil 1:a (diesel, gas) Relay, gear change valve 1-gear
(diesel,LPG)
K 336 Relä växelventil 2:a (diesel, gas) Relay, gear change valve 2-gear
(diesel,LPG)
K 337 Relä drivriktning motor Relay, motor drive direction
K 338 Relä kylfläkt drivmotor Relay, cooling fan drive motor
K 339 Relä kylfläkt elskåp Relay, cooling fan electrical box
K 340 Tidrelä fördröjt tillslag Time relay, start delay
K 341 Tidrelä fördröjt frånslag Time relay, stop delay
K 342 Relä drivning 2/4 hjul Relay, switching 2/4 WD
K 343 Relä dimbakljus Relay, fog light rear
K 344 Relä momentförstärkare Relay, torque amplifier
K 345 Relä låsning vändskiva Relay, interlocking of turntable
K 346 Relä frikoppling stollåsning Relay, releasing of seat interlocking
K 347 Relä stolvändning/ljussignal Relay, multifunction, seat rotation/light
signal
K 348 Relä fläktmotor värmare Relay, fan heating
K 349 Relä fartreglage Relay, speed control
K 350 Relä pumpkontaktor/pumpkontroll Relay, pump contactor/pump control
K 351 Relä hyttlyft upp Relay, cab hoist up
K 352 Relä hyttlyft ner Relay, cab hoist down
K 353 Relä säkerhetsslinga Relay, safety loop
K 354 Relä styrsystem Relay, signal control system
K 355 Relä sensorstyrning Relay, sensor control
K 356 Skiftrelä längskörning/tvärskörning Shift relay, length/sideways driving
K 357 Relä roterande varningsljus Relay, hazard beacon
K 358 Relä komressor luft Relay, compressor air
K 359 Relä Hydrauloljekylare Relay hydraulic oil cooler
K 360 Relä startsolenoid Relay, starting solenoid
K 361 Relä kompressor AC Relay, compressor air conditione
K 362 Relä vattenventil AC Relay, water valve air conditioner
K 363 Relä kondensor AC Relay, condenser air conditione
K 364 Relä stolsbrytare Relay seat switch
K 365 Relä fönsterhiss upp Relay, electrical screen elevator up
K 366 Relä fönsterhiss ner Relay, electrical screen elevator down
K 367 Relä styrning Relay, steerin
K 368 Relä lågt bromstryck Relay, low brake pressure
K 369 Relä centralsmörjning Relay, central lubrication
K 370 Relä centralsmörjning, aggregat Relay, central lubrication, attatchment
K 371 Relä lyfthöjd Relay, liftheight
K 372 Relä blinkande varn.ljus, höjdbegränsn. Relay, flashing beacon, lifting height limiter
K 373 Relä bakljus Relay light

K 375 Huvudkontaktor reglersystem Main contactor, operating control
K 376 Kontaktor fram reglersystem Contactor, forward operating control
K 377 Kontaktor bak reglersystem Contactor, reversing operating control
K 378 Kontaktor by-pass Contactor, ¿by-pass¿ operating control/
reglersystem/Fältförsvagning Field weakening
K 379 Kontaktor pumpmotor Contactor, pump motor
K 380 Kontaktor Contactor
K 381 Kontaktor återladdning Contactor, recharging
K 382 Relä, förbikoppling säkerhetssystem Relay, by-pass safety system
K 383 Relä, Stolsvärme Relay, heated seat
K 384 Relä vattenseparator Relay, waterseparator
K 385 Relä bränslepump insprutning Relay, fuel injection pump
K 386 Relä, hög motortemperatur. Relay, high motor temperature
K 387 Relä alternativ gaspedal Relay alternative throttle pedal
K 388 Relä, Extra färdriktningsväljare Relay, Extra direction selector
K 389 Relä, Pausvärme Relay, Paus heat
K 399 Relä option Relay, option
K 3001 Relä rotation Relay, rotation
K 3002 Relä tilt Relay, tilt
K 3003 Relä sidoföring Relay, side shifting
K 3004 Relä längdinställning Relay, length adjustment
K 3005 Relä twist lock Relay, twist lock
K 3006 Relä spridning Relay, spreading
K 3007 Relä lyft/sänk Relay, lifting/lowering
K 3008 Relä hydraulfunktion extra Relay, extra hydraulic function
K 3009 Relä manöverbrytare hydr Relay, operating switch
K 3010 Relä bromsljus vxl std/blackout Relay, brake light shift std/blackout
K 3011 Relä backljus vxl std/blackout Relay, reversing light shift std/blackout
K 3012 Relä arb.bel hytt vxl std/blackout Relay, working light cab, shift std/blackout
K 3013 Relä arb.bel. bom 20' vxl std/blackout Relay,working light boom20' shift std/b.out
K 3014 Relä arb.bel. bom 40' vxl std/blackout Relay,working light boom40' shift std/b.out
K 3015 Relä vxl bromsljus/blinkers vä Relay, shift brake light/direction indicator
left
K 3015 Relä vxl bromsljus/blinkers hö Relay, shift brake light/direction indicator
right
K 3016 Relä signalhorn relay, horn
K 3017 Relä containerbelysning Relay, Container light
K 3018 Relä containerbelysning IR Relay, Container light IR
K 3305 Relä VBFS, backljus Relay, rotating driver´s seat, reversing light
K 3306 Relä VBFS, helljus Relay, rotating driver´s seat, main beam
K 3307 Relä VBFS, halvljus Relay, rotating driver´s seat, dipped beam
K 3308 Relä VBFS, bromsljus Relay, rotating driver´s seat, brake light
K 3310 Relä VBFS, körvisare vä Relay, rotating driver´s seat, direction
indicator left
K 3311 Relä VBFS, körvisare hö Relay, rotating driver´s seat, direction
indicator right
K 3330 Relä, säkerhetsbälte Relay, seat belt
K 3331 Relä VBFS, drivning fram Relay, rotating driver´s seat, forward driving
K 3332 Relä VBFS, drivning bak Relay, rotating driver´s seat, reversing
driving
K 3349 Relä VBFS, fartreglage Relay, rotating driver´s seat, speed control
K 3404 Relä VBFS, mastljus Relay, rotating driver´s seat, mast light
K 3405 Relä,backalarm Relay,reversealarm
K 3412 Relä bak ljus Relay, rotating driver´s seat, rear light
K 3768 Relä oljetryck hydraulik Relay, hydraulic pressure
K 3769 Relä, blockering av hyttilt Relay, blocking of cab tilt
K 3770 Relä anliggning Relay, alignment
K 3771 Relä Krok Relay, Hook
K 3772 Relä laddsignal (D+) Relay, charge signal (D+)
K 3773 Relä 12V för minne radio Relay 12V for radio memory
K 3774 Relä kylfläkt olja Relay, cooling fan oil
K 3776 Relä värmare ruta Relay heated window
K 93774 Relä hållkrets Relay, Holdcircuit
L 830 Tändspole Ignition coil
M 608 Pumpaggregat hyttlyft Pump unit, cab hoist
M 609 Ställmotor gaspådrag Regulating motor, throttle
M 612 Ställmotor recirkulation Regulating motor, re-circulation
M 650 Torkarmotor fram
M 651 Vindrutespolarmotor Washer motor
M 652 Strålkastarmotor Light motor
M 653 Strålkastarspolarmotor Light washer motor
M 654 Startmotor Starter motor
M 655 Kylfläkt drivmotor (EC) Cooling fan, main motor (EC)
M 656 Kylfläkt elskåp (EC) Cooling fan, electrical box (EC)
M 657 Fläktmotor värme Heating fan
M 661 Fönsterhissmotor Screenelevator motor
M 663 Doseringspump klimatanläggning Dosage pump, air condition
M 664 Cirk pump klimatanläggning Circulating pump, air condition
M 666 Fläktmotor cirkulation Circulation fan
M 667 Cirkulationspump värmesystem Circulation pump heating system
M 668 Kylfläkt hydraulolja Cooling fan, hydraulic oil
M 670 Kompressor Compressor
M 671 Doseringspump diesel Dosage pump diesel
M 672 Spjäll motor, ECC Draught valve motor, ECC
M 674 Kylfläkt bromsolja Cooling fan, brake fluid
M 675 Motor, Stolsvändning Motor, Seat rotation
M 677 Motor Låsning stolsvridning Motor Locking revolving seat
M 693 Pump centralsmörjning Pump, central lubrication
M 694 Styrmotor Steering motor
M 695 Drivmotor (EC) Drive motor (EC)
M 696 Pumpaggregate nödstyrning Pump, emergency steering
M 698 Pumpmotor (EC) Pump motor (EC)
M 9000 Motor höj/sänkbar stolspelare Motor rise/lower seat column
P 700 Hastighetsmätare Speedometer
P 701 Mätare oljetemp v-låda Gear box oil temperature gauge
P 702 Klocka Clock
P 703 Varvtalsmätare Engine rev meter
P 704 Tryckluftsmätare Air pressure gauge
P 705 Mätare oljetryck v-låda Gear box oil pressure gauge
P 706 Termometer temp kylvätska motor Temperature gauge, engine coolant
P 707 Bränslemätare Fuel gauge
P 708 Timräknare Hour meter
P 709 Kapacitetsmätare batteri Capacity gauge, battery
P 710 Tidur motor/kupevärmare Timer, engine- and cab heater
P 711 Räknare, impuls Counter, impulse
P 712 Mätare oljetryck motor Motor oil pressure gauge
P 714 Mätare, temp. Hydraulolja Hydraulic fluidtemperature, guage
P 715 Extra instrument allm Extra instrument, general
P 795 Display Display
Q 144 Batterifrånskiljare Battery disconnecting switch
R 807 Potentiometer Potentiometer
R 820 Motstånd Resistor
R 825 Reglage spakstyrning Controls, (steering with control levers).
R 828 Shuntmotstånd Shunt-resitor
R 8071 Potentiometer lyft/sänk Potentiometer lift/lower
R 8072 Potentiometer tilt Potentiometer tilt
R 8073 Potentiometer sidoföring Potentiometer side shifting
R 8074 Potentiometer spridning Potentiometer spreading
R 8075 Potentiometer extra Potentiometer extra
R 8076 Potentiometer mast in/ut Potentiometer reach in/out
R 8077 Potentiometer höger framhjul Potentiometer right front wheel
R 8078 Potentiometer vänster framhjul Potentiometer left front wheel
R 8079 Potentiometer höger bakhjul Potentiometer right rear wheel
R 8080 Potentiometer vänster bakhjul Potentiometer left rear wheel
R 8081 Potentiometer tiltvinkel Potentiometer tilt angle
R 8082 Potentiometer fläkthastighet, ECC Potentiometer fan speed, ECC
R 8083 Potentiometer temperatur, ECC Potentiometer temperature, ECC
R 8084 Potentiometer spjäll, ECC Potentiometer draught valve, ECC
R 8085 Potentiometer rotation Potentiometer rotation
R 8086 Potentiometer sax Potentiometer extender
R 8087 Potentiometer klämma Potentiometer clamp
R 8088 Potentiometer skevning Potentiometer levelling
R 8089 Potentiometer kroklåsning Potentiometer flaps
S 100 Strömställare ljus Switch, light
S 101 Strömställare omk hel/halvljus Switch, main/dipped beam
S 102 Strömställare dimljus Switch, fog light
S 103 Strömställare fjärrljus Switch, distance light
S 104 Strömställare lastljus Switch, mast lights
S 105 Strömställare arbetsljus Switch, working lights
S 106 Strömställare containerljus Switch, container light
S 107 Strömställare park broms Switch, parking brake
S 108 Strömställare centr smörjning Switch, central lubricator
S 109 Strömställare varningsljus Switch, hazard lights
S 110 Strömställare rot varningsljus Switch, rotating hazard beacon
S 111 Strömställare fönsterhiss Switch, window regulator
S 112 Strömställare kylanläggning (AC) Switch, air conditioner (AC)
S 113 Strömställare styrning alt Switch, alternative steering
S 114 Strömställare läsbelysning Switch, reading light
S 115 Strömställare instr belysning Switch, instrument illumination
S 116 Strömställare innerbelysning Switch, interior lighting
S 117 Strömställare värme Switch, heating
S 118 Strömställare fläktm värme Switch, heater fan
S 119 Strömställare vindrutetorkare Switch, wiper
S 120 Strömställare spolare Switch, washer
S 121 Strömställare blackout Switch, blackout
S 122 Strömställare nöd hydraulpump Switch, emergency hydraulic pump
S 123 Strömställare backspegel Switch, observation mirror
S 124 Strömställare kallstart Switch, cold start
S 125 Strömställare avgasbroms Switch, exhaust brake
S 126 Strömställare diff spärr/broms Switch, diff. Block
S 127 Strömställare värmesystem diesel Switch, heating system diesel
S 128 Strömställare kraftuttag sida Switch, power take off side
S 129 Strömställare kraftuttag bak Switch, power take off rear
S 130 Strömställare hög/lågväxel Switch, high/low gear
S 131 Strömställare färdväljare fram Switch, gear selector forward
S 132 Strömställare färdväljare bak Switch, gear selector rear
S 135 Strömställare växelväljare Switch, gear shift
S 136 Strömställare framhjuls styrning Switch, forward wheel steering
S 137 Strömställare 4-hjuls styrning Switch, 4-wheel steering
S 138 Strömställare crab styrning Switch, crab steering
S 139 Strömställare defroster Switch, defroster
S 141 Strömställare Stegbelysning Switch, Steplight
S 142 Strömställare fot Switch, foot
S 143 Strömställare sitsvärme Switch, seat heater
S 145 Strömställare AT-regulator Switch, AT-regulator
S 147 Strömställare körvisare Switch, direction indicators
S 149 Strömställare signalhorn Switch, horn
S 150 Strömställare startlås/ellas Switch, main key switch
S 152 Strömställare intervalltorkare Switch, intermittent wiper
S 156 Strömställare kupevärmare Switch, cab heating
S 157 Strömställare stoltilt Switch, seat tilt
S 158 Strömställare dimbakljus Switch, rear fog light
S 159 Strömställare extra fram/back väljare Switch, extra direction selector
S 160 Strömställare komb fram/back Switch, combi-forward/reverse
S 161 Strömställare komb signal, ljus hel/halv Switch, combi-horn, light main/dipped
spol,torkare m intervall körvisare beam, washer, wiper (intermittent), direction
indicator
S 162 Strömställare komb signal ljus hel/halv, Switch, combi horn, light main/dipped
spol, torkare m 2 int, fram/bacK beam, washer, wiper w 2int., forward/revers
S 163 Strömställare start på 2-an Switch, start 2nd gear

S 165 Strömställare stolvärme Switch, seat heater
S 166 Strömställare låsning vändskiva Switch, interlocking of turntable
S 167 Strömställare luftfjädring Switch, pneumatic springing
S 168 Strömställare låsn stol Switch, interlocking of seat
S 169 Strömställare stolsvändning Switch, reversible seat
S 170 Strömställare förångare (LPG) Switch, evaporator (LPG)
S 171 Strömställare v-skiva upp/ner Switch, fifth wheel up/down
S 172 Strömställare v-skiva fr/back Switch, fifth wheel forward/reverse
S 173 Strömställare v-skiva skevning Switch, fifth wheel, levelling
S 174 Strömställare,utskjut Switch, projecting
S 175 Strömställare hyttlyft upp Switch, cab hoist up
S 176 Strömställare hyttlyft ner Switch, cab hoist down
S 177 Strömställare hyttskjutning Switch, cab movement
S 178 Strömställare nollställning Switch, reset
S 179 Strömställare Aut/man växling Switch Aut/man gearshifting
S 180 Strömställare fyrhjulsdrift Switch, 4-WD
S 190 Strömställare klimatanläggning Switch, air conditioner
S 191 Strömställare recirkulation Switch, re-circulation
S 192 Strömställare vattenavskiljare
S 195 Strömställare joy-stick X Switch, joy-stick X
S 196 Strömställare joy-stick X+Y Switch, joy-stick X+Y
S 197 Strömställare längs/tvärskörning Switch, length/sideways driwing
S 198 Strömställare flytläge skevning Switch, equalizing fifth wheel
S 199 Strömställare option Switch, option
S 200 Brytkontakt lampa park broms Contact, breaking,warning lamp,parking
brake
S 201 Brytkontakt lampa färdbroms Contact, breaking, warning lamp, brake
S 202 Brytkontakt lampa oljetryck motor Contact, breaking, warning lamp, oil
pressure engine
S 204 Brytkontakt tryck ackumulator Contact, breaking, pressure
accumulatortank
S 205 Brytkontakt innerbelysning Contact, breaking, interior lighting
S 206 Brytkontakt handskfack belysning Contact, breaking, glove
S 207 Slutkontakt diff spärr Contact, making, diff. interlock
S 208 Slutkontakt lampa temperatur spolkrets Contact, making, warning lamp temperature
bromsar brake
S 214 Slutkontakt överväxel Contact, making, over drive
S 215 Slutkontakt temp motor Contact, making, temperature engine
S 216 Slutkontakt bromsljus Contact, making, brake lights
S 217 Slutkontakt backljus Contact, making, reversing light
S 218 Slutkontakt AT-regulator Contact, making, AT-control
S 219 Slutkontakt lampa luftfilter Contact, making, indicating light air filter
S 220 Brytkontakt drivning Contact, breaking, drive cut off
S 221 Slutkontakt temp växellåda Contact, making, temperature gear box
S 222 Slutkontakt lampa temp moment - Contact, making, warning lamp temperature
förstärkare torque amplifier.
S 223 Släpkontakt signal Contact, brush, horn
S 224 Slutkontakt insprutningspump Contact, making, injection pump
S 225 Brytkontakt säkerhetsbälte Contact, breaking, seat belt
S 228 Slutkontakt hyttlåsning Contact, making, cab locking
S 229 Slutkontakt stolslåsning Contact, making, seat locking
S 230 Brytkontakt stol Contact, breaking, seat
S 231 Slutkontakt fotkontroll stolvändning Contact, making, seat rotation, foot switch
S 232 Brytkontakt lampa luftanslutning släp Contact, breaking, warning lamp air
connection
S 233 Slutkontakt lampa låsning vändskiva Contact, warning, interlocking of turntable
S 235 Slutkontakt sidoskjutning stol Contact, making, side shifting of seat
S 236 Slutkontakt vattennivå Contact, water level
S 239 Brytkontakt termisk Contact, breaking, thermic
S 240 Slutkontakt termisk Contact, making, thermic
S 241 Brytkontakt lampa luftmatning släp Contact, breaking, warning lamp air supply
to trailer
S 242 Slutkontakt lampa oljetryck v-låda Contact, making, warning lamp, oil
pressure gear box
S 243 Brytkontakt tryck kylmedia AC Contact, breaking, coolant pressure (air
condition)
S 244 Slutkontakt hydraulik aktiverad Contact, making, hydraulics
S 245 Slutkontakt hydraultryck styrning Contact, making, hydraulic pressure control
S 246 Slutkontakt tryck kylmedia Contact, pressure refrigerant

S 250 Manöverbrytare Operating Switch
S 251 Slutkontakt vändbar förarstol Contact, making, VBFS
S 260 Slutkontakt lyft steg 1 Contact, making, hoist step 1
S 261 Slutkontakt lyft steg 2 Contact, making, hoist step 2
S 262 Slutkontakt tilt Contact, making, tilting
S 263 Slutkontakt gaffelspridning Contact, making, fork positioning
S 264 Slutkontakt sidoföring Contact, making, sideshift
S 265 Slutkontakt stativ in/ut Contact, making, lifting mast in-out
S 266 Brytkontakt hyttdörr Contact, breaking cab door
S 267 Slutkontakt bromstryck Contact, making, brake pressure
S 268 Slutkontakt kompressor Contact, making, Compressor
S 269 Slutkontakt sax inne Contact, making extender in
S 270 Slutkontakt överlastskydd Contact, making, overload protection
S 271 Slutkontakt, filter växellåda Contact, making, filter gearbox
S 299 Slut/brytkontakt option Contact, making/braking option
S 720 Givare vändbar förarstol Transmitter, revolving driver´s seat (VBFS)
S 800 Startelement Start element

S 815 Manöverspak Control lever
S 840 Strömfördelare Distributor
S 1001 Strömställare, TW Switch, TW
S 1002 Strömställare, lossa TW Switch, unlocking of TW
S 1003 Strömställare, låsa TW Switch, locking of TW
S 1004 Strömställare, stopp vid 30'-35' Switch, stop at 30 -35¿
S 1005 Strömställare, förbikoppling av Switch, overriding of the safety system
säkerhetssystem
S 1006 Strömställare, fällning främre ben Switch, front legs down
S 1007 Strömställare, fällning bakre ben Switch, rear legs down
S 1008 Strömställare, klämma/lossa ben Switch, clamping/-releasing legs
S 1009 Strömställare, Motor information Switch, Engine information
S 1010 Srömställare, tilt av hytt Switch, tilt of cab
S 1011 Strömställare IR ljus Switch IR light
S 1012 Strömställare utskjut 20¿-40¿ Switch, Extension 20¿-40¿
S 1013 Strömställare stödben Switch, Support jacks
S 1014 Strömställare förbikoppling rotationstopp Switch, over ride rotation stop
S 1015 Strömställare förbikoppling höjdbeg/tp-beg Switch, over ride height limit/tp-limit
S 1017 Strömställare diagnostik öka/minska Switch, diagnostics increase/decrease
S 1018 Strömställare diagnostik on/off Switch, diagnostics on/off
S 1019 Strömställare rastvärme Switch, paus heat
S 1020 Strömställare automatisk släpp/kläm Switch automatic release/clamp funktion
funktion
S 1021 Strömställare sax Switch extender
S 1022 Strömställare vertikalhållning Switch, vertical position
S 1023 Strömställare låsning övre arm Switch, lock upper arm
S 1024 Strömställare Korta Armen av/på Switch, Short Arm on/off
S 1025 Strömställare pappersfunktioner av/på Switch, paper funktions on/off
S 1026 Strömställare omkoppling Switch, switch papper/bale clamp
pappers/klämmagregat
S 1027 Strömställare lyfthöjdsförval Switch, lift height selection
S 1028 Strömställare lyfthöjdsförval öka Switch, lift height selection increase
S 1029 Strömställare lyfthöjdsförval minska Switch, lift height selection decrease
S 1030 Strömställare läraringång givare ultraljud Switch, teaching ultrasonic sensor
S 1031 Strömställare, Over Height Upp/Ned Switch, Over Height Up/Down
S 1032 Brytare backljus Switch reverse light.
S 1033 Flytta korta armen Move short arm
S 1034 Strömställare förbikoppling startspärr Switch Override Start interlock
S 1035 Strömställare Val av klämtryck Switch, Clamp pressure selection
S 1036 Strömställare Korta Armen av/på Switch , Short Arm on/off
S 1037 Strömställare låsning skevning Switch, lock levelling
S 1038 Strömställare Övre armpar/Sidoföring Switch Upper arms/Sideshift
S 1039 Strömställare Inching Switch, Inching
S 1040 Switch stopp motor Switch, Stop engine
S 1041 Strömställare motorrumsbelysning Switch, light engine compartment
S 1042 Strömställare höjdjustering stol Switch, Seat height level
S 1043 Strömställare längdjustering stol Switch, Seat for/aft adjustment
S 1044 Strömställare Tankväljare Switch, Tankselector
S 1045 Strömställare Avstängning backalarm Switch, Rev. Alarm on/off
S 1046 Strömställare eluppvärmd ruta Switch electrical heated shield
S 1047 Henrik testar en brytare!
S 1048 Strömställare fjärrstyrning Switch remote control
S 1049 Strömställare styrning spegel Switch mirror control
S 1440 Huvudströmbrytare
S 7200 Givare, axeltryck höger Sensor, axle pressure right
S 7201 Givare, axeltryck vänster Sensor, axle pressure left
S 7202 Givare, anliggning vänster fram Sensor, alignment left front
S 7202 Givare, anliggning höger fram Sensor, alignment right front
S 7203 Givare, anliggning vänster bak Sensor, alignment left rear
S 7203 Givare, anliggning höger bak Sensor, alignment right rear
S 7204 Givare, öppen vänster twistlock Sensor, unlocked twistlock left
S 7204 Givare, öppen höger twistlock Sensor, unlocked twistlock right
S 7205 Givare, låst vänster twistlock Sensor, locked twistlock left
S 7205 Givare, låst höger twistlock Sensor, locked twistlock right
S 7206 Givare, gaffel aggregat Sensor, fork attachment
S 7207 Givare, 2WD/4WD Sensor, 2WD/4WD
S 7208 Givare, hytt i körläge Sensor, Cab in drive position
S 7209 Givare, oljefilter indikering Sensor, Oil filter indication
S 7210 Givare, hytt i transportläge Sensor, Cab in transportation position
S 7211 Givare, lyfthöjd Sensor, lifting height
S 7212 Givare, körläge Sensor, driving position
S 7213 Givare, Anliggning främre ben Sensor, Alignment front legs
S 7214 Givare, Anliggning bakre ben Sensor, Alignment rear legs
S 7215 Givare, kläm främre ben Sensor, Clamp front legs
S 7216 Givare, kläm bakre ben Sensor, Clamp rear legs
S 7217 Givare, främnre knä Sensor, front knee
S 7218 Givare, bakre knä Sensor, rear knee
S 7219 Givare, främre ben Sensor, front legs
S 7220 Givare, bakre ben Sensor, rear legs
S 7221 Givare, styraxel Sensor, steering axle
S 7222 Givare, stödben uppe Sensor, brace up
S 7223 Givare, stödben nere Sensor, brace down
U 741 FleetManager batterifilter FleetManager battery filter
U 823 Signalomvandlare höger Signal amplifier, right
U 824 Signalomvandlare vänster Signal amplifier, left
U 901 Spänningsomvandlare Voltage converter
U 910 Spänningsomvandlare 80V/24V Voltage converter 80 V / 24 V
U 941 Laddningsutjämnare Even charger
V 665 Diod Diode
V 8090 Laser, pappersaggretgat Lase, Pulp an Paper
W 903 Antenn radio Aerial, radio
W 906 Antenn kommunikationsradio Aerial, communication radio
W 8093 Genomföring, kablage Lead-through, harness
X 37 Terminal stomanslutning Earthing terminal on chassis
X 39 Terminal minusanslutning Terminal, negative terminal
X 72 Stickuttag 2-polig Outlet, 2-pole
X 77 Stickuttag 7-polig Outlet, 7-pole
X 78 Stickuttag extra 7-polig Outlet, extra, 7-pole
Y 600 M-ventil avgasbroms Solenoid valve, exhaust brake
Y 601 M-ventil diff spärr Solenoid valve, diff. interlock
Y 602 M-ventil broms Solenoid valve, brake
Y 603 M-ventil värme Solenoid valve, heater
Y 604 M-ventil kraftuttag sida Solenoid valve, power take off, side
Y 605 M-ventil kraftuttag bak Solenoid valve, power take off, rear
Y 606 M-ventil 2/4 hjulsdrift Solenoid valve, 2/4WD
Y 607 M-ventil hög/låg växel Solenoid valve, high/low gear
Y 610 M-ventil hydraulsystem allm Solenoid valve, hydraulics, general
Y 611 M-ventil flödesbegränsning Solenoid valve, flow restriction
Y 613 M-ventil momentförstärkare Solenoid valve, torque amplifier
Y 614 M-ventil rangespärr Solenoid valve, ranging interlock
Y 615 M-ventil hjulvridning Solenoid valve, wheel turning
Y 616 M-ventil kallstart Solenoid valve, cold start aid
Y 617 M-ventil AT-regulator by-pass Solenoid valve, AT-regulator ¿by-pass¿
Y 618 M-ventil vatten klimatanläggning Solenoid valve, water air conditioner
Y 620 M-ventil vändskiva upp Solenoid valve, fifth wheel up
Y 621 M-ventil vändskiva ner Solenoid valve, fifth wheel down
Y 622 M-ventil vändskiva fram Solenoid valve, fifth wheel forward
Y 623 M-ventil vändskiva bak Solenoid valve, fifth wheel rear
Y 624 M-ventil skevning hö Solenoid valve, levelling right hand
Y 625 M-ventil skevning vä Solenoid valve, levelling left hand
Y 626 M-ventil AT-regulator Solenoid valve, AT-regulator
Y 627 M-ventil vakuum Solenoid valve vacuum
Y 628 M-ventil bränsleblandning Solenoid valve fuelmixture
Y 630 M-ventil v-låda fram Solenoid valve, gear box, forward gear
Y 631 M-ventil v-låda back Solenoid valve, gear box, rear gear
Y 632 M-ventil v-låda spole 1 Solenoid valve, gear box, 1 gear
Y 635 M-ventil klämtryck Solenoid valve, clamping pressure
Y 636 M-ventil styrning Solenoid valve, steering
Y 637 M-ventil flytläge skevning Solenoid valve, equalizing fifth wheel
Y 638 M-ventil stopp insprut pump Solenoid valve, stop injection pump
Y 639 M-ventil låsning orbitrol ls Solenoid valve, locking LS orbitrol
Y 640 M-ventil gasol Solenoid valve, LPG
Y 641 M-ventil förångare (LPG) Solenoid valve, evaporator (LPG)
Y 642 M-ventil park broms Solenoid valve, parking brake
Y 643 M-ventil låsning stol (VBFS) Solenoid valve, seat locking (VBFS)
Y 644 M-ventil låsning vändskiva Solenoid valve, fifth wheel locking
Y 645 Magnetkoppling komp AC Magnetic clutch, compressor AC
Y 646 M-ventil stolsvändning Solenoid valve, seat rotation
Y 647 M-ventil stolstilt Solenoid valve, seat tilt
Y 648 M-ventil luftfjädring Solenoid valve, pneumatic springing
Y 673 Vatten ventil motor, ECC Water valve motor, ECC
Y 676 M-ventil Broms stolsvändning Solenoid valve Brake seat turning
Y 699 M-ventil option Solenoid valve, option
Y 826 Ventil spakstyrning Valve, (steering with control levers).
Y 6001 M-ventil blockering höger Solenoid valve, blocking right
Y 6002 M-ventil blockering vänster Solenoid valve, blocking left
Y 6003 M-ventil inkoppling av hydraulik till topplyft Solenoid valve, activation of toplift
hydraulics
Y 6004 M-ventil sänk Solenoid valve, lower
Y 6005 M-ventil lyft Solenoid valve, lift
Y 6006 M-ventil bom ut Solenoid valve, boom out
Y 6007 M-ventil bom in Solenoid valve, boom in
Y 6008 M-ventil vridning medsols Solenoid valve, rotation clockwise
Y 6009 M-ventil vridning motsols Solenoid valve, rotation counter-clockwise
Y 6010 M-ventil tilt ut Solenoid valve, tilt out
Y 6011 M-ventil tilt in Solenoid valve, tilt in
Y 6012 M-ventil tilt Solenoid valve, tilt
Y 6013 M-ventil fällning främre ben Solenoid valve, lowering front legs
Y 6014 M-ventil fällning bakre ben Solenoid valve, lowering rear legs
Y 6015 M-ventil klämma/lossa ben Solenoid valve, clamping/releasing legs
Y 6016 M-ventil Hyttskjutning fram Solenoid valve, cab movement forward
Y 6017 M-ventil Hyttskjutning bak Solenoid valve, cab movement reverse
Y 6018 M-ventil spridning ut Solenoid valve, spreading out
Y 6019 M-ventil spridning in Solenoid valve, spreading in
Y 6020 M-ventil sidoföring vänster Solenoid valve, side shift left
Y 6021 M-ventil sidoföring höger Solenoid valve, side shift right
Y 6022 M-ventil extra hydraulfunktion ut Solenoid valve, extra hydraulic function out
Y 6023 M-ventil extra hydraulfunktion in Solenoid valve, extra hydraulic function in

Y 6024 M-ventil stativ ut Solenoid valve, mast out
Y 6025 M-ventil stativ in Solenoid valve, mast in
Y 6026 M-ventil höger framhjul styrning vänster Solenoid valve, right front wheel, steering
left
Y 6027 M-ventil höger framhjul styrning höger Solenoid valve, right front wheel, steering
right
Y 6028 M-ventil vänster framhjul styrning vänster Solenoid valve, left front wheel, steering left
Y 6029 M-ventil vänster framhjul styrning höger Solenoid valve, left front wheel, steering
right
Y 6030 M-ventil höger bakhjul styrning vänster Solenoid valve, right rear wheel, steering
left
Y 6031 M-ventil höger bakhjul styrning höger Solenoid valve, right rear wheel, steering
right
Y 6032 M-ventil vänster bakhjul styrning vänster Solenoid valve, left rear wheel, steering left
Y 6033 M-ventil vänster bakhjul styrning höger Solenoid valve, left rear wheel, steering
right
Y 6034 M-ventil skevning Solenoid valve, levelling
Y 6035 M-ventil skevning höger Solenoid valve, levelling right
Y 6036 M-ventil skevning vänster Solenoid valve, levelling left
Y 6037 M-ventil kylfläkt Solenoid valve, Cooling fan
Y 6038 M-ventil frikoppling koppling Solenoid valve, lockup clutch
Y 6039 M-ventil öppna twistlock Solenoid valve, unlocked twist lock
Y 6040 M-ventil låsa twistlock Solenoid valve, locked twist lock
Y 6041 M-ventil nöd, twistlock Solenoid valve, emergency, twistlock
Y 6042 M-ventil mellan bom Solenoid valve, middle boom
Y 6043 Magnetventil, fällning torn (RTCH) Solenoid valve, boom lowering (RTCH)
Y 6044 M-ventil blockering twistlock Solenoid valve, blocking twistlock
Y 6045 M-ventil blockering lyft Solenoid valve, blocking lift
Y 6046 M-ventil utskjut Solenoid valve, projecting
Y 6047 M-ventil, hyttilt upp Solenoid valve, cab tilt up
Y 6048 M-ventil, hyttilt ner Solenoid valve, cab tilt down
Y 6049 M-ventil, kylkrets broms Solenoid valve, cooling cicuit brake
Y 6050 M-ventil blockering utskjut Solenoid valve, blocking projecting
Y 6051 M-ventil, regenerering höger Solenoid valve, regeneration right
Y 6052 M-ventil, regenerering vänster Solenoid valve, regeneration left
Y 6053 M-ventil, körläge Solenoid valve, driving position
Y 6054 M-ventil, klämma ihop Solenoid valve, clambing in
Y 6055 M-ventil, klämma isär Solenoid valve, clambing out
Y 6056 M-ventil, främre knä ut Solenoid valve, front knee out
Y 6057 M-ventil, främre knä in Solenoid valve, front knee in
Y 6058 M-ventil, bakre knä ut Solenoid valve, rear knee out
Y 6059 M-ventil, bakre knä in Solenoid valve, rear knee in
Y 6060 M-ventil, främre ben upp Solenoid valve, front legs up
Y 6061 M-ventil, bakre ben upp Solenoid valve, rear legs up
Y 6062 M-ventil, urkoppling hydraulpump Solenoid valve interruption hydraulic pump
Y 6063 M-ventil, stödben upp Solenoid valve, brace up
Y 6064 M-ventil, stödben ner Solenoid valve, brace down
Y 6065 M-ventil, frikoppling vridbroms Solenoid valve, lockup rotation brake
Y 6066 M-ventil, v-låda, drivning Solenoid valve, gearbox, drive
Y 6067 M-ventil, v-låda, oljetryck till 1:a/3:e växeln Solenoid valve, gearbox,oilpressure to
1st/3rd gear
Y 6068 M-ventil sax/rotation Solenoid valve externder/rotation
Y 6069 M-ventil, v-låda, oljetryck till 2:a/4:e växeln Solenoid valve, gearbox,oilpressure to
2nd/4th gear
Y 6070 M-ventil Over Height upp Solenoid valve, Over Height up
Y 6071 M-ventil Over Height ner Solenoid valve, Over Height down
Y 6072 M-ventil klämtryck Solenoid valve clamp pressure
Y 6073 Propertional ventil, Opti speed Proportional valve, Opti speed
Y 6074 M-ventil, v-låda, växelväljare för 2:a/4:e Solenoid valve, gearbox, gearswitch for
växeln 2nd/4th gear
Y 6075 M-ventil, v-låda, växelväljare för 1:a/3:e Solenoid valve, gearbox, gearswitch for
växeln 1st/3rd gear
Y 6076 M-ventil blockering sänk Solenoid valve, blocking lower
Y 6077 M-ventil Inching Solenoid valve, Inching
Y 6078 M-ventil,Avstängning Övre klämarm Solenoid valve, upper arm off
Y 6079 M-Ventil, Sidoföring/Övre armar Solenoid valve, Sideshift/Upper arms
Y 6080 M-ventil, aktivering hyttkörning Solenoid valve, activate sliding cab
Y 6081 M-ventil, ackumulatorladdning Solenoid valve, accumulator charge
Y 6082 M-ventil tryckbegränsning Solenoid valve, pressure restriction
Z 822 Signalfilter Signal filter

F:1
F Technical data
Contents F Technical data

Technical data .................................................................................................... F:3
Data ................................................................................................................ F:3
Volumes .......................................................................................................... F:4
Specification for lifting capacity and dimensions............................................. F:6
Oils and lubricants, recommendation.............................................................. F:8
Tightening torques, recommendations.......................................................... F:10
Tightening torque, connections for air conditioning .......................................F:11
Tightening torque, ORFS connections .......................................................... F:12
Unit explanations .......................................................................................... F:13
Conversion SI-units....................................................................................... F:14
Conversion table length ................................................................................ F:15
Conversion table area................................................................................... F:15
Conversion table volume .............................................................................. F:15
Conversion table weight................................................................................ F:15
Conversion table pressure ............................................................................ F:16

F:2

F Technical data – Technical data F:3
F Technical data
Data
The machine's weights and dimensions vary depending on how the
machine is equipped. Detailed information regarding this is given in the
product specification and data sheet for the machine in question.
1. Engine Volvo TAD760VE Cummins QSB6.7

Power acc. to ISO 3046 (net power) 180 kW at 2200 rpm 164 kW at 2200 rpm
Torque ISO 3046 1100 Nm at 1500 rpm 949 Nm at 1500 rpm
Max. rotation speed 2200 rpm
Number of cylinders 6 cylinders
Alternator, output 1920 W 2240 W
System voltage, voltage-capacity 2x12 V – 135 Ah
2. Transmission Dana-Spicer Off Highway TE17

No. of gears, forward - reverse 3 – 3
3. Power transmission
Drive axle, type Kessler D81
Kessler D91
4. Brakes
Service brake system – actuated wheel Wet Disc Brake - drive wheel
Parking brake system – actuated wheel Spring brake - drive wheel
5. Steering
Steering system Hydraulic servo
6. Wheels
Dimensions, front and rear 12.00x24
14.00x24
Tyre pressure, also see pressure plate 1.0 MPa
Tyre type, front and rear Inflated. Spare and replacement tyres must be from a manu-
facturer approved by Cargotec.
9. Cab Spirit Delta
Equivalent sound pressure level Volvo TAD760VE Cummins QSB6.7

in cab according to EN12053 with LpAZ 72 dB(A) LpAZ 65 dB(A)
measurement uncertainty σR=2.5 dB.
Measurement value with standard
engine.
Whole-body vibrations according 0.4 - 0.7 m/s2
to EN13059 with measurement
uncertainty k=0.3 x measured value.

F:4 F Technical data – Technical data
9.6 Frame, body, cab and accessories, lighting system

Lamp Output (W) Socket
Check lamps 1.2 W2x4.6d
Interior lighting 10 S8.5
Tail lights 5 BA15s
Brake light 21 BA15s
Direction indicators 21 BA15s
Position lamps 5 W2.1x9.5d
Headlights (high and low beams) 75/70 P43t-38 (H4)
Back-up lights 70 PK22s (H3)
Work lights 70 PK22s (H3)
Work lights, Xenon 35 D1S Xenon tubes. Cartridge and
ballast replaced complete.
Revolving beacon 70 PK22s (H3)
Volumes
Any deviation from this table must be approved in writing by Cargotec.
1.2 Engine, fuel system Volvo TAD760VE Cummins QSB6.7

Fuel tank, volume 380 l
Fuel quality Diesel according to:
EN590,
ASTM D 975 No 1-D,
ASTM D 975 No 2-D.
1.7 Engine, cooling system
Coolant volume 29 l
Coolant, filling point Volvo Penta Coolant VCS, ES Compleat, Premix
ready-mixed.
See Oils and lubricants, recommendation, page F:8.
CAUTION
Risk of engine damage and damage to the cooling system if
different types of coolant are mixed.
When changing and topping up coolant, the same type of
coolant must be used as was used before.
1.8 Engine, lubrication system

Oil type, quality See Oils and lubricants, recommendation, page F:8.
Oil volume, incl. filter 23 l 20 l
2.6 Transmission, lubrication Dana-Spicer Off Highway TE17

system
Oil type See Oils and lubricants, recommendation, page F:8.
Oil volume 37 l

Kessler D81
3.3 Power transmission, drive axle Kessler D91
Oil grade See Oils and lubricants, recommendation, page F:8.
Oil volume, differential 42 l 54 l
Oil volume, hub reduction 2x4 l 2x4 l
7 Load handling

Refrigerant, air conditioning R134a
Refrigerant volume See air conditioning plate
Lubricant, air conditioning ZEXEL PAG oil ZXL100
Washer fluid, volume 5 l
Hydraulic oil tank, volume 320 l
Hydraulic oil system, volume 450 l

Specification for lifting capacity and

dimensions
β α
A2
100 100
H4
H5
B S
H3
R1
R2
H6
H8
H10
100
014020
100
L3 L2 A1
L
DCT80 DCT90
E5 E6 E7 E8 E5 E6 E7 E8
Lifting capacity
Classed [kg x 103] 8 9
Centre of gravity distance (L4 [mm]) 1220 1220
Number of containers, 8'6” container 5 6 7 8 5 6 7 8
Number of containers, 9'6” container 5 5 6 7 5 5 6 7
Dimensions
Truck length (L [mm]) 6900 6900
Truck width (B [mm]) 4050 4100
Height, base machine Spirit Delta (H6 [mm]) 3940 4000
Seat height (H8 [mm]) 2800 2860
Distance drive axle - attachment front section 1185 1185
(L2 [mm])
Wheelbase (L3 [mm]) 4550 4550
Track (front - rear) (S [mm]) 3270 – 2250 3270 – 2200
Slewing radius, outer (R1 [mm]) 6750 7000
Slewing radius, inner (R2 [mm]) 1150 1500

DCT80 DCT90
E5 E6 E7 E8 E5 E6 E7 E8
Ground clearance, min. [mm] 250 300
Minimum aisle width for 90° stacking, 20' 10600 10850
container (A1 [mm])
Minimum aisle width for 90° stacking, 40' 14200 14350
container (A2 [mm])
Standard Duplex mast
Lifting height (H4 [mm]) 15220 16220 18720 21220 15280 16280 18780 21280
Mast height, min. (H3 [mm]) 8540 9040 10290 11540 8600 9100 10350 11600
Mast height, max. (H5 [mm]) 15040 16040 18540 21040 15100 16100 18600 21100
Mast tilting, forward - backward (α - ß [mm]) 3 – 3 3 – 3
Attachment
Height under twistlock (H10 [mm]) 2220 2280
Height under lifting hooks (H10 [mm]) - -
Side shift ± (V1 [mm]) 600 600
Weight
Service weight [kg x 103] 35.5 36.1 37.6 39.1 36.4 37.0 38.5 40.0
Axle pressure front, (without load) [kg x 103] 22.7 23.3 24.8 26.3 22.9 23.5 25.0 26.5
Axle pressure front, (with classified load) [kg x 34.9 35.5 37.0 38.5 36.7 37.3 38.8 40.3
103]
Axle weight rear, (without load) [kg] 12800 13500
Axle weight rear, (with classed load) [kg] 8600 8700

Oils and lubricants, recommendation

The service intervals specified by Cargotec in the maintenance manual
only apply if oils are selected in accordance with the table below. The
table indicates recommended viscosity for different oil types, and
grades, depending on the outdoor temperature.
Any deviation from this table must be approved in writing by Cargotec,

and may mean changed service intervals.
Oil type, quality °C -40 -30 -20 -10 0 +10 +20 +30 +40
ºF -40 -22 -4 +14 +32 +50 +68 +86 +104
1.8 Engine, lubrication system
Volvo TAD760VE SAE 15W-40 (motor oil)
VDS-3 (Note 1) SAE 5W30 (engine oil)
Cummins QSB6.7 SAE 15W-40 (motor oil)

API CH-4 or ACEA E5 SAE 5W-30 (motor oil)
2.6 Transmission, lubrication system

ATF Dexron III DEXRON III (brand name)
3.3 Power transmission, drive axle

API GL-5 SAE 80W-140
SAE 75W-90
4 Brakes (UTTO oil, Note2)

GM Allison C-4 SAE 5W30 (transmission oil)
John Deere J20 C, D
Caterpillar TO-4
7 Load handling
Oil planetary gear hydraulic motor, hypoid SAE 80W140
oil API GL-5
SAE 75W90
DIN 51524 Part 3 HVLP ISO VG 68
ISO VG 46 HV
ISO VG 32
NOTE
Oil filters shall always be changed in connection with oil change.
Change interval for engine oil requires that the sulphur content in
the fuel does not exceed 0.5%.
Note 1: Lubricating oil that fulfils VDS-2 and ACEA E5 may be used.
API CH-4 or CI-4 is approved for markets outside of Europe (instead of
ACEA E5).
Note 2: The oil in the brake system must fulfil one of the quality
requirements.
ACEA = Association des Constructeurs Européenne d'Automobiles

API = American Petroleum Institute
VDS = Volvo Drain Specification
Lubricating grease
Use a universal grease type EP according to NLGI Grade 2 (EP2) for
all lubrication points except hoisting equipment and slide plates.
For hoisting equipment use a universal grease type EP according to

NLGI Grade 2 (EP2) with 3-5% molybdenum sulphide content.
For slide plates use a lubricant approved by Cargotec. Order from

Cargotec Spare Parts Department. 0.65 kg cartridge for grease gun,
part no. 923110.0360 and 5 kg can part no. 923595.0003.
NOTE
Select lubrication class according to the prevailing climate.
Contact grease
Contact grease 923836.0552.
Sealant silicone
Sealant silicone 923107.0308.
Silicone adhesive
Silicone adhesive 923854.0100.
Coolant
Use ready-mixed recommended coolant. Choose the mixture of
coolant that is adapted for the right temperature.
NOTE
It is important that the coolant is mixed correctly all year round to
ensure adequate corrosion protection. The corrosion-protective
properties decline with time which is why the coolant has to be
changed in accordance with specified intervals.
CAUTION

Tightening torques, recommendations

The tightening torques in the following table are recommendations
when tightening bolts and nuts.
When torque-tightening using a machine, for example, bolt runner, the
tightening torque should be reduced by approx. 5%.
For soft surfaces (lower hardness than 200 HB), use washer under
both bolt head and nut. As an alternative, flange bolt or flange nut
can be used.
Tighten to the prescribed torque without stopping.
Recommended tightening torque may vary depending on surface
treatment. Certain combinations of nut and bolt require lubrication in
accordance with the table below.
Condi- Screw Nut Lubrication

tion
1 untreated untreated oil
2 bright galvanised untreated or bright galvanised dry or oil
3 hot-galvanised untreated dry or oil
Quality 8.8 10.9 12.9

Condition 1 2 3 1 1
Fine M-thread
M8×1 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm
M10×1.25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm
M12×1.25 96 Nm 85 Nm 108 Nm 135 Nm 162 Nm
M16×1.5 230 Nm 205 Nm 260 Nm 323 Nm 388 Nm
M18×1.5 330 Nm 294 Nm 373 Nm 466 Nm 559 Nm
M-thread
M4 3.2 Nm 2.9 Nm 3.6 Nm 4.6 Nm 5.5 Nm
M5 6.4 Nm 5.7 Nm 7.2 Nm 9.1 Nm 11 Nm
M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm
M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm
M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm
M12 91 Nm 81 Nm 103 Nm 128 Nm 154 Nm
M16 220 Nm 198 Nm 250 Nm 313 Nm 375 Nm
M20 430 Nm 386 Nm 490 Nm 620 Nm 732 Nm
M24 750 Nm 668 Nm 848 Nm 1050 Nm 1270 Nm
M30 1480 Nm 1317 Nm 1672 Nm 2080 Nm 2500 Nm
UNC-thread
1/4 12.5 Nm 11.1 Nm 14.1 Nm 17.6 Nm 20 Nm
5/16 25 Nm 22.3 Nm 28.3 Nm 35 Nm 42 Nm
3/8 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm
7/16 70 Nm 62 Nm 79 Nm 100 Nm 118 Nm
1/2 107 Nm 95 Nm 121 Nm 151 Nm 178 Nm
9/16 153 Nm 136 Nm 173 Nm 216 Nm 255 Nm
5/8 210 Nm 187 Nm 237 Nm 298 Nm 353 Nm

Quality 8.8 10.9 12.9

3/4 370 Nm 390 Nm 418 Nm 524 Nm 619 Nm
7/8 594 Nm 528 Nm 671 Nm 839 Nm 990 Nm
1 889 Nm 791 Nm 1005 Nm 1260 Nm 1480 Nm
1 1/8 1260 Nm 1120 Nm 1424 Nm 1780 Nm 2100 Nm
1 1/4 1760 Nm 1565 Nm 1990 Nm 2490 Nm 2940 Nm
1 3/8 2320 Nm 2065 Nm 2620 Nm 3280 Nm 3870 Nm
1 1/2 3060 Nm 2720 Nm 3455 Nm 4320 Nm 5100 Nm
Tightening torque, connections for air

conditioning
O-ring couplings cooling hoses
Hose diameter Thread Tightening torque
mm inch inch Nm
6 1/4" 7/16" 7-13 Nm
10 3/8" 5/8" 14-20 Nm
10 3/8" 11/16" 14-20 Nm
12 1/2" 3/4" 14-26 Nm
16 5/8" 7/8" 27-41 Nm
19 3/4" 1 1/16" 34-46 Nm
Pressure switch 3/8" 7-13 Nm
7/16"
The above values should be considered guidelines and may vary

depending on installation.

Tightening torque, ORFS connections

Pipe and hose fitting
Pipe diameter Tightening torque

mm inch Nm
6 1/4 23-25
8 5/16
33-38
10 3/8
12 1/2 51-57
14 -
15 - 80-90
16 5/8
18 3/4
120-130
20 -
22 7/8
150-170
25 1"
28 -
30 - 180-200
32 1"1/4
35 -
200-240
38 1"1/2
Wrench size Tightening torque

mm inch Nm
17 11/16 23-25
22 13/16 33-38
24 15/16 51-57
36 1 3/8 120-130
41 1 5/8 150-170

Material fitting
UNF-UN Metric-ISO BSSP

Thread (inch) Tightening torque Thread Tightening torque Thread (inch) Tightening torque (Nm)
(Nm) (mm) (Nm)
7/16-20 21 10x1 20 1/8-28 20
1/2-20 27 12x1.5 35 1/4-19 35
9/16-18 40 14x1.5 45 3/8-19 70
3/4-16 78 16x1.5 55 1/2-14 100
7/8-14 110 18x1.5 68 3/4-14 190
1"1/16-12 180 20x1.5 80 1"-11 300
1"3/16-12 230 22x1.5 98 1"1/4-11 330
1"5/16-12 285 26x1.5 170 1"1/2-11 400
1"5/8-12 320 27x2 180
1"7/8-12 400 33x2 310
42x2 330
48x2 400
Unit explanations
Unit Abbreviation
Newton metre Nm
Kgf/m kpm
Kilo pascal kPa
Mega pascal MPa
Kilowatt kW
Kilojoule kJ
British thermal unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometre km

Conversion SI-units
Recalculation Recalculation
SI-unit factor Non-SI factor SI
Torque
Nm x 10.2 = kg·cm x 0.8664 = lb·in
Nm x 0.74 = lbf·ft x 1.36 = Nm
Nm x 0.102 = kg·m x 7.22 = lb·ft
Pressure (Pa = N/ m2)
kPa x 4.0 = in.H2O x 0.249 = kPa
kPa x 0.30 = in.Hg x 3.38 = kPa
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp/cm 2 x 14.22 = psi x 0.070 = kp/cm2
N/mm 2 x 145.04 = psi x 0.069 = bar
MPa x 145 = psi x 0.00689 = MPa
Power (W = J/s)
kW x 1.36 = hp (cv) x 0.736 = kW
kW x 1.34 = bhp x 0.746 = kW
kW x 0.948 = Btu/s x 1.055 = kW
W x 0.74 = ft·lb/s x 1.36 = W
Energy (J = Nm)
kJ x 0.948 = Btu x 1.055 = kJ
J x 0.239 = calorie x 4.19 = J
Speed and acceleration
m/s2 x 3.28 = ft/s2 x 0.305 = m/s2
m/s x 3.28 = ft/s x 0.305 = m/s
km/h x 0.62 = mph x 1.61 = km/h
Horsepower/torque
Bhp x 5252 rpm= TQ (lb·ft) TQ x rpm 5252 = bhp
Temperature
°C = (°F – 32)/1.8 °F = (°C x 1.8) + 32
Flow factor
l/min (dm3 /min) x 0.264 = US gal/min x 3.785 = litre/min

Conversion table length

Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm – 1 mm = 0.001 m
Conversion table area

Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000

yd2 - 0.83613 - 0.008361 9 1 1296.00
in2 6.4516 0.000645 - - 0.006943 0.000771 1
1 ha = 100 a – 1 mile2 = 259 ha = 2.59 km2
Conversion table volume

Unit cm3 = cc m3 l in3 ft3 yd3
cm3 = ml 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
dm3 (l) 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
yd3 764529.8 0.76453 764.53 46656 27 1
1 gal (US) = 3785.41 cm3 = 231 in3 = 0.83267 gal (UK)
Conversion table weight

Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 tonne (metric) = 1.1023 ton (US) = 0.9842 ton (UK)

Conversion table pressure

Unit kp/cm2 bar Pa = N/m2 kPa lbf/in2 lbf/ft2
kp/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa = N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm2 = 735.56 Torr (mmHg) = 0.96784 atm

G:1
Contents G Terminology and index

Terminology and index .....................................................................................G:3
Terminology.....................................................................................................G:3

G:2

G Terminology and index – Terminology and index G:3

Terminology
Explanations
Term Description
Accumulator Reservoir that stores (accumulates) pressure for, i.e. hydraulic functions.
Attachment Part of the machine that grips the load when lifting.
Anti-corrosion agent Prevents oxidation, in simple terms, rustproofing.
Working hydraulics All load handling functions, that is, lift and lower, tilt, side shift, spreading (extension)
and levelling.
Wheelbase Distance between drive axle and steering axle.
Bar Unit to express pressure.
Battery disconnector Cuts off power supply from battery.
Daily inspection Actions that should be performed daily to ensure the machine's functionality.
Decitonne Tenth of a tonne, measure of machine's lift capacity.
Display "Window" showing digital information, i.e. on steering panel in the cab.
Operating time Number of hours machine has been in operation, shown on hour meter in cab.
Drive axle Driving axle that receives the torque from the drive-train.
Drive-train Parts in machine involved in power transmission; engine, torque converter, transmission,
propeller shaft, and drive axle with differential and hub reduction.
ECC Electric Climate Control. Air conditioning system with thermostat-controlled cooling,
dehumidification and heating.
EHC Electric Heat Control. Heating system with thermostat-controlled heating.
Electrolyte level Fluid level in battery cells.
Expansion tank Tank for coolant.
Fixed displacement Non-adjustable volume (capacity) in a pump.
Hanging load Lifted load.
FMI Fault Message Identifier.
Main fuse Located by battery. Breaks the current to all systems in the whole machine.
Hydraulic oil Oil for hydraulic system. See specifications in operator's manual.
Hydraulic oil pump Pump in hydraulic system.
Hydraulic system System that uses oil pressure to transfer power to different functions.
Indicator Manual "sensor", for example, shows that a filter is clogged and needs to be changed.
Refrigerant Fluid/gas in air conditioning. Must only be handled by authorised trained personnel.
Low-emission engine Engine with low emissions of hazardous substances. Manufactured in accordance
with regulations.
LC Load centre.
Lift capacity Indicates machine's maximum lift capacity.
Lifting point Attaching point for lift device when lifting an object.
Trolley Lifts the load, located on the mast.
Solenoid valve An electro-magnetically controlled valve. See also proportional valve.
Control valve Valves that can be used to control something, for example, to release pressure and thus
lower a boom or a fork.
Machine model Machine type. Specified, for example: DCT 80-90. See also type designation.

G:4 G Terminology and index – Terminology
Term Description
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Torque converter Hydraulic, variable clutch.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque
from the drive-train.
Pilot oil pressure A low control pressure to, for example, a valve.
Planetary gear Type of transmission with the gears in constant mesh.
Product alternative One of several alternatives is selected for a machine, e.g. engine alternative.
Proportional valve An electro-magnetically controlled valve. If a voltage is applied, the valve is activated
in proportion to the voltage amplitude. In simple terms, infinitely variable valve, as
opposed to on/off valve. For example, found on transmission's valve housing.
Frame member Structural members in the frame.
Recirculation Circulate over and over again.
Serial number Unique machine designation. On the machine plate.
Service position How machine should be safely positioned before service may be started.
Servo A small movement by the user results in a large angle, i.e. servo steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side lift Attachment. See attachment.
Side shift Parallel sideways movement of attachment.
Levelling Attachment is tilted, for example if load stands on uneven ground.
Spirit Delta Enclosed type of cab.
SPN Suspect Parameter Number.
Spreading (positioning) Widening of attachment.
Mast Carrier of trolley, attachment and load.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, which is emptied
automatically during operation.
Steering axle Wheel axle with steering.
Buzzer Acoustic alarm to catch the operator's attention.
Option Extra equipment for machine.
Tilting Load is leaned forward or backward.
Transmission oil Oil for transmission and torque converter. See specifications in operator's manual.
Securing machine for transport Actions before transporting machine.
Twistlocks Two lock pins, one in each corner of the attachment, pushed down in corresponding
holes in container and twisted to lock the container when lifting.
Type designation Indicates machine type and capacity. See also machine model.
Maintenance Periodic maintenance actions so that machine functions safely and for a long service life.
Wet brakes Brake discs in oil bath.
Valve slide Moveable part in valve. Determines oil's path.

G Terminology and index – Index G:5
Index Cab structure and suspension . . . . . . . . . . . . 9:75

Cab substructure . . . . . . . . . . . . . . . . . . 9:76
CAB, menu 1. . . . . . . . . . . . . . . . . . . . 8:36
CAB, menu 2. . . . . . . . . . . . . . . . . . . . 8:37
A CAB, menu 3. . . . . . . . . . . . . . . . . . . . 8:38
CAB, menu 4. . . . . . . . . . . . . . . . . . . . 8:39
About the documentation . . . . . . . . . . . . . A:12 CAB, menu 5. . . . . . . . . . . . . . . . . . . . 8:40
About the Workshop Manual . . . . . . . . . . . . . A:3 CAB, menu 6. . . . . . . . . . . . . . . . . . . . 8:41
Accelerator pedal . . . . . . . . . . . . . . . . . . 1:22 CAB, menu 7. . . . . . . . . . . . . . . . . . . . 8:42
Accumulator . . . . . . . . . . . . . . . . . 4:10, 10:5 CAB, menu 8. . . . . . . . . . . . . . . . . . . . 8:43
Accumulator charging valve . . . . . . . . . . . . . 4:7 Cable harness . . . . . . . . . . . . . . . . . . 11:27
Accumulator drain valve . . . . . . . . . . . . . . . 10:3 Calibrate DRIVE-TRAIN . . . . . . . . . . . . . . 8:117
Accumulator lift . . . . . . . . . . . . . . . . . . . 7:29 Calibration . . . . . . . . . . . . . . . . . . . . 8:114
Air cleaning system . . . . . . . . . . . . . . . . . 1:26 CAN bus . . . . . . . . . . . . . . . . . . . . 11:36
Air distributor . . . . . . . . . . . . . . . . . . . . 9:46 CAN bus drive-train . . . . . . . . . . . . . . . . 11:40
Air intake and exhaust outlet . . . . . . . . . . . . . 1:26 CAN/POWER . . . . . . . . . . . . . . . . . . . 8:12
Air suspension . . . . . . . . . . . . . . . . . . . 9:15 CAN/POWER, menu 1 . . . . . . . . . . . . . . . 8:12
Alternator . . . . . . . . . . . . . . . . . . . . . 11:6 CAN/POWER, menu 10 . . . . . . . . . . . . . . . 8:20
Arm rest . . . . . . . . . . . . . . . . . . . . . . 9:16 CAN/POWER, menu 11 . . . . . . . . . . . . . . . 8:21
ATTACH . . . . . . . . . . . . . . . . . . . . . . 8:77 CAN/POWER, menu 12 . . . . . . . . . . . . . . . 8:21
ATTACH, menu 1 . . . . . . . . . . . . . . . . . . 8:77 CAN/POWER, menu 13 . . . . . . . . . . . . . . . 8:22
ATTACH, menu 10 . . . . . . . . . . . . . . . . . 8:82 CAN/POWER, menu 14 . . . . . . . . . . . . . . . 8:22
ATTACH, menu 2 . . . . . . . . . . . . . . . . . . 8:77 CAN/POWER, menu 8 . . . . . . . . . . . . . . . 8:18
ATTACH, menu 21 . . . . . . . . . . . . . . . . . 8:89 Central lubrication . . . . . . . . . . . . . . . . . 9:83
ATTACH, menu 3 . . . . . . . . . . . . . . . . . . 8:78 CLIMATE . . . . . . . . . . . . . . . . . . . . . 8:44
ATTACH, menu 4 . . . . . . . . . . . . . . . . . . 8:78 CLIMATE, menu 1 . . . . . . . . . . . . . . . . . 8:44
ATTACHMENT . . . . . . . . . . . . . . . . . . 8:105 CLIMATE, menu 7 . . . . . . . . . . . . . . . . . 8:48
CLIMATE, menu 8 . . . . . . . . . . . . . . . . . 8:49
Common electrics . . . . . . . . . . . . . . . 11:3, E:6
B Common hydraulics . . . . . . . . . . . . . . 10:3, E:3
Back rest cushion . . . . . . . . . . . . . . . . . . 9:13 Communication. . . . . . . . . . . . . . . . . . 11:36
Back-up lights . . . . . . . . . . . . . . . . . . . 9:59 Communication between PC and machine . . . . . . 11:41
Batteries. . . . . . . . . . . . . . . . . . . . . . 11:4 Complete machine . . . . . . . . . . . . . . . . . 0:3
Battery disconnector . . . . . . . . . . . . . . . . 11:3 Compressor . . . . . . . . . . . . . . . . . . . . 9:36
Body structure . . . . . . . . . . . . . . . . . . . 9:81 Compressor air-suspension seat . . . . . . . . . . . 9:15
Brake cylinder . . . . . . . . . . . . . . . . . . . 4:24 Condenser . . . . . . . . . . . . . . . . . . . . . 9:39
Brake light . . . . . . . . . . . . . . . . . . . . . 9:59 Container counter. . . . . . . . . . . . . . . . . . 7:72
Brake oil filter . . . . . . . . . . . . . . . . . . . 4:6 Control breaker . . . . . . . . . . . . . . . . 9:10, 11:3
Brake pedal . . . . . . . . . . . . . . . . . . . . 4:3 Control levers . . . . . . . . . . . . . . . . . . . 7:4
Brake valve . . . . . . . . . . . . . . . . . . . . 4:14 Control system . . . . . . . . . . . . . . . . 8:3, D:70
Brakes . . . . . . . . . . . . . . . . . . . . . . 4:3 Control system, engine . . . . . . . . . . . . . . . 1:37
Break contact (opening switch) brake pressure . . . . . 4:18 Control system, transmission . . . . . . . . . . . . . 2:18
Break contact (opening switch) parking brake . . . . . 4:34 Control unit KID . . . . . . . . . . . . . . . . . 11:26
Breather filter hydraulic oil tank . . . . . . . . . . . 10:25 Control unit KIT. . . . . . . . . . . . . . . . . . 11:25
Bumper . . . . . . . . . . . . . . . . . . . . . . 9:15 Control unit, attachment . . . . . . . . . . . . . . 11:20
Buzzer, automatic spreading 20'-40' . . . . . . . . . . 7:53 Control unit, cab . . . . . . . . . . . . . . . . . 11:17
Bypass . . . . . . . . . . . . . . . . . . . . . . 8:7 Control unit, engine (D794) . . . . . . . . . . . . 11:23
Bypass valve, cooler . . . . . . . . . . . . . . . 10:24 Control unit, transmission (D793) . . . . . . . . . . 11:22
Control units . . . . . . . . . . . . . . . . . . . 11:16
Control valve, attachment . . . . . . . . . 7:32, 7:45, 7:64
Control valve, lift and tilt . . . . . . . . . . . . 7:13, 7:57
C Controls and instruments . . . 1:22, 2:10, 4:3, 7:4, 8:4, 9:3
CAB . . . . . . . . . . . . . . . . . . . . . . . 8:36 Coolant . . . . . . . . . . . . . . . . . . . . . . 1:32
Cab fan . . . . . . . . . . . . . . . . . . . . . . 9:29 Cooler hydraulic oil . . . . . . . . . . . . . . . . 10:21
Cab frame . . . . . . . . . . . . . . . . . . . . . 9:75 Cooling fan . . . . . . . . . . . . . . . . 1:31, 10:22
Cab interior . . . . . . . . . . . . . . . . . . . . 9:77 Cooling system . . . . . . . . . . . . . . . . 1:29, 2:17

Counterweights. . . . . . . . . . . . . . . . . . . 9:82 Foreword . . . . . . . . . . . . . . . . . . . . . A:3

Frame . . . . . . . . . . . . . . . . . . . . . . . 9:80
Frame control unit . . . . . . . . . . . . . . . . 11:18
D Frame, body, cab and accessories . . . . . . . . . . 9:3
FREELIFT . . . . . . . . . . . . . . . . . . . . . 8:91
Defroster nozzles . . . . . . . . . . . . . . . . . . 9:47
Fresh air filter . . . . . . . . . . . . . . . . . . . 9:25
Diagnostics . . . . . . . . . . . . . . . . . . . . 8:9
Fresh air filter or recirculation damper . . . . . . . . . 9:26
Direction indicators . . . . . . . . . . . . . . . . . 9:60
Fuel system . . . . . . . . . . . . . . . . . . . . 1:24
Disc pack . . . . . . . . . . . . . . . . . . . . . 4:23
Fuel tank . . . . . . . . . . . . . . . . . . . . . 1:24
Distribution block . . . . . . . . . . . . . . . . . . 9:85
Fuses . . . . . . . . . . . . . . . . . . . . . . . 11:3
Distribution of electricity . . . . . . . . . . . . . . . 11:7
Doors . . . . . . . . . . . . . . . . . . . . . . . 9:75
Drive axle . . . . . . . . . . . . . . . . . . . . . 3:4
Drive axle block . . . . . . . . . . . . . . . . . . 4:17 G
DRIVE-TRAIN . . . . . . . . . . . . . . . . . . 8:110 Gear pump with fixed displacement . . . . . . . . . . 10:7
Driveline/Axle . . . . . . . . . . . . . . . . . . . 3:3 Gear selector and multi-function lever . . . . . . . 2:10, 9:8
General safety information . . . . . . . . . . . . . . B:3
Glass/windows/mirrors . . . . . . . . . . . . . . . 9:68
E
EL-STEERING . . . . . . . . . . . . . . . . . . . 8:90
Electric protection. . . . . . . . . . . . . . . . . . 11:3 H
ELECTRIC SERVO . . . . . . . . . . . . . . . . . 8:99 Headlights . . . . . . . . . . . . . . . . . . . . . 9:59
Electronic box . . . . . . . . . . . . . . . . . . 11:14 Heat exchanger heat . . . . . . . . . . . . . . . . 9:32
Electronic box frame . . . . . . . . . . . . . . . 11:15 Heat exchanger, cooling . . . . . . . . . . . . . . . 9:45
Electronic box, cab . . . . . . . . . . . . . . . . 11:14 Heating coil . . . . . . . . . . . . . . . . . . . . 9:14
ELSERV. . . . . . . . . . . . . . . . . . . . . . 8:70 Heating, ventilation and air conditioning . . . . . . . . 9:18
ELSERV, menu 1 . . . . . . . . . . . . . . . . . . 8:70 Hood engine compartment . . . . . . . . . . . . . . 9:81
ELSERV, menu 10 . . . . . . . . . . . . . . . . . 8:75 Horn . . . . . . . . . . . . . . . . . . . . . . . 9:65
ELSERV, menu 11 . . . . . . . . . . . . . . . . . 8:75 Hoses, pipes and valves . . . . . . . . . . . . . . 10:14
ELSERV, menu 12 . . . . . . . . . . . . . . . . . 8:75 HYD . . . . . . . . . . . . . . . . . . . . . . . 8:50
ELSERV, menu 13 . . . . . . . . . . . . . . . . . 8:76 HYD, menu 1 . . . . . . . . . . . . . . . . . . . 8:50
ELSERV, menu 2 . . . . . . . . . . . . . . . . . . 8:70 HYD, menu 4 . . . . . . . . . . . . . . . . . . . 8:51
ELSERV, menu 7 . . . . . . . . . . . . . . . . . . 8:74 Hydraulic cylinders . . . . . . . . . . . . . . . . 10:31
ELSERV, menu 8 . . . . . . . . . . . . . . . . . . 8:75 Hydraulic oil . . . . . . . . . . . . . . . . . . . 10:27
ELSERV, menu 9 . . . . . . . . . . . . . . . . . . 8:75 Hydraulic oil filter . . 4:28, 7:29, 7:37, 7:54, 7:59, 7:71, 10:25
Emergency stop switch voltage (15E) . . . . . . . . 11:11 Hydraulic oil pump . . . . . . . . . . . . 4:6, 4:28,
Engine . . . . . . . . . . . . . . . . . . . . 1:3, D:9 5:3, 7:10, 7:31, 7:44, 7:56, 7:63
ENGINE . . . . . . . . . . . . . . . . . . . . . . 8:54 Hydraulic oil tank . . . . . . . . . . . . . . . . . . 10:5
Engine control unit . . . . . . . . . . . . . . . . . 1:37
ENGINE, menu 1 . . . . . . . . . . . . . . . . . . 8:54
ENGINE, menu 2 . . . . . . . . . . . . . . . . . . 8:54 I
ENGINE, menu 3 . . . . . . . . . . . . . . . . . . 8:55
ENGINE, menu 4 . . . . . . . . . . . . . . . . . . 8:55 I/O . . . . . . . . . . . . . . . . . . . . . . . . 8:94
ENGINE, menu 5 . . . . . . . . . . . . . . . . . . 8:56 Ignition . . . . . . . . . . . . . . . . . . . . . . 1:22
ENGINE, menu 6 . . . . . . . . . . . . . . . . . . 8:57 Ignition voltage (15) . . . . . . . . . . . . . . . . . 11:9
ENGINE, menu 7 . . . . . . . . . . . . . . . . . . 8:58 Initialization . . . . . . . . . . . . . . . . . . . . 8:96
ENGINE, menu 8 . . . . . . . . . . . . . . . . . . 8:58 Instrument and control panels . . . . . . . . . . . . 9:77
ENGINE, menu 9 . . . . . . . . . . . . . . . . . . 8:59 Insulation . . . . . . . . . . . . . . . . . . . . . 9:78
Entertainment and communication . . . . . . . . . . 9:67 Intercooler . . . . . . . . . . . . . . . . . . . . . 1:28
Environment . . . . . . . . . . . . . . . . . . . B:22 Interior fittings, plastic . . . . . . . . . . . . . . . . 9:78
Error code menu . . . . . . . . . . . . . . . . . . 8:4 Interior fittings, textile . . . . . . . . . . . . . . . . 9:78
Error codes . . . . . . . . . . . . . . . . . . . . D:3 Interior lighting . . . . . . . . . . . . . . . . . . . 9:61
Exhaust system . . . . . . . . . . . . . . . . . . 1:27
Expansion valve . . . . . . . . . . . . . . . . . . 9:42
EXT-ATTACH . . . . . . . . . . . . . . . . . . . 8:91 L
EXTRA . . . . . . . . . . . . . . . . . . . . . . 8:90
Levelling. . . . . . . . . . . . . . . . . . . . . . 7:60
Lift cylinder . . . . . . . . . . . . . . . . . . . . 7:14
Lift, tilt and attachment control valve. . . . . 7:37, 7:53, 7:71
F Lifting/lowering . . . . . . . . . . . . . . . . . . . 7:8
Feedback . . . . . . . . . . . . . . . . . . . . A:13 Lighting system. . . . . . . . . . . . . . . . . . . 9:55
Fine filter hydraulic oil . . . . . . . . . . . . . . . 10:29 LIGHTS . . . . . . . . . . . . . . . . . . . . . . 8:25
Fire extinguisher . . . . . . . . . . . . . . . . . . 9:10 LIGHTS, menu 1 . . . . . . . . . . . . . . . . . . 8:25
Flashing hazard lights . . . . . . . . . . . . . 9:60, 9:65 LIGHTS, menu 10 . . . . . . . . . . . . . . . . . 8:32
Flex plates . . . . . . . . . . . . . . . . . . . . . 2:11 LIGHTS, menu 11. . . . . . . . . . . . . . . . . . 8:32
Floor covering . . . . . . . . . . . . . . . . . . . 9:78 LIGHTS, menu 12 . . . . . . . . . . . . . . . . . 8:33
Footsteps and hand rail . . . . . . . . . . . . . . . 9:81 LIGHTS, menu 13 . . . . . . . . . . . . . . . . . 8:34

G Terminology and index – Index G:7
LIGHTS, menu 14 . . . . . . . . . . . . . . . . . 8:35 Reading instructions . . . . . . . . . . . . . . . . A:4

LIGHTS, menu 15 . . . . . . . . . . . . . . . . . 8:35 Reading-lamp . . . . . . . . . . . . . . . . . . . 9:79
LIGHTS, menu 2 . . . . . . . . . . . . . . . . . . 8:25 Rear view mirror . . . . . . . . . . . . . . . . . . 9:74
LIGHTS, menu 3 . . . . . . . . . . . . . . . . . . 8:26 Rear window . . . . . . . . . . . . . . . . . . . . 9:74
LIGHTS, menu 4 . . . . . . . . . . . . . . . . . . 8:27 Redundant CAN bus . . . . . . . . . . . . . . . 11:38
LIGHTS, menu 5 . . . . . . . . . . . . . . . . . . 8:28 Redundant voltage feed of control units . . . . . . . . 11:7
LIGHTS, menu 6 . . . . . . . . . . . . . . . . . . 8:28 Relief valve, attachment . . . . . . . 7:37, 7:53, 7:71, 10:3
LIGHTS, menu 7 . . . . . . . . . . . . . . . . . . 8:29 Reverse alarm . . . . . . . . . . . . . . . . . . . 9:66
LIGHTS, menu 8 . . . . . . . . . . . . . . . . . . 8:30 Revolving beacon. . . . . . . . . . . . . . . 9:60, 9:66
LIGHTS, menu 9 . . . . . . . . . . . . . . . . . . 8:31 Rim . . . . . . . . . . . . . . . . . . . . . . . . 6:16
Lines . . . . . . . . . . . . . . . . . . . . . . . 9:86 RMI . . . . . . . . . . . . . . . . . . . . . . . . 8:95
Link arm . . . . . . . . . . . . . . . . . . . . . . 5:11 Roof window . . . . . . . . . . . . . . . . . . . . 9:73
Load carrier . . . . . . . . . . . . . . . . . . . . 7:61 Running lights . . . . . . . . . . . . . . . . . . . 9:59
Load handling . . . . . . . . . . . . . . . . . . . 7:3
Load holding valve . . . . . . . . . . . . . . . . . 7:58
Lock cylinder . . . . . . . . . . . . . . . . . . . . 7:65 S
Lock mechanism . . . . . . . . . . . . . . . . . . 7:66
Lubrication system . . . . . . . . . . . . . . . . . 2:13 Safety . . . . . . . . . . . . . . . . . . . . . . . B:3
Safety and emergency equipment. . . . . . . . . . . 9:10
Safety instructions . . . . . . . . . . . . . . . . . B:4
M Safety valves. . . . . . . . . .
Schematics . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . 10:3
. . E:3
Main beam, side lift attachment . . . . . . . . . . . . 7:48 Seat . . . . . . . . . . . . . . . . . . . . . . . 9:11
Main valve . . . . . . . . . . . . . . . . . . . . 10:15 Seat belt. . . . . . . . . . . . . . . . . . . . . . 9:10
Make-contact (closing switch) brake lights . . . . . . . 4:20 Seat buzzer . . . . . . . . . . . . . . . . . . . . 9:10
Mast . . . . . . . . . . . . . . . . . . . . 7:15, 7:58 Seat cushion . . . . . . . . . . . . . . . . . . . . 9:13
Mast position sensor . . . . . . . . . . . . . . . . 7:24 Sensor cab temperature . . . . . . . . . . . . . . . 9:49
Mechanical seat adjustment . . . . . . . . . . . . . 9:16 Sensor fuel level . . . . . . . . . . . . . . . . . . 1:25
Moisture filter . . . . . . . . . . . . . . . . . . . 9:41 Sensor hydraulic oil temperature . . . . . . . . . . 10:22
Monitoring . . . . . . . . . . . . . . . . . . . . . 8:7 Sensor twistlocks . . . . . . . . . . . . . . . . . . 7:69
MOVE-CAB . . . . . . . . . . . . . . . . . . . . 8:91 Sensor, ambient temperature . . . . . . . . . . . . . 9:50
Sensor, contact . . . . . . . . . . . . . . . . . . . 7:68
Sensor, engine temperature . . . . . . . . . . . . . 9:35
N Sensor, operator-in-seat . . . . . . . . . . . . . . . 9:17
NO (normally open) switch, disengagement . . . . . . 2:18 Sensor, temperature outlet fan . . . . . . . . . . . . 9:48
Nut, washer and clamp . . . . . . . . . . . . . . . 6:17 Sensor, temperature refrigerant . . . . . . . . . . . . 9:43
Service indicator . . . . . . . . . . . . . . . . . . 8:8
Setup . . . . . . . . . . . . . . . . . . . . . . . 8:96
O Side shift . . . . . . . . . . .
Side shift cylinder . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . 7:30
. . 7:35
Oil cooler . . . . . . . . . . . . . . . . . . 2:16–2:17 Side window . . . . . . . . . . . . . . . . . . . . 9:71
OLS . . . . . . . . . . . . . . . . . . . . . . . 8:90 Signalling system . . . . . . . . . . . . . . . . . . 9:63
OPT . . . . . . . . . . . . . . . . . . . . . . . 8:91 SLIDING-CAB . . . . . . . . . . . . . . . . . . 8:114
Other . . . . . . . . . . . . . . . . . . . . . . 10:31 Solenoid valve parking brake . . . . . . . . . . . . . 4:29
Other functions . . . . . . . . . . . . . . . . . . . 7:72 Speed limitation . . . . . . . . . . . . . . . . . . 8:7
Spreader beam . . . . . . . . . . . . . . . . . . . 7:46
Spreading (positioning) . . . . . . . . . . . . . . . 7:38
P Spreading cylinder . . . . . . . . . . . . . . . . . 7:45
Paint/coatings . . . . . . . . . . . . . . . . . . . 9:87 Start/stop . . . . . . . . . . . . . . . . . . . . . 1:38
Parking brake caliper . . . . . . . . . . . . . . . . 4:32 Starter battery . . . . . . . . . . . . . . . . . . . 11:4
Parking brake disc . . . . . . . . . . . . . . . . . 4:33 Starter motor . . . . . . . . . . . . . . . . . . . . 1:38
Parking brake pads . . . . . . . . . . . . . . . . . 4:32 Steering . . . . . . . . . . . . . . . . . . . . . . 5:3
Parking brake system . . . . . . . . . . . . . . . . 4:27 STEERING . . . . . . . . . . . . . . . . . . . 8:109
Parking brake unit . . . . . . . . . . . . . . . . . 4:30 Steering axle cradle . . . . . . . . . . . . . . . 5:11, 6:4
Passenger seat. . . . . . . . . . . . . . . . . . . 9:16 Steering cylinder . . . . . . . . . . . . . . . . . . 5:9
Pipes and hoses . . 4:24, 4:34, 5:11, 7:29, 7:37, 7:53, Steering valve . . . . . . . . . . . . . . . . . . . 5:7
7:59, 7:71, 10:4, 10:6, 10:13–10:14, 10:29 Stopping device . . . . . . . . . . . . . . . . . . 1:38
Position sensor, spreading . . . . . . . . . . . . . . 7:53 Suspension . . . . . . . . . . . . . . . . . . . . 6:3
Power assisted system . . . . . . . . . . . . . . . 5:3 Switch, automatic spreading . . . . . . . . . . . . . 7:7
Power-assisted brake system . . . . . . . . . . . . 4:5 Switch, direction indicators . . . . . . . . . . . . . . 9:9
Pressure reducer . . . . . . . . . . . . . . . . . . 7:10 Switch, lock twistlock . . . . . . . . . . . . . . . . 7:5
Pressure relief valve . . . . . . . . . . . . . . . . 10:4 Switch, spreading 20\q-40\q . . . . . . . . . . . . . 7:6
Pressure switch . . . . . . . . . . . . . . . . . . 9:41 Switch, stop at 30\q . . . . . . . . . . . . . . . . . 7:6
Preventive maintenance . . . . . . . . . . . . . . . C:1
Priority valve . . . . . . . . . . . . . . . . . . . . 5:4
Propeller shaft . . . . . . . . . . . . . . . . . . . 3:3 T
Pump unit . . . . . . . . . . . . . . . . . . . . . 9:85
Tail lights . . . . . . . . . . . . . . . . . . . . . 9:59
Pumps . . . . . . . . . . . . . . . . . . . . . . 10:7
Tanks and accumulators . . . . . . . . . . . . . . . 10:5
Technical data . . . . . . . . . . . . . . . . . . . F:3
Temperature control, cleaning and hydraulic oil . . . . 10:19
R Terminal console . . . . . . . . . . . . . . . . . . 9:79
Radiator and expansion tank . . . . . . . . . . . . . 1:30 Terminology . . . . . . . . . . . . . . . . . . . . G:3

Terminology and index . . . . . . . . . . . . . . . G:3 VBFS . . . . . . . . . . . . . . . . . . . . . . . 8:90

Tilt . . . . . . . . . . . . . . . . . . . . . . . . 7:55 Voltage converter . . . . . . . . . . . . . . . . . 11:12
Tilt cylinder . . . . . . . . . . . . . . . . . . . . 7:58 Voltage feed . . . . . . . . . . . . . . . . . . . . 11:7
Torque converter/Clutch system . . . . . . . . . . . 2:11
TRANSM . . . . . . . . . . . . . . . . . . . . . 8:59
TRANSM, menu 1 . . . . . . . . . . . . . . . . . 8:59 W
TRANSM, menu 10 . . . . . . . . . . . . . . . . . 8:67
TRANSM, menu 11 . . . . . . . . . . . . . . . . . 8:68 Warning parking brake . . . . . . . . . . . . . . . 9:66
TRANSM, menu 12 . . . . . . . . . . . . . . . . . 8:68 Washer motor and reservoir . . . . . . . . . . . . . 9:51
TRANSM, menu 13 . . . . . . . . . . . . . . . . . 8:68 Water valve . . . . . . . . . . . . . . . . . . . . 9:35
TRANSM, menu 14 . . . . . . . . . . . . . . . . . 8:69 Wheel brakes . . . . . . . . . . . . . . . . . . . 4:22
TRANSM, menu 2 . . . . . . . . . . . . . . . . . 8:60 Wheel hub . . . . . . . . . . . . . . . . . . . 5:11, 6:8
TRANSM, menu 3 . . . . . . . . . . . . . . . . . 8:61 Wheel spindle . . . . . . . . . . . . . . . . . 5:11, 6:6
TRANSM, menu 4 . . . . . . . . . . . . . . . . . 8:62 Windscreen . . . . . . . . . . . . . . . . . . . . 9:69
TRANSM, menu 5 . . . . . . . . . . . . . . . . . 8:63 Wings . . . . . . . . . . . . . . . . . . . . . . . 9:81
TRANSM, menu 6 . . . . . . . . . . . . . . . . . 8:64 Wiper front . . . . . . . . . . . . . . . . . . . . . 9:51
TRANSM, menu 7 . . . . . . . . . . . . . . . . . 8:65 Wiper motor front . . . . . . . . . . . . . . . . . . 9:52
TRANSM, menu 8 . . . . . . . . . . . . . . . . . 8:66 Wiper motor rear . . . . . . . . . . . . . . . . . . 9:54
TRANSM, menu 9 . . . . . . . . . . . . . . . . . 8:66 Wiper motor roof . . . . . . . . . . . . . . . . . . 9:53
Transmission. . . . . . . . . . . . . . . . . 2:3, D:43 Wiper rear . . . . . . . . . . . . . . . . . . . . . 9:51
Transmission cable harness . . . . . . . . . . . . . 2:18 Wiper roof . . . . . . . . . . . . . . . . . . . . . 9:51
Transmission control unit . . . . . . . . . . . . . . 2:18 Wiper/washer system . . . . . . . . . . . . . . . . 9:51
Trolley. . . . . . . . . . . . . . . . . . . . 7:25, 7:35 Work lights, front wing . . . . . . . . . . . . . . . . 9:62
Twistlock overcentre valve . . . . . . . . . . . . . . 7:65 Working lights, attachment . . . . . . . . . . . . . . 9:62
Twistlocks . . . . . . . . . . . . . . . . . . 7:61, 7:66 Working lights, cab . . . . . . . . . . . . . . . . . 9:61
Tyres . . . . . . . . . . . . . . . . . . . . . . . 6:15 Working lights, mast. . . . . . . . . . . . . . . . . 9:60
Tyres and rims . . . . . . . . . . . . . . . . . . . 6:13 Writing desk . . . . . . . . . . . . . . . . . . . . 9:79
V
Valve block brake system . . . . . . . . . . . 4:25, 4:34


last page
Cargotec Sweden AB
Cargotec improves the efficiency of cargo flows by offering solutions for Torggatan 3
the loading and unloading of goods on land and at sea – wherever cargo SE-340 10, Lidhult, Sweden
is on the move. Cargotec’s main daughter brands for cargo handling
Hiab, Kalmar and MacGregor are global market leaders in their fields. tel. +46 372 260 00
Cargotec’s global network offers extensive services that ensure the fax +46 372 263 90
continuous, reliable and sustainable performance of equipment. www.cargotec.com

Workshop DCT80

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Workshop DCT80

Uploaded by

Copyright:

Available Formats

Empty Container Handler 8-9

9 Frame, body, cab and accessories

G Terminology and index

Workshop Manual DCT 80-90 VDCT01.03GB

VDCT01.03GB Workshop Manual DCT 80-90

Cargotec will not accept any responsibility in the event of a modification

About machine version

Cargotec reserves the right to make changes to specifications and

All duplication by any means, such as copying, printing, etc., is

Workshop Manual DCT 80-90 VDCT01.03GB

Read operator's manual

Read the operator's manual

Read the Maintenance manual

refers to important information in the Maintenance manual.

Read the Maintenance manual

VDCT01.03GB Workshop Manual DCT 80-90

The workshop manual's contents

The workshop manual is divided into the following sections.

Workshop Manual DCT 80-90 VDCT01.03GB

Function group structure

The function groups are intended to be used as search terms in

The maintenance manual and the workshop manual contain different

References are indicated by either section and group numbers, e.g.

References between sections in the same manual are indicated with

References between Maintenance manual and Workshop manual are

VDCT01.03GB Workshop Manual DCT 80-90

References between different information types

The basic rule of searching for information is to use the function

Function descriptions Hydraulic diagrams

Diagnostics Wiring diagrams

• From Function description to Component description, to enable

Workshop Manual DCT 80-90 VDCT01.03GB

Product alternatives and optional equipment

Special equipment is not described in the manual. If uncertain as

Equivalent information for different product alternatives is described

Optional equipment refers to options that can be added to standard

Information on auxiliary equipment is described in separate segments

VDCT01.03GB Workshop Manual DCT 80-90

The machine card indicates which drawings the machine is

If the information on the machine card is inadequate, contact Cargotec.

Workshop Manual DCT 80-90 VDCT01.03GB

The function descriptions describe the function in a logical flow from

The function descriptions use symbols to illustrate components such as

Example of function description

VDCT01.03GB Workshop Manual DCT 80-90

Symbol explanation function descriptions

Symbol explanation function descriptions

Workshop Manual DCT 80-90 VDCT01.03GB

About the documentation

Always indicate publication number when ordering.

For publication number, see machine card.

VDCT01.03GB Workshop Manual DCT 80-90

Your feedback is important to be able to improve the information.

To: Cargotec Sweden AB

Date: .................................... - .................. - ..................

Section / page number: ................................................................................................................................

Workshop Manual DCT 80-90 VDCT01.03GB

VDCT01.03GB Workshop Manual DCT 80-90

Workshop Manual DCT 80-90 VDCT01.03GB

VDCT01.03GB Workshop Manual DCT 80-90

In this publication Cargotec has documented and warned for situations

A near accident is a warning!

Workshop Manual DCT 80-90 VDCT01.03GB

Service position entails: